2300(1)

SSPC-CS 23.00(I)
March 1, 2000

SSPC: The Society for Protective Coatings

2300(1)
COATING SYSTEM CS 23.00(1)
Interim Specification
Specification for the Application
Application of
(Mehanizing) of Aluminum, Zinc,
Thermal Spray Coatings (Metallizing)
and Their Alloys and Composites
for the Corrosion Protection of Steel

Foreword
This SSPC Interim Specification
Specification for the Application
Application of Thermal
Thermal Spray Coatings (Metallizing)
(Metallizing) of Aluminum, Zinc, &
Their Alloys & Composites for the Corrosion Protection of Steel is issued to meet a critical industry and govemment
government need.
SSPC Interim
Interim Specifications
Specifications are effective for a maximum of two years pending completion of a normal-track
normal-track specification.
specification.
Thermal spray coatings (TSCs) are used extensively for the corrosion protection of steel and iron in a wide range
of environments.
environments. The corrosion tests carried
carried out by the American Welding Society1
SocietyI and the 34 and 44 year marine-—
marine-
atmosphere performance reports of the LaQue Center for Corrosion Technology;3 confirm the effectiveness of flame
Technology2~ confirm flame
sprayed aluminum and zinc coatings over long periods of time in a wide range of hostile environments.
environments. The British
British
Standards
Standards Institution
Institution code of practice
practice for the corrosion protection of steel4
steel4 specifies
specifies that only TSCs give protection greater
greater
than 20 years to first
first maintenance for the 19 industrial
industrial and marine environments considered and that only sealed, sprayed
aluminum or zinc gives such protection in sea water immersion
imn~rsion or splash zones.
This guide presents basic information
information for the application
application of quality TSCs. Annexes present additional
additional
information. standard and may be used to find
information. The Table of Contents gives an overview of this standard find specific
specific information.
information. The
following flow
flow diagram is the overview of the thermal
thermal spray coating process presented in this standard.
standard.

'Corrosz'on
~Corrosion Tests of Flame-Sprayed Coated Steel, 19-Year Report, American Welding Society
Society C2.14~74.
C2.14-74. AWS publications
publications available
available from
American Welding Society,
Society, PO.
P.O. Box 351040,
351040, Miami, FL 33135.
33135.
22 RM.
R.M. Kain and EA.
E.A. Baker, Marine Atmospheric
Atmospheric Corrosion Museum Report on the Petfonnance
Performance of
of Thermal Spray Coatings on Steel,
Steel,
ASTM STP 947. ASTM publications
publications available
available from American Society
Society for Testing and Materials,
Materials, 1916 Race Street, Philadelphia,
Philadelphia, PA
19103.
33 SJ.
S.J. Pikul,
Piku],Appearmce
Appearcow.eof
of Yhemral
Thermal Sprayed Coatings
Coatings We
aft~ 44 Years
Years Marine
Marine Atmomhenb
At~1osptwric Emom
E.wosune at Kare
Kure Beach.
Beack~ North
North Carolina,
Carolina, February
Febru,~ 1966,
1966,
Center for Corrosion
LaQue Center Corrosion Technology,
T~hnology, Inc.
Inc.
4Code
4Code of Practice for
for Protective Coatings of
of Iron and Steel Structures Against Corrosion, British Standards Institution
Institution BS.
B.S. 5493: 1977.
Available
Available from American National Standards Institute, 11
11 West 42nd Street, New York, NY 10036.

255
SSPC-CS
SSPC-CS 23.0003
23.000)
March 1, 2000

I Specification
Specification I I Job
8:
Job
II _ II Equipment
Equipment
. . . . [I __
~urTace
Surface
Requirements Reference
Reference ~ Setup
~etu 8:
I:) ..~ I~1 Preparation
Preparation
Standard Prepration

V
Standard P,~lJ,,z, iu,, i it1,t

Fail Pass
n~Proceea In—P recess

AI
AI &
8:. Zn
Zn TSC ._~ Sealer
Sealer

® I Appl
TSC
Applicationn
icatio 17 and [or
To pcoat

. J . .
Accept )

1. Scope
This standard is a procedure for the application of metallic thermal spray coatings (TSC) of aluminum, zinc, and their
application procedures, and in-process
alloys and composites for the corrosion protection of steel. Required equipment, application
specified. This standard may be used as a procurement
quality control checkpoints are specified. document. Annex A presents a fill—
procurement document. fill-
in~the-blanks model procurement
in-the-blanks specification.
procurement specification.
requirements for design and fabrication, thermal spray equipment qualification,
Not included in this standard are requirements qualification,
coating selection, and operator and inspector certification.
certification.
This standard may involve hazardous materials, operations, and equipment. This standard does not purport to address
all of the safety
safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate
safety regulatory limitations prior to use.
determine the applicability of regulatory
safety and health practices and determine

Description
2. Description
The procedure
procedure for application
application of TSCs for the corrosion protection of steel includes proper (a) surface
surface preparation of
the substrate steel, (b) application of the TSC and, (0)(c) application of the sealer or sealer and t0pcoat.
topcoat. The procedure
procedure
includes use of suitable abrasive blasting, thermal spraying, sealing/topcoating,
sealing/topcoating, and in-process QC checkpoints.
2.1 This standard may be used by owners and engineers
engineers to detail and contract for the application
application of TSCs for the
preservation and maintenance
maintenance of steel structures.
stru~Xures. This standard may also be used by TSC inspectors and Thermal Spray
Coating Applicator (TSCA) to develop and maintain application procedures, equipment inventory,inventory, and an operator-
training program.
2.2 This standard is not meant to be an inspection standard. See SSPC 97-07 for inspection guidance.

3. Reference Standards
Standards
3.1 The standards referenced
referenced in this specification
specification are listed in Sections 3.4 through 3.7 and form a part of this
specification.
specification. A standard listed here may be referenced
referenced only in the Notes, which are not requirements
requirements of this specification.
specification.
amendment of the referenced
3.2 The latest issue, revision, or amendment referenced standards in effect
effect on the date of invitation to bid shall
govern, unless otherwise specified.
govem, specified.

256
 SSPC-CS
SSPC-CS 23.00(1)
2300(1)
March
March 1,
1, 2000
3.3 If there is a conflict
conflict between the requirements
requirements of any of the cited reference specification, the
reference standards and this specification,
requirements of this specification
specification shall prevail.
3.4 SSPC STANDARDS AND JOINT STANDARDS:
SSPC-AB 11 Mineral and Slag Abrasives
SSPC-PA 11 Maintenance Painting
Shop, Field, and Maintenance
SSPC-PA 2 Measurement
Measurement of Dry Coating Thickness with Magnetic Gages
SSPC-SP 5//NACE No. 11 White Metal Blast Cleaning
SSPC—SP 10/NACE No. 2 Near-White Blast Cleaning
SSPC-SP
189
SSPC-V18 1-89
SSPC-VIS Visual Standard for Abrasive Blast Cleaned Steel

3.5 AMERICAN SOCIETY FOR

FOR TESTING AND MATERIALS (ASTM) STANDARI~: STANDARDS:
ASTM B 833 Standard Specification
Specification for Zinc Wire for Thermal Spraying (Metallizing)
ASTM C 633 Adhesive! Cohesive Strength of Flame Sprayed Coatings
Test Method for Adhesive/Cohesive
ASTM D 1210 Pigment—Vehicle Systems
Test Method for Fineness of Dispersion of Pigment-Vehicle
ASTM D 4285 Method for Indicating Oil or Water in Compressed Air
ASTM D 4417 Test Method for Field Measurement Profile of Blasted Steel
Measurement of Surface Profile
ASTM D 4541 Test Method for Pull-Off Strength of Coating Using Portable Adhesion Testers
ASTM D 4940 Test Method for Conductimetric Contamination of
Conductimetric Analysis of Water Soluble Ionic Contamination
Blasting Abrasives
3.6 A N S I / A W S JJOINT
ANSI/AWS STANDARD:
OINT S TANDARD:
ANSI/AWS C2.18-93
C2.18—93 Guide for the Protection of Steel with Thermal Spray Coatings of Aluminum, Zinc,
and Their Alloys & Composites
3.7. INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) STANDARD:
ISO 8502-3 Application of Paints and Related Products
Preparation of Steel Substrates Before Application

Terminology
4. Terminology
Aluminmn MMC
Aluminum MMC TSC: Aluminum metal matrix composite (MMC) TSC is a coating that contains a composite
material in an aluminum matrix. It is produced by flame
flame or are
arc spraying a solid or cored wire that contains the composite
material.
(180-degree
Bend test: The bend test (1 80-degree bend on a mandrel diameter based on the TSC thickness) is a qualitative test of
the ductility and tensile bond of the TSC. The bend test is a macro-system
macro-system test of surface
surface preparation, equipment setup,
and spray parameters and application procedures. The bend test passes if there is no cracking or spalling
spallmg of the TSC
material or only minor cracking visually observed on the bend—radius.
bend-radius. The bend test fails if the coating cracks with lifting
substrate.
from the substmte.
Contract pre-award validation: The purchaser’s
purchaser's contract pre-award evaluation of the thermal spray coating
applicator (TSCA) includes (a) written procedures
applicator procedures for and (b)
Co) demonstration
demonstration of surface
surface preparation
preparation and thermal spray
materials and equipment capabilities and application process proposed for the contract work.
Cut test: The TSC cut test shall consist of a single out
cut 1.5 in. [40 mm] long through the TSC to the substrate without
severely
severely cutting into the substrate.
subslrate. All cuts shall be made with sharp tools. The chisel cut shall be made at shallow angle.
The bond shall be considered unsatisfactory
unsatisfactory if any part of the TSC along the cut lifts from the substrate. The cutting tool
specified in the contract.
shall be specified
Hash
Flash rusting: Rusting that occurs on metal within minutes to a few hours after blast cleaning or other cleaning is
completed. The speed with which flash
flash rusting
resting occurs may be indicative of soluble salt contaminants on the surface, high
humidity,
humidity, or both.

257
ssPc-cs
SSPC—CS 23.oo(i)
2300(1)
March
March 1,
1, 2000

Holding period: Holding period is the time between the completion of the final final brush
final anchor-tooth blasting, or final
blasting, and the completion of the thermal spraying. There shall be no flash flash rusting during the holding period. The
flash rusting.
definition, ends with onset of flash
holding period, by definition,
Job conlrol enumerates the essential job information and the in-
control record (JCR): The JCR is a record form, which enumerates in—
process QC checkpoints required by this standard. The JCR includes information on safety precautions, and the
equipment, parameters, and procedures
procedures for surface thermal spraying, and sealing. Annex B is a model JCR.
surface preparation, thennM
Job reference
Job reference standard (JRS): The JRS representative of the whole job or
reference standard repre-sentative
IRS is a job site pass/fail reference
13.2 and Figure 2.
major sections of the job. See Section 13.2 ,
Topcoat: The topcoat is a paint coat over the seal coat. Note: Paint topcoats should never be applied over an unsealed
TSC.
Sealer: The sealer is a very thin paint coat about 1.5 mil [38 ~un]
um] thick that will be absorbed into the pores of the TSC.
See Note 1.
1.
Soluble salt contaminants"
contaminants: These water-soluble com-pounds (such as chlorides and sulfates) that
water—soluble salts are inorganic compounds
contaminate
contaminate a product. When soluble salts are present on a prepared steel surface, they may cause flash flash rusting and
premature coating failure.
premature
TSC: thermal spray coating
TSCA: applicator
TSCA: thermal spray coating applicator

5. Surface Preparation
finish, SSPC-SP
5.1 SURFACE FINISH: The steel substrate shall be prepared to a white metal finish, SSPC—SP 5/NACE No. 11 for
finish, SSPC-SP 10/NACE
marine and immersion service or a minimum of near-white metal finish, service
lO/NACE No. 2, for other service
applications. Confirm finish and cleanliness per SSPC-VIS 1-89
Confirm surface finish l-89 and ASTM D 4417.
PROFII,E DEPTH:
5.2 ANGULAR PROFILE DEPTH: The steel substrate shall have, at a minimum, an angular profile
profle depth 2:
> 2.5
um] with a sharp angular shape.
mil [63 Jam]
5.3 ANGULAR DEPTH PROFILEPROFII.E MEASUREMENT SCHEDULE: SCHEDULE: The profileprofile depth shall be measured
measured per
ASTM D 4417, Method C (replica tape, x-coarse, 1.5-4.5
1.5-4.5 mils [38-1
[38-113 ~m])
13 [.LmD or Method B (profile
(profile depth gage), or both.
5.3.1 Manual Blasting: At a minimum, take one profile
profile depth measurement
measurement every 10 to 20 ft2
fiE [1-2 ml]
mE] of blasted
surface.
profile depth measurement
5.3.2 Automated Blasting: Take one profile measurement every 1000 to 2000 ft2
~ [100-200 ml]
m 2] of blasted
surface.
5.3.3 Angular Blast Media: Use clean dry angular blasting media. Mineral and slag abrasives shall be selected and
evaluated per SSPC-AB 1. 1. Confirm
Confinn absence of oil contamination
contamination with the water sheen test per ASTM D 4940. The q-he
suitability of the angular blasting media, blasting equipment, and blasting procedures
pr~xiures shall be validated per Section 14,
Contract Pre-Award Evaluation, Demonstration and Validation.
Pre-Award Evaluation,

6. Thermal Spray Coating (TSC) Requirements

THICKNF_.SS
6.1 FEEDSTOCK AND TSC THICKNESS
The TSC feedstock
feedstock material and thickness should be selected
selected according
according to intended service environment
environment and service
service
C2.18-93, Annex B.)
life. (See AWS C2.18—93,
1. Specify
1. feedstock material per Annex C or ASTM B 833-93.
Specify the TSC feedstock
Specify the minimum and maximum TSC thickness as measured in accordance
2. Specify SSPC-PA 2.
accordance with SSPC—PA

258
 sspf-cs 23
SSPC—CS 23.c~(0
00(1)
March 1,
1, 2000

6.2 TSC
TSC COATING THICKNESS
COATING THICKNESS
6.2.1. Thickness Less Than
Than Canlract
Contract Specification: inspection, the TSC thickness is less than the
Spea'fication: If upon later inspection,
contract
contract requirement,
requirement, then the applicator shall apply additional
additional TSC to meet the thickness requirement. additional
requirement. This additional
thickness rust.
thickness shall only be applied to clean and dust-free TSC without any visible substrate oxidation or rest.
I.
1. Remove any contamination from the TSC surface or confirm contamination.
confirm the absence of contamination.
2. Oil, grease or chemical contaminants may require solvent cleaning, high-pressure water washing or more intense
cleaning, high-pressure
cleaning methods.
cleaning
3. Apply additional specification.
additional TSC thickness to meet the contract specification.
6.2.2. Thickness Greater
Greater Than
Than the Contract
Contract Specification.
Specification. If the TSC thickness is greater than the contract
- specification,
specification, record information inspector, who in turn should notify the purchaser
information in the JCR and immediately notify the inspector,
for resolution
resolution of this discrepancy. TSC thickness greatergreater than 15 mils [375 ktm] edges/corners, shall be
um] on exterior edges/comers,
reapplied to the contract specified
removed and reapplied thickness.
specified thickness.

