Chapter 2

Do's:
1. Understand the Importance of Surface Preparation: Recognize that proper surface preparation is crucial
for ensuring the adhesion and longevity of paint coatings.
2. Consider Degree of Cleanliness and Surface Profile: Understand that both the degree of cleanliness and
surface profile are essential factors to consider during surface preparation.
3. Follow Specified Procedures: Adhere to the specified procedures outlined in the job specification for
surface preparation to ensure compliance and quality.
4. Choose Suitable Surface Preparation Methods: Select appropriate surface preparation methods based
on factors such as cost, efficiency, ease, and suitability for the substrate.
5. Use Correct Abrasives: Ensure that the selected abrasives meet safety and regulatory requirements, and
choose abrasives suitable for the specific surface preparation needs.
6. Measure and Assess Surface Profile: Utilize proper tools and methods for measuring and assessing
surface profiles to ensure they meet specified requirements.
7. Maintain Consistency: Strive for consistency in surface preparation techniques and standards across the
entire substrate to achieve uniform results.

Don'ts:
1. Neglect Surface Contamination: Avoid neglecting to remove corrosion products and other contaminants
from the substrate before applying paint coatings, as this can lead to poor adhesion and coating failure.
2. Disregard Surface Profile Requirements: Do not disregard surface profile requirements specified in the
job specification, as they are crucial for ensuring proper adhesion of paint coatings.
3. Use Improper Abrasives: Refrain from using abrasives that do not meet safety standards or are
unsuitable for the substrate, as this can result in inefficient surface preparation and subpar coating
performance.
4. Ignore Surface Preparation Standards: Don't ignore industry standards and guidelines for surface
preparation, as adherence to these standards is essential for achieving quality results.
5. Skip Surface Profile Measurement: Avoid skipping surface profile measurement and assessment, as this
step is necessary for verifying compliance with specified requirements and ensuring coating adhesion.
6. Overlook Rust Grades: Don't overlook rust grades when assessing the condition of the substrate before
surface preparation, as this information informs the appropriate surface preparation method and standard
to be followed.
7. Rush Surface Preparation: Avoid rushing through the surface preparation process, as thoroughness and
attention to detail are critical for achieving the desired surface cleanliness and profile.
By following these do's and don'ts, you can ensure effective and efficient surface preparation for paint
application, resulting in durable and long-lasting coatings.
Chapter 3
Do's:
1. Conduct Surface Contaminant Tests: Ensure that appropriate tests are conducted to detect surface
contaminants such as soluble iron salts, soluble chlorides, mill scale, dust, moisture, oil, or grease before
applying paint.
2. Follow Test Procedures: Adhere to the specified procedures for each test to ensure accurate detection of
contaminants and reliable results.
3. Use Proper Testing Equipment: Utilize the correct testing equipment and materials, such as potassium
ferricyanide test papers, silver nitrate solution, Merkoquant strips, Bresle sample patches, salt
contamination meters, acidic copper sulphate solution, self-adhesive tape, talc or powdered chalk, and
solvents, for conducting the tests.
4. Document Test Results: Record the results of each test accurately, including any observations or
findings, to inform decisions regarding surface preparation and paint application.
5. Take Corrective Action: If the test results indicate the presence of contaminants exceeding specified
limits, take appropriate corrective actions such as washing down the surface, reblasting, or retesting to
ensure compliance with standards and specifications.

Don'ts:
1. Overlook Surface Contamination: Do not neglect to perform surface contaminant tests before painting,
as contaminants can compromise paint adhesion and affect coating performance.
2. Ignore Test Results: Avoid disregarding test results indicating the presence of contaminants, as failing
to address surface contamination can lead to paint failure and costly rework.
3. Use Improper Testing Methods: Refrain from using incorrect or inadequate testing methods, as this can
result in inaccurate detection of contaminants and unreliable results.
4. Skip Documentation: Don't skip documenting the results of surface contaminant tests, as proper
documentation is essential for quality control and compliance purposes.
5. Neglect Corrective Measures: Do not overlook the need for corrective measures if test results reveal the
presence of contaminants, as addressing surface contamination is critical for ensuring the success and
longevity of the paint coating.

By following these guidelines, you can effectively detect and address surface contaminants to ensure the
successful application and performance of paint coatings.