6.3 TSC T H I C K N E , ~ MEASUREMENT

THICKNESS MEASUREMENT SCHEDULE
1.
1. The TSC thickness measurement shall be made in accordance with SSPC-PA 2.
2. Use a rrmasurement flat surfaces. Take the average value of 5 readings taken in line at 11 in. [2.5 cm]
measurement line for flat
intervals. The line measurement will measure the peaks and valleys of the TSC.
3. transitions. The measurement spot should be
Use a measurement spot for complex geometries and geometry transitions.
in.22 [10 cm
approximately 1.6 in. measurement may not measure the peaks and valleys of the
cm2]2] area. The spot rreasurement
TSC.
measurements.
illustrates the line and spot measurements.
Figure 3 illustrates

6.4 TSC TENSILE

6A MEASUREMENT SCHEDULE
TENSILE BOND AND MEASUREMENT
The TSC tensile bond shall be measured per ASTM D 4541 using a self-alignment equivalent.
self-alignment adhesion tester or equivalent.
1. Specify the minimum
rrrinimum TSC tensile bond value per Table 1. specified.
1. Higher values may be specified.

Table Minimum
Table 1 - M i n i m u m Tensile Bond
Tensile B Requirements
o n d Requirements
-
using self-aligning
(Per ASTM D 4514 usin8 adhesion tester)
;elf-aligning adhesion
Feedstock psi [MPa]
Zn 500 [3.45]
AI
A1 1000 [6.89]
85/15 700 [4.83]
A1202 MMC
90/10 A12Oz 1000 [6.89]

2. Make one portable tensile bond measurement about every 500 ft2
~ [50 m2].
mE]. Ifthe
If the tensile bond is less than the
contract specification,
specification, remove the degraded TSC and reapply.
3. For non-destructive measurement:
measurement: Measure tensile force to the contract-specified
contract-specified tensile. Then reduce the
tensile force and remove the tensile fixture
fixture without damaging the TSC.
Note: The tensile—bond
tensile-bond measurement
me~urernent of the portable test instrument
instrument may be related to the ASTM C 633 laboratory
laboratory
method in Annex D.

259
SSPC-CS
SSPC-CS 23.0(KI)
2300(1)
March
March 1,2000
1, 2000

6.5 BEND TEST: TEST: The bend test (180-degree

(ISO-degree bend on a mandrel) qualitative test for proper surface
mandrel) is used as a qualitative
preparation,
preparation, equipment setup, and spray parameters.
parameters. The bend test puts the thermal mandrel
thermal spray coating in tension. The mandrel
substrate thickness,
diameter for the threshold of cracking depends on substrate thickness, and mandrel diameter.
thickness, coating thickness,
cracking threshold
The following table summarizes a very limited bend-test cracking arc—sprayed Zn TSC thickness on steel
threshold for arc-sprayed
[13mm]
coupons 0.050 in [13ram] thick versus mandrel
mandrel diameter.

Table 2 -— Bend Test Cracking Threshold: Mandrel Diameter vs. TSC Thickness
(For steel coupons 0.050 iin.
~ [13 nun]
mm] thick)
TSC Thickness (mils) 210
>10 215
>15 225
>_25
Mandrel Diameter 1/2"
1/ ” 5/8"
5/ ” <1"*
<1”*
* Confirm
Confirm diameter with JRS

6.5.1 Bend Test

Tat Procedure for TSC Thickness Range 7-12 mils [175-350 larn]: five corrosion-control
tun]: Spray five corrosion—control bend
coupons and pass the following bend test:
1. 1.25 mm].
1. Use carbon steel coupons of approximate dimensions 2 x 4 to 8 x 0.050 in. [50 x 100 to 200 x 1.25
2. required by the contract
Prepare the surface of the coupons as required specification.
contract specification.
3. Spray 7-12
7—1 2 mils [200-250 gm]tun] thick TSC. The 'Ihe TSC should be sprayed in crossing passes laying down
tun] per pass.
[75—100 larn]
approximately 3-4 mils [75-100
4. ISO-degree around a 0.5 in.J13
Bend coupons 180-degree mandrel.
in.[13 mm] diameter mandrel.
5. spalling or (b) only minor
Bend test passes if, on the bend-radius (see Figure 1), there is (a) no cracking or spalling
substrate with a knife blade.
cracking which cannot be lifted from the substrate
6, ifthe
Bend test fails if substrate
the coating cracks with lifting from the substrate

F'~m'e
Figure 1 - TSC Bend Test: Pass and Fail Examples

PASS PASS FAIL

NO MINOR CRACKS with CRACKS with
CRACKS NO LIFTING or LIFTING or
SPALLING SPALLING

6.6 TSC FINISH: The deposited TSC shall be uniform without blisters, cracks, loose particles,
particles, or exposed steel as
examined with a 10x loop.

260
 SSPC-CS 23
SSPC-CS 23.00(I)
.000)
March 1,1,2000
March 2000
6.7 TSC POROSITY: If required by the purchaser, specify rnetallographic
specify the maximum allowable porosity and the metallographic
measurement
measurement method to be used for the evaluation. Note: porosity measurements in—process quality
measurements are not used for in-process
measurements may be used to qualify thermal
control in metallizing for corrosion protection of steel. However, porosity measurements
spray application process and spray parameters.
6.8 TSC QC QC MEASUREMENT
NIEASUREMENT PROCEDURES
PROCEDURES AND INSTRUMENTS: The suitability of the TSC thick- thick—
ness, portable tensile bond, bend test, and cut test measurement
measurement procedures
procedures and instruments,
instruments, shall be validated during the
Conwact
Contract Pre-Award
Pre—Award Validation
Validation per Section 14.

7. TSC Application PProcedure

TSC Application rocedure
Annex E details the key production and quality control checkpoints for applying TSCs.
7.1 THERMAL
THERMAL SPRAY EQUIEVIENT EQUIPMENT SETUP:.SETUP: Thermal spray equipment shall be set up, calibrated, and
operated (1) per the manufacturer's
manufacturer’s instructions and technical manuals or the TSCA's refinement thereto, and (2) as
TSCA’s refinement
validated by the JRS
IRS (see Section 13.2).
1. Specified thermal spray material
1. Spray parameters and thickness per crossing pass shall be set for spraying the specified
and, at a minimum, be validated with the bend test.
2. The thermal spray equipment spray parameter setup shall be validated with a bend test at the beginning of each
shift or crew change.
3. A copy of the spray parameters used shall be attached to the JCR.
7.2 POST-BLASTING SUBSTRATE CONDITION AND THERMAL SPRAYING PERIOD PERIOD
7.2.1 Steel Surface Temperature: The steel surface [5°F] above the dew point.
temperature shall be at least 3°C [5°F]
surface temperature
7.2.2 Holding Period: "time
Time between the completion of the final final brash
final anchor-tooth blasting (or final brush blasting) and
the completion
completion of the thermal spraying should be no greater than six hours for steel substrates with the following
exceptions:
environments, shorter holding periods shall be used. If rust bloom or a degraded coating
In high humidity and damp environments,
appears at any time while spraying, stop spraying. Section 8.2.4 applies.
In low-humidity
low-humidity environments
environments or in con-trolled
con-trolled environments
environments with enclosed structures using industrial
dehumidification surface finish
dehumidification equipment, it may be possible to retard the oxidation of the steel and hold the surface finish for more than
six hours. The TSCA, with the concurrence
concurrence of the purchaser, can establish a holding period greater than six hours by
determining
determining the acceptable temperature-humidity
temperature-humidity envelope for the work enclosure by spraying and analyzing bend
coupons or tensile bond coupons, or both.
For small and movable parts, if more than 15 minutes is expected to elapse between completion of surface
surface preparation
and the start of thermal spraying, or if the part is moved to another location, the prepared surface should be protected from
contamination, and finger/hand
moisture, contamination, finger/hand marks. Wrapping with clean ink—flee
ink-free paper is normally adequate.
7.3 TSC FLASH/PRIMER
FLASH/PRIMER COAT
7.3.1 Application Time: A 12 pan] flash/primer
1-2 mil [25-50 um] flash/primer coat of the TSC may be applied within six hours of
completing surface preparation
preparation to extend the holding period for up to four further hours beyond the complete application of
the flash
flash coat. The final
final TSC thickness, however,
however, shall be applied within four hours of the completion of the application of
the flash
flash coat provided the TSC can be maintained free of contamination.
contamination.
7.3.2 Validation Procedure: The use of a flashflash TSC to extend the holding period shall be validated with a tensile
bond measurement
measurement or bend test, or both. Validate by:
1.
1. Cleaning and abrasive blasting a representative job area for a portable tensile bond measurement or a bend
test coupon, or both.
2. flash TSC.
Applying a flash
SJ‘P‘PN

3. Waiting the delay period and applying the final

final TSC thickness.
4. Measuring the tensile bond or perfonning
performing the bend test, or both.
5. Flash TSC and holding period are acceptable if the tensile bond or bend tests, or both, are satisfactory.

261
SSPC-CS
SSPC~CS 23.00(I)
23.00(I)
March
March 1,
1, 2000

S C Application
TSC
8. T Application
8.1 PREHEAT
PREHEAT
Preheating
Preheating the starting
starting area has been common practice in the past for flameflame spraying and should be continued until
proven either a benefit
benefit or inconsequential. m3]
inconsequential. Preheat the initial 1-2 ft. [0.1-0.2 m starting-spray area to prevent water in the
3] starting-spray
flame from condensing on the subsWate.
flame substrate.
1. flame spraying,
1. For flame starting area to approximately 250°F [120°C].
spraying, preheat the initial starting
2. Validate
Validate preheating
preheating requirements Standard and the bend test or tensile test, or both.
requirements with the Job Reference Standard
THERMAL SPRAYING
8.2 THERMAL
8.2.1 Crossing Passes: The specified
specified coating thickness
thickness shall be applied in several crossing passes. The coating
tensile bond strength increases
strength is greater when the spray passes are kept thin. Laying down an excessively thick spray pass increases
the intemal
intemal stresses in the TSC and will decrease the ultimate tensile bond strength of the total TSC. ConfirmConfirm the
suitability of the crossing pass thickness with a bend test or tensile bond measurement, or both.
Spraying: For manual spraying,
Manual Spraying:
8.2.2 Manual right-angle crossing passes to minimize the thin areas in the
spraying, use right-angle
coating.
8.2.3 Mechanized Spraying:
Spraying: For mechanized spraying (mechanized movement of the gun or workpiece, or both),
specification.
program overlapping and crossing passes to eliminate thin spots and stay within the coating thickness specification.
blistering, or a degraded coating appears
8.2.4 Rust Bloom: If rust bloom, blistering, application of the
appears at any time during the application
flash! primer
TSC or flash/primer TSC, the following procedure applies:
1.
1. Stop spraying.
2. off the acceptable sprayed area.
Mark oiT
3. cleanliness and surface profile,
Re-prepare the unsatisfactory areas to the required degree of surface cleanliness including
profile, including
any areas that the TSC was applied to unsatisfactory surfaces.
a. Blast the edges of the TSC to provide for a 2-3 feathered area overlap of the new work into
2—3 in. [5-7.5 cm] feathered
the existing TSC.
b. feathered
Apply TSC to the newly prepared surfaces, and overlap the existing TSC to the extent of the feathered
thickness.
edge so that the overlap is a consistent thickness.
specified in Section 6.1.
8.2.5 TSC Thickness: The TSC thickness shall be that specified
8.2.6 Low Temperature
Temperature Spraying: Thermal spraying in low temperature environments (below freezing)
freezing) must:
1.
1. Meet the substrate surface temperature and holding period of Section 7.2.1 and 7.2.2. No moisture
condensation on the surface is permissible during thermal
thennal spraying.
spraying.
2. qualified with a bend test or portable tensile bond test, or both.
Be qualified
Note: TSCs are mechanically bonded to the substrate.
substmte. Substrate
Substmte preheating
preheating may be required to improve the TSC
tensile bond to the substrate
tensile subsWate and reduce intemal
intemal stresses.

Application of Sealers and Topcoats

9. Application T0pcoats
Thermal sprayed steel should be sealed and/or topcoated
topeoated under any of the following conditions:
conditions:
0• The environment is very acidic or very alkaline
alkaline (normal
(normal pH range for pure zinc is 6 to 12 and for pure aluminum 4
to l 1).
toll).
o• The metallic coating is subject to direct attack by specific chemicals.
specific chemicals.
particular decorative finish
• A particular required.
finish is required.
• Additional required.
Additional abrasion resistance is required.
• Frequent salt-water spray or splash or immersion service.
• Frequent fresh water spray, or splash or immersion service, excluding potable water.

262
 SSPC-CS 23.00(1)
SSPC—CS 23 00(1)
March
March 1,
1, 2000
Note: Sealers and topcoats shall meet the local restrictions on volatile organic compound (VOC) (V0C) content. Sealer and
manufacturer’s
topcoat shall be applied per paint manufacturer's instructions
inslructions for use with a TSC, or as specified
specified by the purchaser.
9;1
9.1 Sealer.
Sealer: The seal coat shall be thin enough when applied to peneWate penetrate into the body of the TSC and seal the
porosity. Added thickness to porous TSC should not be ~ measurable. Typically the seal coat is applied at a spreading rate
u r a b l e . Typically
film thickness.
resulting in a theoretical 1.5 mils [38 microns] dry film
field work, sealers should be applied as soon as possible after thermal spraying and preferably within
For shop and field
eight hours.
If sealer cannot be applied within eight hours, verify contaminated and
verify by visual inspection that the TSC has not been contaminated
is dust-free
dust—free using the clear cellophane tape test (ISO 8502-3), before applying the sealer.
chemically compatible with the sealer and
9.2 Topcoat: A topcoat is essentially a full coat of paint. Topcoats shall be chemically
shall be
he applied per paint manufacturer's
manufacturer’s instructions or as specified
specified by the purchaser. Full topcoats will greatly reduce or
entirely diminish the cathodic protection effects
effects of the TSC in immersion or underground service. Do not apply a paint
topcoat over an unsealed TSC.
9.3 Applying Paints: All paint coatings shall be applied according
accorfing to SSPC-PA “Shop, Field and
SSPC-PA 1, "Shop,
Maintenance Painting of
of Steel",
Steel”, and the paint manufacturer's
manufacturer’s recommendations for use of the product
with aa T
with S C system.
TSC

10. Records
The TSCA shall use a JCR
JCR to l~r_.ord
record the TSCA's information required by
information and other infomaation
TSCA’s production and QC information
the purchasing contract. Additionally,
Additionally, the TSCA shall have its own quality assurance program. The TSCA shall keep
records for a time period consistent with the TSCA's
TSCA’s quality assurance and records program and as required for
regulatory compliance and the purchasing contract. Records should be kept a minimum of one year.

11. Debris Containment and Control

The TSCA and the purchaser shall coordinate the specific responsibilities, and actions for the
specific requirements, responsibilities,
containment,
containment, collection, and removal of the debris produced by the TSCA and its sub-contractors.

12. Work Procedures and Safety

The purchaser shall provide its standard operating and safety
safety procedures
procedures and compliance
compliance requirements
requirements to the TSCA.
The TSCA shall follow all appropriate
appropriate procedures
procedures and meet all appropriate regulatory
regulatory requirements.

13. Documentation
13.1 TSCA’S APPLICATION PROCEDURE:
TSCA'S APPLICATION PROCEDURE: The TSCA shall submit its application
application procedure
procedure proposed for the
contract work. The application
application process shall include information
information on the equipment capabilities, materials, and process or
application prooed—ures.
proced-ures. It shall also include in-process quality control checkpoints
checkpoints for surface
surface preparation, thermal
spraying, and paint work (sealer and topcoat).
13.2 JOB REFERENCE STANDARD:
13.2 STANDARD: A job site pass/fail Job Reference
Reference Standard (JRS) representative of the
whole job or major sections of the job shall be prepared by the TSCA. The IRS
JRS shall be used as a “comparator”
"comparatof' to
application process.
evaluate the suitability of the application
1.
1. The IRS
JRS is made on a steel plate approximately
approximately 18 x 18 x 1/4 in. [46 x 46 x 0.6 cm]. See Figure 2. Note: For
structural steel, the reference
reference standard does not need to be greater than 1/4 in thick because steel will not thermally
thermally
distort when TSC is applied. When actual work is less than 1/4 in thick, the JRS IRS should be made from material of
a representative thickness.

263
SSPC-CS 2300(1)
SSPC—CS 23.00(I)
March 1,
1, 2000

2. field equipment and the process parameters and procedures (surface preparation;
The JRS is made with the actual field
thermal spraying; sealing or topcoating, or both; and in-process QC checkpoints) that will be used for the
contracted work.
3. The JRS
IRS shall be made in representative environmental
environmental conditions spraying, with or without enclosure, as
appropriate.
4. Make thickness and tensile bond ~measurements
u r e m e n t s per Figure 4: four "5 “5 in-line measurements;” and four
in—line thickness measurements;"
portable tensile bond measurements per Section 6.4. The JRS is unsatisfactory if any measurements are less than
the contract-specified
contract-specified value.
5. The JRS is used as a pass/fail reference for the applicator's purchaser’s inspector.
applicator’s in-process QC and the purchaser's

14. C o n t r a c t PPre-Award
Contract r e - A w a r d Evaluation, Demonstration and
Evaluation, Demonstration Validation
and Validation
TSCA’s application process submitted per 13.1.
14.1 The purchaser shall evaluate the suitability of the TSCA's
14.2 The purchaser, as an option for physically validating the TSCA's witness, and
TSCA’s application process, may schedule, wimess,
evaluate a contract pre-award
pie-award demonstration of the TSCA's
TSCA’s application process for the surface preparation, thermal
spraying, sealing, and topcoating, using the equipment, materials, and process procedures proposed for the contract work.
The JRS should be made during this demonstration and witnessed by the purchaser or his designated representative.

TSCA
15. T Warranty
SCA W arranty
15.1 The TSCA shall warrant the quality of its workmanship as mutually agw~i
agreed to by the purchaser and the TSCA.
Materials Used
15.2 Materials Used
The TSCA shall provide the purchaser with a Certificate
Certificate of Materials Used to include:
1.
1. For angular blasting media: media type, grit size range, chemical composition,
composition, and Material Safety Data
Sheet (MSDS).
2. TSC spray feedstock:
feedstock: alloy typeldesignation,
type/designation, lot number, wire diameter, chemical composition of the wire
lot, and MSDS.
manufacturer's product and application data sheets for application on TSC system and
3. Sealer and topcoat: manufacturer’s
MSDS.
l~]gure 2 - Job Reference Standard
Figure

TSG
Eiztfl

8yst~n
«a re:

I'

‘~:.\

per I .-
Contra~ '....'."
tI
8~mo.~ , ~ p , ~ * * ~ * * * ~ . ~ . ~
' J' /
V iiiiiiii‘hy '
T ~v//~ S~el
Stool plate
plat. approximl~ly
approximatoly ~ f 4 f j F ~ F f /
r . F r J r ./
dri t.8- ft x l.&. ftx 1/4 In. r j r j r/
1.5-ftx1.5-ftx1l4ln. -jrj /
fj,~rfj ,,,,
Jiffifflff
. . . . . . .,rj-~j-j

Refemrm* Standard Conflwntlon

Job Reform“ Configuration
scale)
(not to scale)

264
 SSPC-CS
SSPC—CS 23.00(I)
2300(1)
March 1,1, 2000
March

Notes
Notes
1.
1. Aluminum and zinc TSCs have porosity ranging up to 15%. Interconnected porosity may extend from the surface to
15%. Interconnected
accomplished (a) naturally by the oxidation of the sprayed
the substrate. Sealing extends the service life. Sealing is accomplished
aluminm filling the pores with a tightly adherent oxide layer or (b) by applying thin paint sealer coatings that
aluminum or zinc filling
significant natural
penetrate and are absorbed into the pores of the TSC. The paint seal coat should be applied before significant
oxidation occurs. The pigment particle size for colored sealers must be small enough to flowflow easily into the pores of
the TSC, nominally a 5ofiness
5-finess grind per ASTM D 1210. 1210. The paint component of the TSC system is required for
additional chemical resistance. Paint materials must be compatible with the TSC material and the intended service
environment.
environment. For service temperatures 120°C [250°F],
temperatures > 120°C high-temperature resistant coating such as an aluminum
[250”F], a high-temperature
pigmented silicone sealer is required.

TSC thickness measurement

Figure 3 - Line and spot TSC

.... j.J._I_F--J- ....

5 in line at about 2.5 cm [1 in] intervals

5 iina
n a s spot
p o t oofabout
f a b o u t l O100m
c m 2 [1.6in.
[1.6 in. 2]
2]

265
 2300(1)
sspccs 23.00(I)
SSPC-CS
1, 2000
March 1,
March

Qualification
JRS Qualification
Figure 4. Thickness and Tensile Bond Measurements for JRS

,J

s"
1- Divide t h e area into f o u r q u a d r a n t s .
i
/°l

. . . . . .

- M
22- e a s u r e tthickness
Measure h i c k n e s s iin
n e ach q
each uadrant,
quadrant,
55 iin—Iine
n-line a att a b o u t 1-in.
about 1-in. [[2.5
2 . 5 ccm]
m ] iintervals
ntervals
n h e ccenter
e a r tthe
near enter o a4
off a 45
5 o i a g o n a l lline.
diagonal
° d ine.

PULLNO
PULUNO
FORGE
FORCE[
f 1:0v

IELF ALIGHHG
/ FORCE PLATE
r

GASKET

TENSILE
SUBSTRATE SPECIMEN

33 -- MMeasure
easure ttensile bond
ensile b o n d aat
t tthe
h e ccenter
enter o of
f
each
e a c h quadrant
quadrant with a
with a self-aligning
self-aligning instrument.
instrument.

4 - Record
4- Record measurements
measurements
iin each
n e of
ach o f tthe
h e ffour quadrants.
our q uadrants.

266
2f~
 SSPC-CS 23.00
March 1,2000
1, 2000

Annex
A nnex A Model
A --— M odel P r o c u r e m e n t SSpecification
Procurement pecification

The Model Specification Instructions/Rationale

Instructions/Rationale
(Bolded
(BoldEd text is the model specification. tfused,
optional and if
specification. Scripted text is optional used,
should
shoutd match the.format
the format & s~le the final specification.
style used in the,final specification.)I
1. Scope of Work The major production and quality
1.1 Application Procedure
control (QC) steps for applying a
The thermal spray coating (TSC) system (surface preparation, thermal
spraying, and sealing & topcoating) shall be applied in accordance thermal spray coating system are
Sections 4, 5, and 6 of this specification.
speciflcation. summarized in Annex E. Annex E
should be appended to the
pprocurement
r o c u r e m e n t specification to
iinform
n f o r m the T S C A ooff the
TSCA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -IEQEl_iF?H1§13E§;
Inw—«———————_nu-----u—wqu—p———¢---------mnumw—u———-—------------u-u-uu—u—mI—pu—w— ———————————
r_e_qujr_eme.nts..__________________________
.........................
1.2 Items/Areas
ltemstAreas To Be Thermal Sprayed
Specify the item(s) and surface(s)
Apply TSC systems to:
to be (and not to be) thermal
sprayed. Reference and append
engineering drawings or other
ttechnical
echnical ddocuments
ocuments that
that
quantitatively describes the job.
2. Codes & Standards
This specification takes precedence In event of conflict with cited Codes
and Standards.
The
The following
following codes
codes and
and standards
standards (latest
(latest issue)
issue) apply:
apply: List the Codes and Standards cited
Specification for Zinc Wire for Thermal
ASTM B 833-93, Standard Specification in this procurement specification.
specification.
Spraying (Metallizing). Add other standards as required.
ASTM C 633, Test Method for Adhesive/Cohesive
Adhesive/Cohesive Strength of Flame
Sprayed Coatings.
ASTM D 1210, Test Method for Fineness of Dispersion of Pigment-
Vehicle Systems.
ASTM D 4285, Method for Indicating Oil or Water in Compressed
Air.
ASTM D 4417, Test Method for Field Measurement of Surface ProfileProfile
of Blasted Steel.
ASTM D 4541, Test Method for Pull-Off Strength of Coating Using
Portable Adhesion Testers.
ASTM D 4940, Test Method for Conductmetric Analysis of Water
Soluble Ionic Contamination of Blasting Abrasives.
ANSI/AWS C2.18-93,
C2.18—93, Guide for the Protection of Steel with Thermal
Spray Coatings of Aluminum, Zinc, and Their Alloys &
Composites.
SSPC 97—07,
97-07, The Inspection of Coatings and Linings: A Handbook for
Specifiers.
Inspectors, Owners, and Specifiers.
SSPC-AB
SSPC—AB 1, 1, Mineral and Slag Abrasives.
SSPC-PA 2, Measurement of Dry Paint Thickness with Magnetic
Gages.
SSPC SP-5/NACE
SP-S/NACE No. 1, White-Metal Blast Cleaning.
SSPC—SP 10/NACE
SSPC-SP IO/NACE No. 2, Near-White Blast Cleaning.
SSPC-VIS 1-89, Visual Standard for Abrasive Blast Cleaned Steel.

267
 SSPC-CS 23.00(I)
2300(1)
March 1,
1, 2000

The
The Model Specification
Specification Instructions/Rationale
specification. Scripted text is optional and if
(Bolded text is the model specification. used,
ifused.
should match the format & s~le
theformat siyie used in the ~nal spec{fication.)
thefinai specification.)