Chapter 4
Do's:
1. Understand Paint Classifications: Understand the different classifications of paint based on principles
involved, such as barrier, passivation, and cathodic protection, as well as based on function, such as anti-
fouling, road marking, fireproofing, and heat resistance.
2. Recognize Basic Paint Constituents: Understand the basic constituents of paint, including binder,
pigments, additives, and solvent (if applicable), and their roles in determining paint properties.
3. Consider Environmental Regulations: Be aware of environmental regulations, such as those imposed
by the Environmental Protection Agency (EPA), and explore paint technologies that comply with reduced
volatile organic compound (VOC) requirements.
4. Evaluate Compatibility: Assess the compatibility of different binders and solvents to avoid issues like
lifting, wrinkling, or poor adhesion when applying new coatings over existing ones.
5. Optimize Pigment-Binder Ratio: Understand the importance of the pigment-binder ratio in paint
formulations and aim for the critical pigment volume concentration (CPVC) to achieve desired properties
like opacity, gloss, and film strength.

Don'ts:
1. Neglect Safety Considerations: Do not overlook safety considerations when handling solvents,
especially regarding their toxicity and flammability. Adhere to safety guidelines and use appropriate
personal protective equipment.
2. Ignore Environmental Impact: Avoid using paints with high levels of volatile organic compounds
(VOCs) that can harm the environment and human health. Opt for environmentally friendly paint options
whenever possible.
3. Overlook Pigment Characteristics: Do not overlook the characteristics of pigments, such as their
source, particle size, and shape, as these factors influence properties like opacity, durability, and UV
resistance of the paint film.
4. Disregard Paint Compatibility: Avoid applying coatings with strong solvents over existing coatings that
use weak solvents, as this can lead to compatibility issues, lifting, or wrinkling of the paint film.
5. Exceed Recommended Pot Life: Do not exceed the recommended pot life of chemically curing paints,
as this can lead to user-unfriendly materials that may even be subject to spontaneous combustion after the
specified pot life.

By following these guidelines, you can effectively understand, formulate, and apply paints while
considering safety, environmental impact, and paint performance.

Chapter 5
Do's:
1. Understand Solvent-Solute Relationship: Understand the relationship between solvents, solutes, and
solutions to effectively utilize them in paint formulations.
2. Recognize Dispersions: Identify dispersions in paints, where solid particles are suspended in the
vehicle, and understand their importance in paint formulation and application.
3. Check Degree of Dispersion: Assess the degree of dispersion or fineness of grind, especially in gloss
paints, to ensure optimal performance and appearance.
4. Utilize Emulsions: Utilize emulsions effectively in paint formulations, understanding the role of water
as a carrier and the distinction between continuous and dispersed phases.

Don'ts:
1. Avoid Confusion between Solutions and Dispersions: Do not confuse solutions with dispersions;
understand the difference between a solute dissolving in a solvent to form a solution and solid particles
being suspended in a liquid vehicle in dispersions.
2. Don't Overlook Particle Clustering: Avoid overlooking the formation of aggregates or agglomerates in
suspensions, as they can affect the performance and appearance of the paint.
3. Avoid Misinterpreting Emulsions: Do not mistake emulsions for solutions; recognize that emulsions
involve the dispersion of liquid droplets in another liquid phase where there is no solubility.

By adhering to these guidelines, you can effectively understand and utilize solutions, dispersions,
suspensions, and emulsions in paint formulations, ensuring optimal performance and quality of the final
product.
Chapter 6

Do's:
1. Understand Drying Mechanisms: Understand the different mechanisms involved in drying and curing
of paint films, including solvent evaporation, oxidation, chemical curing, and coalescence.
2. Follow Temperature Guidelines: Adhere to temperature guidelines for air drying, forced drying, and
stoving to ensure proper curing of paint films.
3. Use Appropriate Paint Types: Choose paint types based on the drying mechanism suitable for the
application and environmental conditions.
4. Thoroughly Mix Two-Pack Materials: Ensure thorough mixing of two-pack or multi-component liquid
paints, following instructions on the materials data sheet.
5. Observe Induction Period and Pot Life: Allow for the recommended induction period after mixing and
adhere to the pot life guidelines to prevent material wastage or compromised performance.
Don'ts:
1. Avoid Improper Mixing: Do not skip the mixing process for two-pack materials, as incomplete mixing
can result in inadequate curing and performance issues.
2. Don't Exceed Pot Life: Avoid using paint beyond the recommended pot life, as it may lead to
difficulties in application and compromised film properties.
3. Avoid Excessive Heat: Do not subject paint films to excessive heat during drying and curing, as it can
cause issues such as cracking or peeling.
4. Don't Neglect Environmental Factors: Consider environmental factors such as humidity and
temperature fluctuations, as they can affect the drying and curing process.
5. Avoid Contamination: Prevent contamination of paint films during the drying process, as it can affect
adhesion and film integrity.