__3..
3. .... rs
TSC.c. sy. .tem. R:qui_r.e..m_,_
System Requirements np_ ..................................................
u-n-u-u-————n-n-uIn-..-———¢—n--—--——————-——_~--n--—u—
—————————————————————————
--nu---———n-u-m—m—un-unwn—nu-----up—-u-u----unv—qs-u-n-u-w-uun

3.1 Surface Preparation Requirement

.u—-q—--uww——--n———u
. . . . . . . . . . . . . . . . . . . . .--mw—----'——----'——u_----—
. . . . . . . . . . . . . . . . . . . . . . ——_u-—w—w———u-fi-w—
. . . . . . . . . . . . . . —————‘fifiw-—————-————————w

3.1.1
3.1.1 Surface Finish. The steel substrate shall be abrasive blasted to
(a) Specify either white metal
(a)
4g) SSPC-SP-t if olligrease
.. Degrease per SSPC-SP-1 finish
oil/grease contaminated.
contaminated.
finish, SSPC-SP
SSPC-SP 55/NACE {N ACE N0. No. 11,
for marine and immersion service;
or near-white metal finish,finish, SSPC-
10/NACE No.
SP 10/NACE N0. 2, for other
a_p.p_J
ic_at ............_.._._..-__._
__________________________________________________________ _._ser_Y£<=_e_apeli_ceii99§-____-_____
3.1.2 Blasting Media Requirement. Use (a) angular blasting
angular (a) Specify abrasive basting media
media to produce the angular
angular profile specified by Section 3.1.3
profile depth specified .
ttypee andd size. See Note 1
N e (1).
below. Mineral and slag abrasives shall be selected and evaluated per yp an 5126' See 0t ( )'
._S_SPg-_A.
SSPC-AB B.I_
1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.3 Blast Angular

Angular Profile Depth. The steel substrate shall have an
. ang_ular
angular pro_ffie_
profile de.pth._>__2.._5.mil
depth 2 2.5 mil [_63_1:}m] with a sharp angular shape. . . . . . . . . .
[63 pm] _w]~.a_?h_ar_p.a_n.gular.sh.a_p.e._
profile
angular profile
3.1.4 Blast Profile Measurement Schedule. Measure the angular (a) Specify
(a) minimum area,
the minimum
Specify the e.g.,
area, e.g.,
depth in a measurement
measurement spot approximately every (a) of 100 to 200 ft2 [10_20 m2]
100 to 200 ft2 [10-20 m2].
blasted surface. Take 3 measurements
measurements per spot in approximately a 1.5- '
[1 O-cmz]
in?z [10-cm
in. measurements and record in the Job
z ] area. Average the measurements
Control Record (JCR). (See Note 2 of Annex A)
3.2 Requirement
Thermal spray Coating (TSC) Requirement
-—————nfln—-w—wm—-_u--—I"-—uflann—-—-—-—n-uw—w——-—----I—I—Innu”—w'w—wuwww-wn—u—-—-———-——mu

Requirement
Feedstock Requirement
3.2.1 Thermal Spray Feedstock
3.2.1 (a) wire per
Specify wire
(3.) Specify per Annex C or
Annex C or
_Use a
-992 ._.Li~.h....ae _ .r[n_a/_spr_a_y_.wire_
themalsptaxxv . . . . . . . . . . . . . . . . . . . ._____________
ifi; ._____________ ............. 333-
ASTM BB 83
______ _ AST.M_. .3_ . . . . . . . . . . . . . . . . .
3.2.2TSC Thickness Requirement
Requirement (a)
(a) Specify
Specify the
the minimum
minimum
The minimum thickness shall be
minimum TSC thickness (a) . thickness.
The maximum TSC thickness
thickness shall be (b)
(bi . b S .f h .
Measure
Measure TSC thickness
thickness per SSPC-PA 2. ((h') p e c i f yy
b ) k S peel t e
the maXImum
m aximum
thickness.
t 10 ness.

3.2.3 TSC Tensile Bond Requirement

3.2.3TSC Requirement (3)
(a) Specify the minimum tensile
(a) The TSC shall have a bond of
tensile bond
minimum tensile
a minimum of igi
(a) psi
psi bond.
[MPa] per ASTM D 4541
4541 using a self-aligning
self-aligning portable test .
specified in 3.2.2.
thickness specified
instrument for the coating thickness (b)Adhesive
(b)Adhe31ve type.
type.
following adhesive:
Use the following (bi
(b) manufactured by
manufactured (c)
(0) Manufacturer of
Of the adhesive.
(c)
Record this information
information in the Job Control Record (JCR, see Note (2))
and the expiration date for
for the use of the adhesive.
For the adhesive used, attach the manufacturer's
manufacturer's instructions
instructions to the Job
_5919!?!
_Referen E". S_.9_n.dard (.JR.~
ce $339301 (453.; .se .eNote_(3.))._. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
939...“!!!919):
-
268
 SSPC-CS
SSPC-CS 23.00
March 1,2000
March 1, 2000

The
The Model Specification
Model Specification Instructions/Rationale
Instructioniationale

(Bolded
(Bolded text
text is the
the model
model specification. ifused,
specification. Scripted text is optional and if used,
should match
match the format
~Cormat& s~le final speci~cation.)
style used in the ~nal specification.)

Test
3.2.4 Bend Test The bend test (180-degree bend on
Conduct
Conduct a bend test
test at
at the
the beginning of each
beginning of work shift
each work or crew
shift or change:
crew change: a mandrel) is used as a qualitative
test for proper surface preparation,
(1) Use carbon
carbon steel
steel coupons dimensions 2 x 4 to 8 x
approximate dimensions
coupons of approximate
0.050 mm].
0.050 in. [50 x 100 to 200 x 1.25 mm].
equipment setup, and spray
parameters. The bend test puts the
(a) Surface
Surface preparation
preparation per contract specification.
contract specification.
thermal spray coating in tension.
(b) Spray
Spray 8-10
8-10 mils
mils [200-250
[200-250 ktm]
pm] thick TSC. The
thick TSC. should be
TSC should
The TSC The mandrel diameter for the
sprayed
sprayed in crossing
crossing passes
passes laying
laying down approximately 3-4 mils
down approximately threshold of cracking depends on
[75—100 lam]
[75-100 per pass.
um] per
substrate thickness, coating
substrate
(2) Bend
Bend coupons
coupons 180 degrees
degrees around 0.5-In. [13-mm]
around a 0.5-in. diameter
[13-min] diameter thickness, and mandrel diameter.
mandrel.
mandrel.

Bend test
test passes
passes if there
there is
Is no cracking
cracking or minor cracks
or only minor with no
cracks with
spalling
spalling or lifting
lifting (by a knife blade), substrate.
from the substrate.
blade), from
Bend
Bend test
test fails if the coating cracks with
coating cracks lifting (by a knife blade)
with lifting from the
blade) from
. .
substrate.
substrate.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.5 TSC Porosity Requirement (a) Flame and arc are spraying aluminum
and zinc for
for the corrosion protection
The TSC shall have a porosity S
~_ (a) % per metallographic
of
of steel generally have porosity _~ S
analysis of
of a bend coupon made during the Contract Pre-Award Validation.
Pre—Award Validation.
15%. The TSC thickness should should be
See Note 5.
selected so that there is no inter-
connected porosity to the substrate.
substrate. A
porosity TSC requires
lower porosity requires less
thickness. Porosity measurements are
used for in-process quality control
not usedfor
for corrosion protection
in metallizing for
of steel. However, a metallograph
of metallograph
sample must be used to evaluate the
TSC porosity
porosity andand confirm
confirm the TSC
non-through porosity thickness for
non-through for the
contract-specified
contract-specified thickness. If
If
porosity metallograph
required, the porosity
should be taken from
sample should from the bend
coupon made during the purchaser's
purchaser’s
witnessing of of the preparation
preparation ofof the
———--u--u----u-—mw-n—wfl——‘--—-------------------------flmum
_Job.13_
Jab. fere_ ce flawed]:
Eastern: st_ MerA ___________
...........
3.3
3. 3 Sealers and Topcoats Specijy
Specify use of of sealer when (a) the
service environment
service environment precludes
precludes
1, "Shop,
All paint coatings shall be applied according to SSPC-PA I, "Shop, Field and
eflectiveness
effectiveness ofof the natural oxidation
Maintenance Painting", andand the paint
paint manufacturer's
manufacturer's instructions for
for use of
of
'fill and
to ’j’ill and seal
seal"" the pores or (b) a
the product with a thermal sprayed coating system.
paint topcoat
paint topcoat (cosmetic
(cosmetic and/or
and/or
Use a heat-resistant silicone alkyd aluminum paint or equivalent sealer on functional
functional purpose) is specified.
specified Long
components whose operating temperatures are greater than 80°C [175°F].
[1 75°F]. preclude adequate
delay times will preclude
penetration of of the sealer into the pores
of the TSC.
of The sealer must be
chemically compatible with the TSC
material and the topcoat.

269
 SSPC-CS 23.00(I)
2300(1)
March 1,
1, 2000

The Model Specification Instructions/Rationale

specification. Scripted
(Bolded text is the model specification. ifused,
Scripted text is optional and if used,
should match the prmat final s[peci~cation.
style used in the final
format & st~le specification.)I

3.3.1Sealer
3.3.1 Sealer Specify formula
(a) Specify formula or other unique
(1) identification.
(I) Use
Use the
the sealer
sealer a[_q]~
(a; manufactured
manufactured bby:
y.' b(~__
(b) identification.
(b) Specijy manufacturer.
(2)
(2) Follow
Fallow paint
paint manufacturer's
manufacturer’s application
application instructions
instructions for
for applying
applying the (b) Specify manufacturer.
sealer on TSCs. The seal coat shahshall be thin enough
enough when applied
applied to
penetrate
penetrate into the body of
of the TSC and
and seal the porosity. Added
Added thickness
to porous
porous TSC should
should not be measurable.
measurable. Typically
Typically the seal coat is
applied
applied at a spreading
spreading rate resulting
resulting in a theoretical
theoretical 1.5
l.5 mils [38
microns] dry film thickness.
dryfilm
(3) Sealer Application
Application
For shop work, apply sealers immediately
immediately after thermal spraying.
fieldwork, apply the sealer as soon after thermal spraying
For fieldwork, spraying as possible
possible but
preferably within 8 hours.
preferably
If
If sealer cannot
cannot be applied
applied within 8 hours, verify that the TSC (a) has not
been contaminated
contaminated by visual visual (lOx)
(l) inspection
inspection and and (b) is dust free free using the
_ cJe_aC ce_ll..op.ha.ne,t_agetest. (1.S0.8_502:3_2:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Topcoat. Specify formula
(a) Specify formula or other unique
identification.
identification.
(1)
(I) Use the topcoat (a) manufactured by:
manufactured (b)
(b) Specijy
Specify manufacturer.
manufacturer.
(2) Apply the topcoat to a dry film thickness (DFT) of
dryfilm of (c)
to) per
per
manufacturer's
manufacturer’s instructions. (c) Specify
Specify thickness from
from similar
successful
successful applications
applications or
manufacturer's's recommendations
manufacturer recommendations for
for
topcoating sealers on TSC ’s.
topcoating 's.
4. Surface Preparation Blasting
Blasting media
media is specified
specified in
Use blasting equipment,
equipment, materials,
materials, and procedures that will produce the 3.1.2.
finish and an angular profile
Section 3.1 metal finish profile >
2 2.5 mil [63 t~m].
pm].
The suitability of the blasting, media, procedures, and equipment
equipment shall
be validated in the Contract Pre-Award
Pro-Award Validation. See Note 5.
5. TSC Application
—w—wmuu——-—-—-———u-—-——————-u¢—

5.1 Thermal Spray Equipment

Equipment Setup
5.1.1 Thermal spray equipment
equipment shall be set up, calibrated, and operated
manufacturer's instructions and technical manuals or the TSCA's
per the manufacturer's
refinement
refinement thereof and as validated by the Job Reference Standard
(JRS). See Note 3.
5.1.2 Spray parameters
parameters shall be set for spraying the specified thermal
minimum, be validated with the bend test. A
spray material and, at a minimum,
bend test will be satisfactorily
satisfactorily performed at the beginning of crew and
shift changes.
5.1.3 A copy of the spray parameters
parameters used shall be attached to the JCR.
5.2 Post-Blasting Substrate Condition and Thermal Spraying Period
5.2.1 Steel Surface Temperature
Temperature
The steel surface temperature
temperature shall be at least 5°F [3°C] above the dew
. point_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

270
 SSPC-CS 23.00
1, 2000
March 1,

The Model Specification Instructions/Rationale

Instructions/Rationale
specification. Scripted text is optional and ifused,
(Bolded text is the model specification. if used,
_should.
s.hoW#".m.atyh .t_he
astral! ~ormqt ~..s_~!e.used !n..(heF~_qt-see.c"~c.a.t.i.o~.).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
teetering!sisal?use!lati’efiItQtteeafieeEém-J............................ nun---unpu————--a.was-.._———_q._uu—w—u——__—————_..-
-
5.2.2 Holding Period
(1) Time between the completion
(1) of the final
completion of final anchor-tooth
anchor-tooth blasting (or
completion of the themal
final brush blasting) and the completion thermal spraying
for steel substrates. In high
should be no greater than 6 hours for
humidity
humidity and damp environments,
environments, shorter holding
holding periods shall be
used. If rust bloom or a degraded coating appears at any time while
spraying, 5.5.4 applies.
(2) In low-humidity
low-humidity environments
environments or in enclosed spaces using industrial
industrial
dehumidification equipment,
dehumidification equipment, it will be possible to retard the
oxidation of
of the steel and hold the surface finish
finish for
for more than 6
hours. The TSCA, with the concurrence
concurrence of the purchaser, can
validate a holding
holding period greater than 6 hours by determining
determining the
acceptable
acceptable temperature-humidity
temperature-humidity envelope for for the work enclosure by
spraying and analyzing bend coupons,
coupons, tensile bond coupons, or
both.
(3) For small and movable parts, itif more than 15 minutes is expected to
elapse between completion
completion of surface preparation
preparation and the start of
thermal spraying, or if the part is moved to another location,
location, the
prepared surface should
should be protected
protected from moisture, contamination,
contamination,
and fingerthand
finger/hand marks. Wrapping
Wrapping with clean print-free paper is
.... .. .. .. remain
ng_rrnally " assesses.
ad_ e ( ] u a _ t e _ ......................... ............... ,. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
5.3
5.3 TSC
TSC Flash/Primer
Flash~Primer Coat
Coat Specify the use of
Specifiz of a Flash/Primer
Flash~Primer TSC
5.3.1A
5. 3.1 A 1-2 mil [25-50 pm]
IJm] flash/primer
flash/primer coat
coat of
o f the
the TSC
TSC may
may bebe applied
applied when
when there
there is
is aa requirement
requirement to
to extend
extend
the time-based
time-based holding period
period beyond
within
within 66 hours
hours ofcompleting
of completing surface
surface preparation
preparation to extend the holding period
period that specified
specified in
in 5.2.2.
5.2.2.
that
for
for up to 44further
further hours beyond
beyond the complete application of of the flash
flash coat.
The final
final TSC thickness, however, shall be applied within 4 hours of of the
completion of o f the flash
of the application of flash coat provided
provided the TSC can be
__ metastasis?efeeeteei eattee. __________________
_m.ain_ta_i.n_e4~_ee __o Ic_o_n_ta_m.in_a_ti_o_n_ ________________
.............................................................
u.--—q-—————_————_————_
--————-