By following these guidelines, you can ensure the effective drying and curing of paint films, leading to
durable and high-quality coatings.

Chapter 7
Do's:
1. Understand Paint System Principles: Understand the principles of different paint systems and their
functions in providing corrosion protection.
2. Select Appropriate Primers: Choose primers based on their ability to wet out the substrate, provide
adhesion, and passivate the surface.
3. Use Mid-Coats Effectively: Apply mid-coats to prevent further water ingress, even out irregularities,
and provide a key for subsequent layers.
4. Apply Finishing Coats Properly: Ensure finishing coats meet aesthetic requirements while providing
necessary properties like gloss and durability.
5. Consider Moisture Tolerant Systems: Utilize moisture-curing polyurethanes or high solid epoxies in
environments prone to condensation or moisture exposure.
6. Follow Application Guidelines: Adhere to proper surface preparation and application techniques
specified for each type of coating material.

Don'ts:
1. Don't Neglect Surface Preparation: Avoid applying coatings without proper surface preparation, as this
can lead to poor adhesion and inadequate corrosion protection.
2. Avoid Improper Application Conditions: Do not apply moisture-curing materials in low humidity
conditions, as this can affect curing and performance.
3. Don't Overlook Environmental Factors: Consider environmental conditions such as temperature,
humidity, and exposure to chemicals when selecting and applying coatings.
4. Avoid Inadequate Cure Time: Ensure thermosetting materials are adequately cured with the appropriate
heat and time to achieve optimal performance.
5. Don't Skip Protective Measures: Do not skip applying protective coatings over sacrificial coatings like
galvanizing, as this can compromise long-term corrosion protection.

Following these guidelines can help ensure effective corrosion protection and longevity of painted
surfaces in various applications.
Chapter 9
Do's:
1. Follow Manufacturing Stages: Adhere to the three main stages of paint manufacturing: premixing,
dispersion or grinding, and letdown process.
2. Use Appropriate Equipment: Select the suitable dispersing mill based on the specific requirements and
characteristics of the paint being manufactured.
3. Ensure Proper Agitation: Use equipment like high-speed dispersers to achieve adequate dispersion and
turbulence for proper mixing.
4. Consider Efficiency: Choose equipment that provides efficient dispersion in less time, such as the
attritor mill or high-speed disperser.
5. Maintain Cooling Systems: Implement cooling jackets or other cooling mechanisms to manage heat
generated during the milling process, especially in systems like sand mills.
6. Control Particle Size: Adjust milling parameters and equipment settings to achieve the desired particle
size and consistency for the paint formulation.

Don'ts:
1. Don't Overlook Safety: Follow safety protocols when operating machinery, especially high-speed
equipment, to prevent accidents.
2. Avoid Overloading Equipment: Do not exceed the recommended capacity or operating limits of
dispersing mills to prevent equipment damage or inefficient operation.
3. Don't Neglect Maintenance: Regularly maintain and inspect equipment to ensure proper functioning
and prevent breakdowns during the manufacturing process.
4. Avoid Inadequate Dispersion: Ensure that the dispersion process adequately breaks down aggregates
and agglomerates to achieve uniform consistency and quality in the final paint product.
5. Don't Ignore Environmental Factors: Consider environmental factors such as temperature and humidity
that may affect the milling process and adjust operations accordingly for optimal results.

Chapter 10

Do's:
1. Follow Standard Procedures: Adhere to the specified testing methods outlined in BS 3900 and National
Grid specification PA9.
2. Use Clean Equipment: Ensure all equipment used for testing is clean and dry to prevent contamination.
3. Record Measurements Accurately: Take precise measurements and record data diligently to maintain
accuracy.
4. Handle Solvents Safely: Exercise caution when working with solvents and follow safety protocols,
especially during flash point determination.
5. Maintain Controlled Environment: Conduct tests, particularly viscosity measurements, at a consistent
temperature to ensure reliable results.

Don'ts:
1. Don't Open Flames: Avoid open flames or any potential ignition sources when working with solvents,
especially during flash point determination.
2. Don't Neglect Calibration: Regularly calibrate equipment such as balances, thermometers, and
viscometers to maintain accuracy.
3. Don't Skip Safety Precautions: Always wear appropriate personal protective equipment (PPE) when
handling chemicals or operating equipment.
4. Don't Overlook Environmental Factors: Ensure testing environments are free from drafts or other
factors that could affect test results, particularly viscosity measurements.
5. Don't Ignore Manufacturer Guidelines: Follow manufacturer guidelines for thinners and other additives
to ensure paint formulations meet required standards.

Chapter 11

Do's:

1. Do measure wet film thickness immediately after application: This ensures accurate readings before
solvent evaporation affects the film thickness.
2. Do use appropriate tools: Utilize eccentric wheels or comb gauges for wet film thickness measurement,
and choose suitable methods for dry film thickness measurement based on the substrate and coating type.
3. Do conduct regular checks: Regularly monitor wet film thickness during application to ensure it meets
specifications, which can help avoid major rectifications later.
4. Do follow proper testing procedures: Adhere to standardized testing procedures for mechanical
properties, adhesion, drying/curing tests, and other evaluations to ensure consistent and reliable results.
5. Do consider environmental factors: Take into account factors like temperature, humidity, and substrate
conditions when performing tests and measurements, as they can influence coating performance.

Don'ts:

1. Don't delay wet film thickness measurement: Delaying measurement after application can lead to
inaccurate readings due to solvent evaporation, affecting the overall coating quality.
2. Don't use inappropriate tools: Avoid using tools or methods unsuitable for the substrate or coating type,
as it may result in inaccurate measurements or damage to the coating.
3. Don't neglect regular checks: Failure to regularly monitor wet film thickness during application can
result in deviations from specifications, leading to potential rework or rejection of coatings.
4. Don't skip standardized testing procedures: Skipping or deviating from standardized testing procedures
can compromise the reliability and validity of test results, affecting the overall quality assessment of
coatings.
5. Don't overlook environmental conditions: Neglecting environmental factors during testing and
measurement can lead to misleading results and inaccurate assessments of coating performance,
impacting long-term durability and effectiveness.

By following these do's and don'ts, you can ensure accurate measurements, reliable test results, and
optimal performance of paint coatings in various applications.

Chapter 12

Dos:
1. Adhere to Specified Conditions:
- Follow the conditions specified by the manufacturer's product data sheet and the client's specification
for applying paints or coatings.
- Ensure that the specified ambient conditions, such as temperature and humidity, are met before
applying the coating.
2. Use Proper Equipment:
- Use appropriate equipment, such as a whirling hygrometer or psychrometer, to measure wet and dry
bulb temperatures and calculate relative humidity and dew point.

3. Rotate Equipment Correctly:

- Rotate the whirling hygrometer at the specified speed and direction to obtain accurate wet and dry
bulb temperature readings.
- Ensure that the frame with the thermometers is rotated quickly about a horizontal axis to meet the
required aspiration rate.

4. Repeat Measurements if Necessary:

- Repeat the measurement process with the whirling hygrometer until two consecutive spins yield
readings within the specified tolerance (0.2°C).

5. Measure Steel Substrate Temperature:

- Use appropriate equipment, such as a limpet gauge or digital thermometer, to measure the temperature
of the steel substrate before applying the coating.

Don'ts:
1. Apply Coatings in Unfavorable Conditions:
- Avoid applying paints or coatings during adverse weather conditions such as rain, snow, high winds, or
when the specified ambient conditions are not met.
- Do not disregard the specified conditions provided by the manufacturer or client's specification.

2. Neglect Proper Measurement Techniques:

- Do not neglect to use proper measurement techniques, such as rotating the whirling hygrometer
correctly or ensuring accurate readings from the equipment.
- Avoid inaccurate measurements that could lead to improper coating application and potential defects.

By adhering to these dos and don'ts, coating professionals can ensure that paints and coatings are applied
under suitable conditions, leading to effective protection and durability of the coated surfaces.
Chapter 13

Dos:
1. Maintain Cathodic Protection Integrity:
- Ensure that cathodic protection is applied promptly after coating damage to prevent corrosion of the
underlying steel.
- Use cathodic protection to protect underground and subsea pipelines, especially in areas where coating
damage is likely to occur.

2. Select the Correct Cathodic Protection System:

- Choose between sacrificial anode systems and impressed current systems based on the size and
requirements of the structure to be protected.
- Consider factors such as the area to be protected, potential required, and operating conditions when
selecting the cathodic protection system.

3. Monitor Cathodic Protection Effectiveness:

- Regularly monitor the effectiveness of cathodic protection systems using methods such as half-cell
reference electrodes.
- Conduct periodic checks to ensure that the required potential is being maintained to prevent corrosion.

4. Test Materials for Resistance to Cathodic Disbondment:

- Perform tests on materials used in pipelines to determine their resistance to cathodic disbondment.
- Conduct tests according to established procedures to simulate areas of coating damage and evaluate
disbondment resistance.