5.3.1 Validate the use of o f the Flash TSC holding

holding period
period with a
(a) .
(a) (a) Specify
Specify validation
validation method, i.e.,
Clean and abrasive blast a representative
representative job
job area and 3 bend-test coupons.
coupons, bond measurement
with a tensile bond measurement or
Apply a flash
flash TSC to the representative
representative job
job area and
and the 3 bend coupons.
coupons, bend test,
bend test, or
or both.
both.
Wait the delay period
period in representative
representative environmental
environmental conditions and
and apply
the final
final TSC thickness.
Flash TSC and holding period
period are acceptable if
if the tensile bond specified
specified in
__ new}... itemizetest.
_Se_cji_o_~_3=:_.2_o_rp_e~_q page. ere.
test_,_o_r_b_ot_~ EQ’{SIQ€£Q’2’-________
_ares.a_a.sla_cp_rg. - ....................._______________
. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4
5.4 Preheating
Preheating Specify the preheating requiremen
requirementt
For flame
flame spraying, preheat the initial
Initial starting area to approximately 50°C for flame spraying.
spraying, Preheating is
[120“F]
[120°F] to prevent condensation
condensation of moisture in the flame onto the n o r m a l l y required
not normally required for are
arc
substrate.
substrate. Validate preheating and non-preheating requirements with aa spraying.
(a) spraying.
(e)
(a) Specify validation method, i.e.,
with a tensile bond
bond measurement
measurement
nun—'——I-——mu---—-wn——mHu------—--O
—w—w—mflfiflu------—w——w———w
or E29114
_ 91: bend 'EQSLRTIZQ'CD;
test, or both. ____________
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

271
 2300(1)
sspc-cs 23.00(I)
SSPC-CS
March 1,
March 2000
1, 2000

The
The Model
Model Specification
Specification Instructions/Rationale
Instructions/Rationale
(Bolded text is the model specification.
specification. Scripted text is optior~l
optional and ~used,
ifused.
should match the format
format & s~le the final s•ecification.
styie used in the,final specification.)I

Thermal
5.5 T Spraying
hermal S praying
5.5.1
5.5.1 Apply the specified
specified coating
coating thickness overlapping
thickness (Section 3.2.2) in overlapping
passes. The coating tensile bond strength is ls greater when the spray
thick spray pass
passes are kept thin. Laying down an excessively thick
increases the internal stresses in the TSC and will decrease the ultimate
tensile-bond
tensile-bond strength of the total thermal spray coating. Confirm the
suitability of the crossing-pass
suitability crossing—pass thickness
thickness with (a)
measurement
measurement.
(a) p e c i f y vvalidation
(a) SSpecify alidation m method, i.e.,
e t h o d , i.e.,
with
w i t h a tensile
t e n s i l e bond
b o n d measurement
measurement
-uw—u—--—-——u——-w-—--—u—-—.—-u---swam—www—“u----—-—-—u—-—n—u-u—u-c—o—nnwu—u—uw-—————_——-—-u_—.
or bbend
or test, or
e n d test, or both.
both.
5.5.2 For manual spraying:
(1) On 0n non-fixtured
non-flxtured components,
components, spray perpendicular
perpendicular crossing passes
to minimize thin (below contract-specified
contract-specified thickness) areas.
(2) On 0n fixtured rotating components,
components, spray perpendicular overlapping
perpendicular overlapping
passes so as to obtain the contract-specified thickness as the spray
contract-specified thickness
gun is advanced over the rotating component. component.
5.5.3 For mechanized spraying, program overlapping overlapping or crossing passes,
or both, to eliminate
eliminate thin spots and stay within within the coating thickness
specification.
specification.
5.5.4 If rust bloom, blistering, or a degraded coating appears at any time
during the application
application of the TSC, TSC. the following
following procedure
procedure applies:
(1) Stop spraying.
(2) Mark off the acceptable
acceptable sprayed area.
(3) Call the TSC inspector
inspector to observe, evaluate, and record the error.
inspector shall immediately
The inspector immediately notify the purchaser of the
_. . . ._ _ _def_i_ci_en_c~_an
PEIiEiPPPY _d_r_e9 u_es_t_in_s_t_ru_qt
999.'99!§§t30§tfl9t19.".3; io_n~ .............................
..........................
-
5. 6
5.6 Thermal spraying in low temperature environments (below freezing)
Thermai Include 5.6 for
Inciude for thermal spraying
spraying in
. . . . . . low temperature
tem erature environments (below
beio
moisture or condensation
No morsture condensation on the surface is permissible
permissdale during surface freezingf ( w
freezing).
preparation and thermal spraying. '
. . . (a)
a) Specify
Specifi/ validation
vaiidation method,
method i.e.,
i.e.
Qualify
uatt TSC period with a
eriod With (a)
a . ( . . ’ ’
Q fl) p ( ) with a tenszie
With tensile bond measurement
measurement or
Meet the tensile
tensiie bond and metallographic
metaliographic requirements of
of the purchasing
purchasing bend test, or both.
contract.
contract.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
——-——n—-*mflfiflm_--uu--------u-mfifiuwhwwww——-—---------fl--—_—— . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 T
TSC Measurement
SC M Schedule
easurement S chedule
accordance with SSPC-PA 2.
(1) The TSC shall be made in accordance
(2) Use a measurement for flat
measurement line for flat surfaces. Take the average value of
readings taken
5 readings taken in line at 11 in. [2.5 cm] intervals.
Intervals. The line
measurement will measure the peaks and valleys of the TSC.
measurement
measurement spot
(3) Use a measurement spot for
for complex
complex geometry's
geometry's and geometry;
geomet~
transitions.
transitions. The measurement
measurement spotspot should
should be approximately
approximately 1.5 in.
cm2]. The spot
[10 cmz]. spot measurement
measurement may not measure the peaks and
valleys
valleys ofof the TSC. Illustrates the line and spot
Note 4 Illustrates spot
measurements.
(4) Record in the JCR.

272
272
 SSPC-CS 23.00
March l,
1, 2000

Specification
The Model Specification Instructions/Rationale
(Bolded text is the model specification.
specification. Scripted text is optional
optional and if used,
ifused.
should match the format & s~le the final speci[ication.
style used in the[Thai specification.)!

66. Sealer andTopcoat

and Topcoat if a sealer is
Include this section if
speczfied.
The seal and topcoat shall be applied according to SSPC-PA SSPC—PA 1, I, "Shop, Field specified
and Maintenance Painting", and the paint manufacturer's
manufacturer's recommendations recommendations
_Jew?
for_us e ofthej~_rodu_ct
eithsnreeeet wjtha_
mm TS_C_ _s~stem_ . . . . . . . . . . . . . . . . . . . . . . . . . .____________
2139‘acne-_________________ ................................
6.1
6.] Apply sealer as specified
specified in Section 3.3.1.
3. 3. l. if a sealer is
Include this section if
.————-u---——m——------uw——--------—
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-w—-w*fl-—-----—w—wn—————- . . . . . . . . . . . . . . -mee{fleei-......................
. . . . . . . . . . . . . . . . . . . . .

6.2
6. 2 Apply topcoats as specified in Section 3.3.2. if a topcoat is
Include this section if
specified

7. TSCA's
TSCA’s Detailed
Detailed P rocedure
Procedure Specify the requirements for the
The TSCA shall submit the detailed procedures conforming to Section 4 following
following information required:
as required:
information as
(surface preparation), Section 5 (thermal spraying) and Section 6 (Sealer, Safety, Thermal spray Operator
and topcoat). The procedures shall detail the equipment, application Q ualification,
Qualification, T SCA
TSCA work
work
process, in-process quality control, and Job Control Record to be used performance history, and customer
performance history, and customer
the contract
for the work. The
contract work. information shall
The Information include:
shall include: contact
for contact references
references for
for validation.
validation.
(1) Detailed procedures for
for surface preparation, thermal spraying,
sealing/topcoating,
sealingltopcoating, and the in-process
ln-process quality control checkpoints.
(2) Equipment (surface preparation, thermal
themal spraying, sealing & 8-
topcoating, and the in-process quality control) to be used and for
for
which the detailed procedures apply.
(3) Blasting media, thermal spray feedstock, and sealingltopcoating
sealingltopcoatlng
materials.
(4) Job Reference Standard (JRS). See Note 3.
(5) Job Control Record (JCR). See Note 2 and Annex B.
(61
(6) Repair procedure for
for defective TSCs.

8. Contract
8. Contract Pre-Award
Pro-Award Evaluation,
Evaluation, D e m o n s t r a t i o n and
Demonstration
Validation
Validation
8.1
8.1 Data Requirements
The TSCA shall submit the detailed Information
information cited in Section 7. This
information shall be submitted prior to contract approval and at least (a) Specify lead time.
(a) days prior to Contract Pre-Award
Pro-Award Evaluation
_ p_e_m_o_n.s_t
_ _re_u_o_n_a_n_dVa_,_d_ Lo _n. _S_e_e
Psmqnsseflsn.3991?@9999; _N_o_t_e15).: .........................
$9.519}? ........................ u-m—-—————-—-——-—w—m—hw—w—--—-

8.2 E quipment &

Equipment 8. P rocess D
Process emonstration &
Demonstration 8. Validation
Validation
The actual equipment and processes to be used for for the contract work
shall be demonstrated and validated to produce the specified TSC. This
demonstration and validation shall be scheduled (a) days (a) Specify lead time.
after delivery of the data requirements, Section 8.1.

273
SSPC-CS 23.00(I)
2300(1)
March 1, 2000
Notes
N o r tthe
o t e s ffor Model
he M Specification:
odel S pecification:
(1) Blastin,q
Blasting Media. --—-
- Use blasting
blasting equipment,
equipment, media,
media, and mesh
mesh size appropriate to meet
appropriate to finish
surface finish
meet the surface
and the
the anchor-tooth
anchor-tooth profile
profile requirements
requirements of
of the purchaser
purchaser or
or purchasing contract. Mineral
purchasing contract. abrasives
slag abrasives
Mineral and slag
should
should conform
conform to
to SSPC-AB
SSPC-AB 1:
Type I - Natural
Natural Mineral
Mineral Abrasives,
Abrasives, Grade 3 (2.0 to
to 3.5 mils) or Grade 4 (3.0 to
mils) or mils).
to 5.0 mils).
Type IIll - Slag Abrasives,
Abrasives. Grade
Grade 3 (2.0 to
to 3.5 mils)
mils) or
or Grade 4 (3.0 to
to 5.0 mils). suitability of
mils). The suitability blasting
of the blasting
media
media and surface
surface preparation
preparation process
process shall
shall be validated preparation of
during the preparation
validated during the JRS.
of the
Blasting ;ize Found
and Mesh Size
Blasting Media and Found Suitable
Suitable for Substrates
for TSCs on Steel Substrates
Thermal Process MediaII
Blasting Media" Size”b
Size
Spray
Material
AI, Zn, Flame Wire Aluminum
Aluminum oxide 10-30 Mesh
90110
85115, 90110
85/15, &
8: Angular steel grit G-16 to G-24
6-24 G-16
6-16 to G-24
6-24
MMC Arc Wire Copper &
a nickel slag
Garnet 30i40
6—16 to 30/40
G-16

AI,
Al, Zn Flame Powder Aluminum
Aluminum oxide 10-30
10—30 Mesh
Angular steel grit G-16
6-16 to G-24
6-24
a. All blasting media should be dry and free of all oil/grease, fines, and materials not allowable in the blasting media material
oillgrease, fines, material
specification.
specification.
b. Select mesh size appropriate to the anchor-tooth depth requirement and the blasting equipment used.

(2) Job
Job Control
Control Record
Record (JCR) --—-——
- The JCR is a permanent
permanent record
record of
of the
the job. JCR contains
job. The JCR job
essential job
contains the essential
information
information and the
the in-process
in-process QC checkpoints
checkpoints required
required by this
this standard.
standard. The JCR
JCR includes
includes information
information on
safety
safety precautions,
precautions, and
and the equipment,
equipment, parameters,
parameters, and
and procedures
procedures for
for surface
surface preparation, spray, and
thermal spray,
preparation, thermal
sealing.
seafing.

(3) Job
Job Reference Standard
Standard (JRS) -—-—-——TThe
h e JRS is a job
Job site pass/fail
passlfaii reference standard
standard representative
representative of
of the
whole
whole job
Job or
or major sections of
major sections job.
of the job.
a. The JRS is made
made with
with the actual
actual field
field equipment
equipment and
and the
the process
process parameters
parameters and and procedures
procedures (surface
(surface
preparation,
preparation, thermal spraying, and
thermal spraying, sealing or
and sealing and ttopcoating
sealing and
or sealing o p c o a t i n g with in-process quality
with in-process control
quality control
checkpoints)
checkpoints) that
that will
will be used for
for the
the contracted work.
contracted work.
b. The JRS shall
shall be mademade in representative
representative environmental
environmental conditions
conditions during during the
the contract
contract work,
work, with
with or
or
without
without enclosure,
enclosure, as appropriate.
appropriate. The JRS shall shall be used
used as passlfail
pass/fail reference
reference for for the
the applicator’s
applicator's in-process
in-process
QC and the purchaser's
purchaser’s inspector.
inspector.
c. Make TSC thickness
thickness and tensile
tensile bond
bond measurements
measurements per the Note (3) illustration.
illustration.
.• Four
Four "5 in-line thickness
“5 in-line measurements".
thickness measurements".
.• Four
Four portable tensile bond
portable tensile measurements.
bond measurements.
.• The JRS is unsatisfactory
unsatisfactory ifIf any measurements
measurements are less than
than the contract
contract minimum
minimum specified
specified value.
Note (3) Illustration
Illustration

s/
/
i
/
./
. . . . . /r./ . . . . . . .

1 - D i v i d e t h e a r e a i n t o f o u r quadrants.
2- Measure
2— M e a s u r e thickness,
t h i c k n e s s , 5 in-iine
In-line at
about
a b o u t 1-in,
l-In, [2.5 cm]
c m ] intervals
I n t e r v a l s near
near
the
t h e center
c e n t e r of
of a
s 45
4 5 °o diagonal
d i a g o n a l line.
IIn~

Repeat & record measurements

4- Repeat
in each of the four quadrants.
ofthe

3- M e a s u r e ttensile
Measure bond
emllle b at the
o n d at
ccenter off tthe
enter o he q quadrant.
uadrenL

274
274
 SSPC-CS
SSPC—CS 23.00
March 1,2000
Measurement
(4) TSC Thickness Measurement
One measurement m2]
measurement spot every 100 to 200 ftft22 [10-20 m 2] of TSC.
applied TSC.
of applied
Take the average value of 5 readings per measurement
measurement line or spot.
Use a measurement
measurement line for
for flat 1 in. [2.5 cm]
flat surfaces. Take the average value of 5 readings taken in line at 1
intervals. The line measurement
measurement will measure the peaks and valleys of the TSC.
Use a measurement
measurement spot for for complex geometries
geometries and geometry transitions. measurement spot should
transitions. The measurement
be approximately 1.6 in.
in.2z [10 cm2].
cm2]. The spot measurement T30.
measurement will not measure the peaks and valleys of the TSC.

Note (4) Illustration

Illustration

B_M_B-P--P- . . . .

5 in line at about 2.5-cm [1-in, ] intervals

5 in a spot of about
spot of cm22 [1.6
about 10 cm in.2]
[1.6 in. 2]

(5) Contract Pre-Award

Pre-Awgrd Validation
Validation

If
if required by the purchaser, the evaluation of the suitability
suitability of the TSCA's equipment,
equipment, application
application and QC
processes, and technician/operator
technicianloperator capabilities
capabilities should be made prior to contract
contract award. The contract
contract pre-award
validation should include:
(1) A written summary of the equipment
equipment capabilities,
capabilities, the process instruction,
instruction, and operator experience
proposed for
for the contract
contract work.
(2) The written summary should include items cited in Sections (A), (B), and (C) below.
(A) Surface Preparation
information on the abrasive blasting media,
(1) Equipment, material and MSDS, and process information media, the surface
preparation
preparation procedure, and the in-process QC method to be used.
Demonstration of the surface preparation
(2) Demonstration preparation and QC actions with the equipment
equipment and personnel proposed
for
for performing
performing the entire project.

(3) JCR.
(4) Other information
information and demonstrations
demonstrations required by the purchasing
purchasing contract.

(B)
(3) Thermal Spraying
feedstock and MSDS, procedure
(1) Equipment, feedstock procedure and parameters, and the QC method to be used.
Demonstration of the procedure
(2) Demonstration procedure and QC actions with the equipment
equipment and personnel proposed for
for
performing
performing the entire project.
(3) JCR.
(4) Other information
information and demonstrations
demonstrations required by the purchasing
purchasing contract.

275
SSPC-CS
SSPC~CS 23.00(I)
2300(1)
March 1,2000
1, 2000

(C) Sealerand
Sealer and Topcoat
(1) Equipment, liquid coating products and their MSDS, manufacturer's
manufacturer’s application instructions for the
application on the contract specified TSC feedstock, and the QC method to be used.
for
(2) Demonstration of the procedure and QC actions with the equipment and personnel proposed for
performing the entire project.
(3) JCR.
(4) Other information and demonstrations required by the purchasing contract.

276
 SSPC-CS 23 00(1)
SSPC—CS 23.00(I)
March l,
1, 2000

Annex B - Model Job Control

- Control Record

Model Job
Model Record ((JCH)
Control Record
Job Control JCR)
(Add steps specified
Specified in the contract if not specified
specified in the model JCR. Delete steps not specified con tract.)
specified in the contract.)
T§CA:
TSCA: JJCFl
C R #: Date:
T§CA
TSCA PPoint
oint o Contact:
off Contact: Tel:
Customer/Contract
C ustomer~-nt~t #:
#:
Customer
Customer POC: POC: Tel:
Spray
§pray Equipment
Equlpment Data: Spray machine
beta: spray mfg:
machine mfg: Model:
Model:
Feedstock:
Feedstock: TSC minimum/maximum
mlnimumlmaxlmum thickness,
thickness, mils:
mils: minJ
min! max.
Thickness/pass:
Thicknesslpass: i n . in. Standoff
Standofl D istance:
Distance: in. Other:
Other:
DAIEY'FHUD‘U'C‘HUN‘RECUHD
D AILY PHODUE;]iQN HI=CUPID Dare:
Date:
Work ItIt ee mIArea:
Work m/Area:
Environmental Requirements
Environmental Requirements Inltlals
In hints for
Check-Off
1- The steel surface temperature
temperature shall be at least 3-dog point
til-deg C [5-deg F] above the dew poinL
-flgl

Step Producfion Process

Production Process
Requirement ] In-Process
ln-Process QC Check Check P Point
oint
~ u r t a c e P ' r e p a r a u o n - u ~ ' u ~P-~/NA(.;~- ; Z w n n > z.b-mil - a n g u l a r p r o i l l e ))
(White metal
meta! finish rsc uired for madne,
required marine. immersion, service.)
immersion. and other critical service.)
Degrease to
Degrease to remove salts. &
oil, salts,
remove oil, 8: t1.1-
.1- DusVdirt:
. . Dust/dirt: Clear
Clear tape
tape pulloff
pullofl &
& visual/10x
visual/10x magnification.
magnification.
other contamination.
contamination.
12-
1.!— Oil/grease:
Uil/grease: Solvent evaporation
evaporation test,
test.
1.3-
1.3- Na &8: S salts: Potassium ferrocynlde filter
Potassium ferrocynide filter paper test.
Validate clean 10lasting
Validate blasting air & ti: 2.1- Clean blasting media per ASTM D 4950 (water sheen test). No
media,
media. fines.
fines.
2.2- Clean blasting
22- Blasting air per ASTM
Kg I M D U 4285
4§§5 (air through clean cloth or
air in bottle condensation
condensation test).
finish with
specified finish
Blast to specified t > 2.5- 3.1- Angular profile profile depth: Profile depth-gage measurement
Profile tape or depth-gage
rail angular profile,
mil profile. per ASTM D 4542 & contract sampling schedule. schedule.
4.1- Clean & dust/dirt
4.1— dusVdirt free
tree surface per visual/10x
visuai/iOx magnification
magnification & the
4 dust-free surface.
Clean & dust-free “clear-tape pull-oft' test.
"clear-tape pull.off" test.
Thermal
l'hermal SEpraying
praying
Holding Pefiod
Holding Period between 5,1- Holding periods shall be no greater than 6 hours for steel
5.1-
completion of surface propitiation
substrates if there is no flash
flash rusting prior to completion
completion of thermal
and completion
completion of thermal
spraying.
spraying.
Spraying.
environments or in enclosed spaces using ' ' _
in Iow-humidty environments
5.3- In
dehumidification equipment.
industrial dehumidification equipment, validate a holding period > 6
bend coupons.
hrs with band coupons, portable tensile bond test.test, or both.
5.4- Protect small and movable parts. parts, itif more than 15
15 minutes is
preparation and the start of
expected to elapse between surface preparation
thermal spraying, or if the part is moved to another location.
6.1-
5.1- A WwDM {1.002 in.] flashfprimer
25-50 itm [0.001-0.002 flash/primer coat of the T80
TSC may
applied within six hours of completing
be applied completing surface preparation
preparation to
6 TSC Flash Primer
extend the holding period for up to four further hours beyond the
complete application
corrplete applicaUon of the flash coat.
l fie final
6.2- ''The llnal TSC
ISC thickness,
thickness. however,
However, shall be 5e applied
applléa within
wllhin four
hours oi of the completion
completion of the application
application of the flash coat provided
provided
TSC can be maintained
the T80 maintained free of contamination.
contamination.
7.1 For flame
7.1 flame spraying, preheat the initial starting area to
approximately 120°C [250°F] to prevent water in the flame from
approximately
7 Preheating
Preheating condensing on the substrate. Validate preheating and non-
condensing
preheating requirement
preheating requirement with a bend test or tensile-bond
tensile-bond
measurement, or both.
measurement,

277
SSPC-CS 23.00(1)
2300(1)
March l,1,2000
2000

Annex B -—-— Model

Annex B Record
Job Control Record
Model Job

Initialsfor
' Tnifials for '
Step
Step Production Process
Production Process Check-Off
Check-Off

fiequlrement
Requirement in-firocess QC
In-Process h e c k Faint
oc CCheck Point
8.1- spam
8.1 - The specitied coating thicl<ness, [insert value trom
the specification] in overlapping passes.
8 Thermal Spraying
Confirm
Confirm the suitability of the inter-pass thickness with a bend test,
test.
tensile-bond measurement,
measurement. or both.
8.2-
8.2— If rust bloom, blistering, or a degraded coating appears at any
time during the application of the TSC:
T80:
a) Stop spraying.
b) Mark off the acceptable sprayed area.
c)
0) Call the TSC
T80 inspector to observe and evaluate the error,
error.
report deficiency to the purchaser for remedial action, and record the
deficiency and actions taken to resume the job.
9 TSC Measurement Schedule Measure per Contract and record in the JCR:
9.1- Measure the TSC T80 in accordance with SSPC-PA 2.
9.2- Take the average value of 5 readings per measurement line or
spot
spot.
9.3-
9.3— Use a measurement
measurement fine flat surfaces .. Take the average
line for flat
value of 5 readings taken in line at 2.5 cm [1 [1 in.] intervals. The line
measurement will measure the peaks and valleys of the T80. TSC.
Usa a measurement
9.4- Use measurament spot for complex
comp/ex geometries and geometry
transitions. The measurement spot should be approximately 10
transitions. t 0 sq.
[1.6
cm [1 .6 sq. in.]. The spot measurement may not measure the
of the TSC.
measure the peaks and valleys of_§1_e_j§g_ -_ __
~eallng
Siding &E Topcoaung
Topoo"a""'fin""g'
TSC
10.1- Apply the liquid seal coats as soon as possible after the T80
has been applied and before visible (10x magnification) oxidation of
10 specified:
If liquid sealer is Specified:
the TSC occurs: < 8 hrs
hre for zinc and zinc alloy T805
TSCs and < 24 hours
for aluminum and aluminum alloys.
for
10.2- Apply liquid seal coat per manufacturer's instructions or as
surfaces,
purchasing contract and only to clean dry TSC surfaces.
11 If lnterrnediate
Intermediate & Topcoating is 11.1 —- Intermediate and topcoats shall be applied per manufacturer's
manufacturer's
11
specified:
specified: instructions or the purchasing contract.
Remarks:

Thermal Sprayer (or QC Inspector) print name: Signiture:

Date:

278
 SSPC-CS 2300(1)
SSPC—CS 23.00(I)
1, 2000
March 1,

Annex
Annex C - Chemical
Chemical Composition
Composition Requirements Aluminum, Zinc, and Their
Requirements for Aluminum, Wires
Their Alloy Wires

Aluminum, zinc, 85/15 ZrdAI,

Zn/Al, 55AI/45Zn
55Al/4SZn arc-spray pseudo alloy, and 90 aluminum/10 currently
aluminum/ 10 alumina (volume %) metal matrix composite (MMC) are currently
Zn/Al, and 90/10 MMC are available in wire form. Aluminum and zinc are also available in
used for corrosion protection of steel. Aluminum, zinc, 85/15 Zn/AI,
C-l.
aforementioned wires is given in Table C-1.
powder form. The classification, by chemistry, of the aforementioned