Don'ts:
1. Neglect Coating Maintenance:
- Avoid neglecting coating maintenance, as damaged or deteriorated coatings can compromise the
effectiveness of cathodic protection.
- Address coating damage promptly to prevent corrosion of the underlying steel.
2. Misapply Cathodic Protection:
- Avoid applying cathodic protection to areas where an electrolyte is not present or where it may not be
effective, such as external surfaces of tanks without an electrolytic medium.
- Use cathodic protection systems appropriately based on the specific requirements of the structure and
operating conditions.

3. Overprotect Damaged Areas:

- Avoid overprotecting damaged areas with cathodic protection, as this can lead to cathodic
disbondment and further coating damage.
- Ensure that cathodic protection systems are properly designed and operated to prevent overprotection
and associated risks.

By following these dos and don'ts, users can effectively implement and maintain cathodic protection
systems to prevent corrosion and protect steel structures from damage.

Chapter 14
Dos:
1. Use the Detector Correctly:
- Wet the sponge electrode with water and a small amount of detergent.
- Squeeze out excess water from the sponge.
- Traverse the sponge methodically over the area to be tested.
- Work upwards on vertical surfaces for better coverage.

2. Select the Correct Operating Voltage:

- Choose the appropriate voltage setting based on the dry film thickness (DFT) of the coating.
- Use the 9V setting for DFTs less than or equal to 300μm.
- Use the 90V setting or an intermediate setting for DFTs of 300-500μm.

3. Interpret the Results:

- Pay attention to the high-pitched bleep indicating the presence of a pinhole.
- Use the corner of the sponge to locate the exact position of the pinhole.
 - Mark the position for repair.

Don'ts:
1. Neglect Safety Precautions:
- Avoid using the detector in wet or damp conditions to prevent electrical hazards.
- Ensure proper insulation and grounding of the equipment to prevent shocks.

2. Use Incorrect Voltage Settings:

- Avoid using voltage settings that are too high or too low for the DFT of the coating, as this may lead to
inaccurate results or damage to the coating.

3. Ignore Calibration and Maintenance:

- Regularly calibrate the equipment according to manufacturer recommendations to ensure accurate
detection.
- Maintain the equipment properly, including replacing batteries as needed and keeping terminals clean,
to avoid malfunction or inaccurate readings.

Chapter 15
Brush Application:
Do:
1. Use various types and quality of brushes, with natural bristles preferred for better paint holding and
spreading.
2. Consider brush application as more environmentally friendly with less waste material and minimal
spotting or overspray damage.
3. Work paint into the substrate profile and any fine detritus present for better adhesion.

Don't:
1. Expect uniform coating thickness with brush application.
2. Use brush application in areas where a more even coating thickness is required or where rapid
application is necessary.
Roller Application:
Do:
1. Use rollers for quick paint application.
2. Choose rollers appropriate for different surfaces and applications.
3. Apply a stripe coat in areas with difficult access or where roller stipple is undesirable.

Don't:
1. Expect a uniform coating thickness with roller application.
2. Use roller application in areas such as internal corners, welds, bolts, rivets, and plate overlaps.

Spray Application:
Do:
1. Use appropriate spray equipment for different paint types and applications.
2. Follow manufacturers' recommendations for equipment setup, including pressure and tip sizes.
3. Observe safety precautions, including wearing recommended safety equipment and depressurizing the
system before maintenance.

Don't:
1. Point the spray gun at yourself or others.
2. Use spray application methods without proper training or understanding of equipment operation.
3. Overlook regular maintenance checks for wear and leaks in fluid lines.

Electro-static Spray:
Do:
1. Use electro-static spray for liquid or powder paints.
2. Adjust the voltage to control coating thickness, especially with powder coatings.
3. Ground the component to be coated to attract the positively charged coating material.

Don't:
1. Use electro-static spray without proper grounding of the component.
2. Neglect safety precautions, including wearing appropriate safety equipment and following
manufacturer recommendations.

Other Paint Application Methods:

Do:
1. Consider alternative methods like dip coating, padding, hot spraying, spin rotating, flow/curtain
coating, and aerosols for specific applications.
2. Use these methods where conventional spray, brush, or roller application may not be suitable.

Don't:
1. Use alternative methods without understanding their suitability for the application.
2. Overlook safety precautions, especially when dealing with hot spraying or rotating equipment.

Following these dos and don'ts ensures efficient and effective paint application while maintaining safety
standards and achieving desired coating results.