Table C-1 Wiresm

C-l - Chemical Composition Requirements for Aluminum, Zinc, and Their Alloy Wires (a)
Co rnposifion~
mposition, WWtt %
% (a)
(21) Other I~Elements
lements
Classification
Classification Common Name Al
AI Cr Cu Fe Mn Pb Si Sn Ti Zn Element Amount
Amount
W-AI-1100
W-Al-l 100 1100 Aluminum 99.00 min ... 0.05-0.20
0.05-0.20 0.95 (Fe+Si) 0.05 ... 0.95 f(Fe+Si)
0.95 ie+S0 ... -- 0. l
0.1 .(d),
((1), (h)..
(h)-- (d),
(d). (h)._
(11)."
W-Al-1350
W-Al- 1 350 1350 Aluminum 99.50 min 0.01 0.05 0.40 0.01 ... 0.10 ... (V+Ti)
0.02 (V+Ti) 0.05 Ga
Ga 0.03
W-AI-4043
W—Al-4043 4043 Silicon rem -- 0.30 0.8 0.05 ... 4.5-6.0
4.5-6.0 ... 0.20 0.10 Mg
M ((1)
g (d) 0.05
Aluminum
W-AI-4047
W-Al-4047 4047 Silicon
4047 rem ... 0.30 0.8 0.15 ... 11.0-13.0 . . . . . . 0.20 Mg
Mg (d)
Aluminum
W-Al-5356
W-AI-5356 5356 Mg Aluminum rem 0.05-0.20
0.05-0.20 0.10 0.40 0.05-0.20
0.05-0.20 ... 0.25 ... 0.06-0.20
0.06-0.20 0. 10
0.10 Mg
M g (d) 4.5-5.5
4.5-5.5
W-Al-Alzog
W-AI-AI203 Al
AI MMC
MMC (c) 88 min . . . . . . . . . . . . AI~O3 ((1)
A1203 (d) 8- 12
8-12
W-Zn-1
W—Zn—i 99.99 Zinc 0.002 ... 0.005 0.003 ... 0.003 ... 0.001 ... 99.99 min Cd 0.003
W-Zn-2 99.9 Zinc 0.0]
0.01 ... 0.02 0.02 ... 0.03 . . . . . . . . . 99.9 min Cd 0.02
W-ZnAl-
W-ZnAI- 11 98/2 Zinc-Aluminum 1.5-2.5 . . . . . . . . . . . . . . . . . . . . . . . . rem Zn/Al
non Zn/AI 0.1
W-ZnAl-2
W-ZnAI-2 85/15 Zinc- 14.0-16.0 Rem
Rem Other
Other 0.05
Aluminum
to Notes: specified.
(a) Single values shown are maximum percentages unless a minimum is specified.
(99.6% pure AI)
(c) Vol% Aluminum Assn. 1060 Alloy (99.6% A1203 powder, 8-10 micron diameter.
Al) with addition ooff 8-12 vol% AI20~
(d) 0.0008 Be max.
(h) Others: 0.05 max each, 0.15 max total.
 A nnex D
Annex D- P r o c e d u r e for
Procedure for Calibration
Calibration of Test IInstruments
Portable Test
of Portable nstruments

General. Procedure is based on spraying a steel plate that has holes drilled
drilled to accept the ASTM tensile—bond test
ASTM C 633 tensile-bond
flush with one surface, and surface preparation and thffmal
specimens, inserting the C 633 tensile specimen flush thermal spraying per
specifications.
application standard or contract specitica6ons.
Procedure. fixture similar
Procedure. Using the calibration fixture similartoFigure D—l:
to Figure D- 1:
1.
1. fixture and the ASTM
Degrease calibration fixture tensile~bond test
ASTM D 4541 portable tester tensile-bond
ASTM C 633 and the ASTM
specimens.
2. Mount the ASTM
ASTM C 633 tensile specimens flush flush with one face of the plate. Use a release agent on the cylindrical
cylindrical
firmly hold
surface of the tensile specimen to ease removal after thermal spraying. Use brackets or masking tape to ru'rnly
the tensile test specimen in place during the blasting and spraying.
3. thermal spray coating per conlract
Prepare the surface (angular grit blast) and apply themaal specifications. Prepare at the
contract specifications.
same time the Job Reference Standard is being prepared. Use the same personnel, equipment, materials, and
procedures that will be used during the production work.
4. Remove C 633 specimens and measure per ASTM
ASTM C 633 method. Designate the average value as C.
5. instrument and measure the tensile bond on the three locations on the
Use ASTM-D 4541 portable tensile testing inslrument
steel plate. Designate the average value as D.
6. The calibration ratio of the portable tensile instntment CID.
instrument measurement to the laboratory tensile measurement is C/D.
7. The PC1533: is estimated by
'lhe portable C 633 equivalent tensile measurement, Pc~,

Pes33=
Poses: p
P (CA))
(CID)

measurement.
where pp is the portable tensile measurement

Holding bracket for

ASTM C 633 test fixture.

leek—4' /
L
o-- -*—-
. .xlr.
’l‘

1-in. diameter
_ I
holes for
i
ASTM C 633
ASTM
*{3

fixture..
test fixture T .Iar‘ ........... e ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASTM C 633 test fixture:
/
/ i i !\ Apply release agent
.L.’

8-
8'
~ ....~.u.... . . .
f4 ...~.-,,k to cylindrical surface.
I

.‘
"s

'

5' l
.............. L.i.'-":'.-...... -(-iS~ ....... 4.--i.-.~............
w"
—r-d—

J
#-

a
i. . i
5...

I ~-'./ ~" '.'; ..

L.o'~
v‘.
u‘

M" ~

"l Back
Bk'd side
acsre

Adhesive contact area for ~

portable tensile
tensile test specimens. ~
1.010 in. diameter holes to receive
1.00 in. diameter ASTM C 633 tensile
tensile test specimens.
\ \
. \
\
\
'~
~1
‘e
< 3/8"to
3/8" to 1/2"
1/2”

All dimensions approximate.

Material: Mild steel plate.
Material:

FFigure D-l
igure D a l i b r a t i o n FFixture
Calibration
- 1 -— C ixture

280
280
 2300(1)
SSPC-CS 23.00(I)
March 1,2000

Annex
A nnex E Application
E -— A p p l i c a t i o n Process Method
Process M ethod
E—l. The applicable Section and Quality
The major production and QC activities are shown in Figure E-1.
corner of each process action.
right—hand comer
Control Checkpoint (QCCP) numbers are noted in the lower right-hand

I SURFACE
PREPARTATION
PREPARTATION
Sectio~
Sections
E.1-E.4
E.1-E.4 _
Section
Section

THERMAL-
SPRAY
EQUIPMENT
SETUP
E.5
E.5_

~ ~HERM~- THERMAL
SPRAY
APPLICATION
Section
E.6
E.6
~Section

Sealer
and/or
Topcoat
E.7

No}
INSPECTION
INSPECTION
&
8:
ACCEPTANCE

communion
CONTAMI'4A'rlON
OCCPI1
OCCP rl
I SPRAY
PARAMETERS SUB81RATETEMP.
SUBSTRATE
r
TEMP.ab
=~>WEG
S-OEGABOVE
ABOVEDEW
DEW POINT
POINT
l
I
OCCP i6 $7.1
occp #7.1
QCCP I Yes
Y es

MASKING I ÷
+ ÷
+
OCCP#2

CLEANA%CCP #3
BEND
,D
TEST
;T C~:CPN
QCCP '3
I afio-DEG F
2r~-DEG

+
FOR FLAME
PREHEAT FOR
F PREHEAT RAYING
SP RAYING
FLAME SP QCCP# 72A I
OCCP # 72A
;
*

SEALER
V
APPLICATION
SPRAYNORMAL
SPRAY NORMAL,.J.
~4-SCI-DEG
30-DEGTO
TO SURFACE
SURFACEII
& AT
AT THE
THE OCCP # 8
SPECIFIED
SPECIFIED STANDOFF
STANDOFF
QCCP#7~B
OCCP # 7.23
BLAST
BLAST MEDIA
MEDIA
OUAUI'Y
QUALITY QCCP
QCCP 84
M
÷ TDPCOAT
’

INEAR-~M4ITE
NEAR-WHI'I'E
NO RUST
I NO BLOOD] OR
RUST BLOOM

+
T‘SC
DEGRADED TSC
OR DEGRADED OCCP# 72C & D
OCCP #TIC I: D
I
APPLICATION
QCCP #9
accp #9
_

I--
FINISH&
FINiSH m TOTAL 13:: THICKNESS PER amuse SCHEDULE
PROFILE QCCP#6
PROFILE OCCP r 'M
OCCP #5

I TSC CUT TEST

TSC CUT F>
TEST IF THBKNESS
SPECIFIED THICKNESS
:- SPECIFIED QCCP#7~ ~--
GCCP I 18

Figure E-1
E—l - Key
Key Production
Production and Quality
Quality Control Checkpoints
Checkpoints for Applying
Applying Thermal
Thermal Spray Coatings

E.1 Surface
E.1 Preparation
Surface P reparation
necessary step for successful
Proper surface preparation is a critical and necessary successful thermal spray operations.
E.1.1 Criteria
E.I.1
The steel substrate shall be prepared to at least a near-white finish per SSPC—SP
near—white metal finish 10/NACE No. 2.
SSPC-SP 10/NACE
finish per SSPC-SP
Marine service requires white metal finish 1.
SINACE No. 1.
SSPC—SP 5/NACE
Abrasive or centrifugal blast with a sharp angular abrasive to > [um] anchor-tooth
2 2.5 mils [~tm] profile so as to
anchor—tooth profile
mechanical anchor for the TSC.
provide a mechanical
E.1.2 Procedure
Procedure

Surface preparation should be accomplished in one abrasive blasting/cleaning operation whenever

possible. Steel substrates require approximately 80-100 air—blasting pressure. Air
80—100 psi [0.6-0.7 MPa] air-blasting
damagefdistortion to thin-gage
pressures and media size should be reduced and adjusted to preclude damage/distortion
materials. The blasting time on the workpiece should be adjusted to just clean the surface and cut the
required anchor-tooth with minimum loss of metal. Blast angle should be as close to perpendicular as
possible but in no case greater than +
:1: 30
30°° from the perpendicular to the work surface. Do not overblast; this
will force the peaks back into the valleys. Use only angular and clean blasting media of suitable mesh size to

281
SSPC—CS 23.00(I)
SSPC-CS
March 1, 2000
March
cut the >_
2 2.5 mils [63 gin]
um] anchor-tooth
anchor—tooth profile. There must
profile. There fines, and no
must be no debris, no excessive fines,
contamination
contamination such as sodium chloride, sulfur salts, and hazardous materials in the blasting media.
hazardous materials
Use angular
angular blasting
blasting media
media (e.g., steel grit, mineral that will cut an
aluminum oxide) that
mineral slag, garnet, and aluminum
anchor-tooth
anchor-tooth (not peen) and which Clean,
adherent residue. Clean,
which leaves only a tightly adherent dry blasting air and clean
blasting
blasting media
media without fines are required.
without excessive fines equipment
blasting equipment
required. Dedicated blasting is recommended
highly recommended
final anchor-tooth
for final thermal spray production.
anchor-tooth blasting in continuous thermal
E.2
E New
.2 N Steel SSubstrate
e w Steel ubstrate
Degreasing
E.2.1 Degreasing
of oil and
Checkpoint # 11 to validate absence of
The substrate shall be degreased per SSPC-SP 1. Use QC Checkpoint
contamination.
grease contamination.
Masking
E.2.2 Masking
E.2.2
The following shall be masked for protection:
fit and function surfaces.
0A1] fit
oAll
OOverspray control areas.
oOverspray
•oAreas thermal sprayed.
Areas not to be thermal
fit and function areas are areas that must
The fit thermal spraying, and
cleaning, thermal
must be protected from the blast cleaning,
sealing and topcoating operations.
of complex geometry where you cannot
Overspray-control areas are areas of eliminate overspray. Use QC
cannot eliminate
masking suitability.
Checkpoint # 2 to validate masking
Checkpoint

QC Checkpoint
QC Grease
Checkpoint #1 -— Oil & Grease
Inspect for the absence ofoil
of oil and grease contamination
contamination by the following:
following:
1.1.
1.1. Visual inspection during removal of oil/grease contamination. Continue degreasing until all visual signs of
contamination are removed.
contamination
1.2. Conduct either the UV light, qualitative
qualitative solvent evaporation test, or the heat test.
(1) Use an UV lamp to confirm
confirm the absence ofoil
of oil or grease contamination.
contamination.
(2) The solvent evaporation test is made by applying several drops or a small splash of a residueless solvent such as
trichloromethane
trichloromethane on the areas suspected of oil and grease retention
retention (e.g., pitting
pitting and crevice corrosion areas, depressed
areas especially those collecting contamination, etc.). An evaporation ring will form if there is oil or grease
contamination.
contamination.
(3) The heat test is made by using a torch to heat the degreased metal to about 225°F [110°C]. Residual oil/grease
contamination
contamination is drawn to the metal surface and is visually apparent.
apparent.
1.3. Continue inspection and degreasing (or high-pressure water blasting or oven- oven— or flame-charring for severe
contamination)
contamination) until the test is passed.

QC Checkpoint
QC Masking
Checkpoint #2 - Masking
Visually inspect the following:
fit and function surfaces and those other surfaces and areas specified
2.1. All fit specified by the purchaser not to be abrasive
blasted or to be thermal
thermal sprayed.
2.2. Ensure that the covers and masking are attached securely and will survive the blasting and thermal spraying
operations.
operations.
flanges, intersections of structural beams, and valve manifolds) to
2.3. Mask on complex geometries (e.g., pipe flanges,
eliminate or minimize overspray. Overspray
Overspray is that TSC applied
apph'ed outside the authorized parameters,
parameters, primarily the
gun-to-substrate
gunwto-substrate standoff distance and spray
standofldistance @erpendicuiar ±
spun; angle (perpendicular 30").
:1: 30°).
2.4. Potential
Potential overspray surfaces should be protected with clean, metal masks or clean, removable masking materials
materials
to prevent overspray from depositin 8 on surfaces not already sprayed to the specified
depositing specified parameters.
parameters.

282
 SSPC-CS 23.00(I)
2300(1)
March 1,2000
March

E.2.3 Blast Equipment

The
The TSCA
TSCA shall use mechanical (centrifugal wheel) and
mechanical (centrifugal pressure—pot blast cleaning
and pressure-pot equipment and
cleaning equipment
Checkpoint #3 to validate clean and dry air.
equipment. Use QC Checkpoint
procedures. Do not use suction blasting equipment.

Clean &
Checkpoint #3 -— Clean
QC Checkpoint Air
Dry Air
& Dry
final anchor-tooth
The air used for final anchor—tooth blasting and brush blasting
blasting prior to thermal
thermal spraying shall be clean and dry without
moisture
moisture and oil. The water and oil content of the compressed air shall be qualitatively measured by the ASTM D
4285 method:
filter or dryer. Allow the air to vent with a slight
3.1. Slightly open a valve downstream of the filter flow into an
slight audible flow
open, dry container for one minute. Any wetting or staining
staining indicates
indicates contamination.
contamination.
moisture or contamination is detected,
3.2. If moisture deficiency before going further.
detected, correct deficiency
3.3. Repeat 3.1 above, but place a clean, white cloth over the valve outlet. Any wetting or staining
staining indicates
indicates
contamination.
contamination.

E.2.4 Surface Finish and Profile

Profile

finish per SSPC-SP 10/NACE

near-white-metal finish
Blast clean to at least a near-white-metal IOfNACE No. 2 with a > um]
2 2.5 mils [63 ktm]
profile. Note: Substrate
angular profile.
angular should be thick
Substrate should enough to preclude
thick enough damage to the work piece or
preclude damage
deformation blasting. Use QC Checkpoint
deformation from the abrasive blasting. Checkpoint #4 to validate
validate clean blasting
blasting media;
media; QC
finish and profile
Checkpoint #5, to validate metal finish
Checkpoint profile depth.

Media
Blasting Media
QC Checkpoint #4 - Clean Blasting

final anchor-tooth
Prior to the use of the abrasive-blasting media for final anchor-tooth blasting
blasting or brush blasting:
contamination and debris using 10x magnification.
4.1. Visually inspect the blasting media for the absence of contamination magnification.
ofoil
4.2. Inspect for the absence of contamination using the following procedure:
oil contamination procedure:
(1) Fill a small, clean bottle (4-6 oz [100-200 ml]) half-full of abrasive particles.
particles.
remainder of the bottle with distilled
(2) Fill the remainder distilled water.
(3) Cap and shake the bottle.
(4) Inspect water for oil sheen. If any oil sheen is observed, do not use the blasting media for final
final anchor-tooth
blasting.
blasting.
equipment, especially the pot and hoses, then replace the blasting
(5) Clean the blasting equipment, blasting media and retest.

QC
QC Checkpoint
Checkpoint #5 —- Near-White
Near-White Finish & Anchor-Tooth Profile
Profile
near-white-metal finish
5.1 Visually inspect for near-white—metal finish or white metal finish
finish if specified
specified in the contract. Use the clear
cellophane
ce110phane tape to confirm
confirm absence of dust as required.
required.
profile with profile
5.2 Measure the anchor-tooth profile profile tape or depth gage micrometer. Make at least one measurement
if2 [10 to 20 m2]
every 100 to 200 ft2 m 2] or as otherwise specified
specified by the purchaser.
purchaser.
profile is < 2.5 mils [65 um]
5.3 If the profile [tm] continue blasting
blasting to obtain 2> 2.5 mils [65 um]
ktm] profile.
profile.
5.4 information on sketches or drawings or as required
Record information required by the purchasing
purchasing contract.
contract.
E.3
E.3 Contaminated
C o n t a m i n a t e d Steel
Steel Substrate
Substrate
Contaminated
Contaminated steel is designated
designated as such by the surface condition
condition (degree of
of corrosion scale and pitting)
pitting)
and by the type and amount
amount ofo f contaminants
contaminants imbedded
imbedded in the surface. It requires
requires more intensive surface
preparation
preparation than
than new steel. To produce the minimum
minimum required near-white-metal finish
required near-white—metal finish with 2> 2.5 mils [65
um]
tam] profile,
profile, the surface preparation
preparation schedule should be tailored for the specific
specific steel surfaces to be cleaned.
High—pressure
High-pressure water cleaning, cleaning, chemical washing
cleaning, heat cleaning, cleaning,
flushing), steam cleaning,
washing (followed by water flushing),
and abrasive blast cleaning,
cleaning, singly and in combination, contaminated steel.
combination, may be required to clean contaminated

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 2100(1)
SSPC—CS 23.00(I)
SSPC-CS
March 1, 2000

E.3.1 Degreasing
The surface shall be degreased as required (e.g., hydroblast, steam clean, solvent wash, or detergent
wash).
E.3.2 Masking and Blasting
Masking, blast equipment, blast media, and surface finishfinish and profile
profile are the same as for new steel as
finish and angular-profile
specified surface finish
given in Section E.2. However, after blasting to the specified angular-profile depth, wait
blast—cleaned surface).
24 hours to observe for any rust bloom (i.e., the visual appearance of rust on the blast-cleaned
E.3.2.1 Light Rust Bloom
of the surface area), the substrate
If there is light rust bloom (light in color and greater than 10% of area that
specified
re—blasted to achieve the specified
will be thermal sprayed within the next six hours shall be re-blasted level of
cleanliness.
E.3.2.2 Heavy Rust Bloom
(e. g.,
If there is heavy rust bloom (dark brown or black color), other cleaning methods shall be continued (e.g.,
wet-abrasive,
wet—abrasive, high- and ultra-high-pressure
ultra—high-pressure water, or thermal charring singly or in combination) to remove
the contamination.
E.3.2.3 Thermal Cleaning

fire
I SAFETY AND PROCEDURE PRECAUTION: Use this procedure only if there is no danger of an explosion or fire
and no degradation of the metal temper. Do not exceed
exceed 575°F [300°C] on steel alloys.

Bake-out
Bake—out or burn-off the contamination (the dark brown or black surface areas) in an oven or with a
[250-300°C] for the time necessary to
480-570°F [250-300°C]
rosebud torch. Keep the substrate temperature between 480-570°F
bum—off the oil and grease contamination.
bake-out or burn-offthe
Anchor-tooth blast the substrate area that will be thermal sprayed within the next six hours, or longer per
finish. If an anchor-tooth
E.4.2, to a minimum near-white metal finish. anchor—tooth profile
profile has already been established, brush
finish.
blast to a minimum near-white metal finish.
Repeat Steps 1) and 2) above as required until the thermal spray job is completed.
E.4 Post-Blasting Substrate
E.4 Post-Blasting Thermal
Substrate Condition and T h e r m a l Spraying Period
Spraying Period
E.4.1 Steel Surface Temperature and Cleanliness
The steel surface temperature shall be at least 5°F
S°F [3°C] above the dew point. The surface cleanliness
finish as a minimum.
shall be SSPC-SP 10/NACE No. 2 finish
E.4.2 Holding Period
TSC shall always be applied to white metal (SSPC-SP 5/NACE No. 1) or near-white finish (SSPC-
near—white metal finish
SP 10/NACE fieldwork to
lO/NACE No.2) surface, free ooff visible and invisible contaminants. It is common practice in fieldwork
final blast cleaning is performed. The logical end point of
apply the TSC during the same work shift as the final
the holding period is when the surface cleanliness degrades or a change in performance (bend or tensile test)
occurs.
final
final anchor-tooth blasting (or final
As a general guide however, the time between the completion of the final
brush blasting) and the completion ooff the thermal spraying shall be no greater than about 6 hours for steel
substrates. In high humidity and damp environments, shorter holding periods shall be used. If rust bloom or
a degraded coating appears at any time while spraying, the procedure at the end of this section shall be
strictly observed.
In low-humidity
low—humidity environments or in controlled environments with enclosed structures using industrial
dehumidification
dehumidification equipment, it may be possible to retard the oxidation of the steel and hold the near-white-

284
 SSPC-CS 23.00(I)
March 1,2000
finish for more than 6 hours. The TSCA, with the concurrence of the purchaser, can validate a holding
metal finish
temperature—humidity envelope for the work
period greater than 6 hours by determining the acceptable temperature-humidity
enclosure by spraying and analyzing bend coupons or tensile bond coupons, or both.
When specified flash coat of
specified by the purchasing contract, a flash um]
of TSC equal to or greater than 11 mil [25 ~tm]
may be applied within 6 hours ofof completing surface preparation to extend the holding period for up to four
hours beyond the complete application of final TSC thickness, however, shall be applied
of the flash coat. The final
of the flash coat. This procedure shall be validated
of the completion ooff the application of
within four hours of
with a tensile bond measurement or bend test, or both, by spraying a flash coat and waiting the delay period
final coating thickness.
before applying the final
For small and movable parts, if more than 15 minutes is expected to elapse between surface preparation
and the start of thermal spraying, or if the part is moved to another location, the prepared surface should be
finger/hand marks. Wrapping
protected from moisture, contamination, and finger/hand Wrapping with clean print-free paper is
normally adequate.
If rust bloom, blistering, or degraded coating appears at any time during the application of the TSC the
following procedure applies:
(1) Stop spraying.
off the satisfactorily sprayed area.
(2) Mark offthe
(3) Repair the unsatisfactory TSC (i.e., remove degraded TSC and re-establish the minimum near-white-
finish and anchor-tooth profile
metal finish profile depth).
(4) Record the actions taken to resume the job in the JCR.
(5) Call the TSC inspector to observe and report the remedial action to the purchaser.
E.5 Thermal Equipment
E.5 Spraying Sequence
Equipment Set-Up & Spraying
E.5.1 Thermal Spray Equipment Set-Up
(1)Thermal
(1) Thermal spray equipment shall be set up, calibrated, and operated per the manufacturer's instructions and
refinement thereto and as validated by the JRS.
technical manuals or the TSCA's refinement
specified thermal spray material and, at a minimum, be
(2) Spray parameters shall be set for spraying the specified
validated with the bend test of QC Checkpoint # 6.
(3) Attach a copy of the spray parameters to the JCR.

QC Checkpoint #6 - Macro-System
QC Checkpoint Macro-System Bend Test (Required at beginning of each work shift or crew change)
6.1.
6.1. Confirm
Confirm that the equipment parameter settings are in accordance
accordance with those used for the validated JRS.
1RS.
6.2.
6.2. Observe the successful surface preparation,
preparation, spraying the specified
specified TSC thickness in crossing passes, and bend
test at least one bend coupon at the beginning of each work shift.
shifi. This is a macro or overall systems check.
check.
fix problems before continuing.
identify and fix
6.3. If the bend test fails, identify
6.4.
6.4. Record results, note identification,
identification, and retain the bend test coupons for the JCR.

E.5.2 Plan the Thermal Spraying Sequence

Thermal spraying should be started as soon as possible after the final
final anchor—tooth
anchor-tooth or brush blasting and
completed within 6 hours for steel substrates subject to the temperature to dew point and holding period
E4.
variations in Section E.4.
(1) The surface geometry of the item or area to be sprayed should be inspected. Spraying pass or sequence
should be planned according to the following:
Maintain the gun as close to perpendicular as possible and within +
:t 30
30°° from the perpendicular to the
substrate.

285
SSPC-CS
SSPC—CS 23.00(I)
March l,
1, 2000
Use the manufacturer's recommended standoff distance for the air cap installed or the TSCA's refinement
refinement
thereto. See Table E1 for nominal standoff and spray pass width values.
Table
Table E1 - Flame—
Flame- and
and Arc-Spray
Arc-Spray Standoff Distances and Spray Widths, Nominal
Thermal Spray Perpendicular Spray Pass Width,
Method Standoff in. [mm]
in. [mm]
in. [mm]
Air Cap
Regular ] Fan
Flame Wire [130-180]
5-7 [130-180] [20]
0.75 [20] Not Available
Flame Powder 8-10 [200—250]
8—10 [200-2501 2 [50]
H50] [75-100]
3-4 [75-100]
Arc Wire [150-200]
6-8 [150—200] 1.5 [40]
1.5 [40] 3-6 [75-150]
3—6 [75-150]
(3) For complex geometries where overspray cannot be eliminated, an overspray control area should be
established. Clean, metal masks or clean, removable masking materials should be used to prevent overspray
from depositing on surfaces not already sprayed to the specified thickness.
E.6
E.6 TSC
T S C Application
Application
(1) Preheating the starting area has been common practice in the past and should be continued until proven
a benefit
benefit or inconsequential. Preheat the initial 1-2 ft2
t2 [0.1-0.2 m2]
m 2] starting-spray area to prevent water
on the flame
flame from condensing on the substrate.
(a) For flame
flame spraying, preheat the initial starting area to approximately 250°F [120°C].
(b) Validate preheating requirements with the Job Reference Standard and the bend test or tensile test, or
both.
(2) Start-up
Start-up and
and adjustment
a d j u s t m e n t of the spray gun shall be made off the workpiece (or surface to be thermal
sprayed). In an enclosed space, spray onto a scrap metal sheet. Do not allow any non-validated spray
coating on the prepared surface to be thermal sprayed.
(3) The specified coating thickness shall be applied in several perpendicular overlapping passes. The
coating tensile bond strength is greater when the spray passes are kept thin. Laying down an excessively
thick spray pass increases the internal stresses in the TSC and will decrease the ultimate tensile-bond
strength of the TSC.
(a) For manual spraying, use crossing passes to minimize the thin spots in the coating.
(b) For mechanized spraying, use overlapping and crossing passes to eliminate thin spots and stay within
the coating thickness specification. Validate the automated spraying parameters and spraying
program with tensile-bond or metallographic analysis, or both.
(c) Use spray gun extensions to reach into recessed spaces and areas.

(4) If rust
rust bloom, blistering, or
or a degraded coating appears at any time during the application of the TSC,
the following procedure applies:
(a) Stop spraying.
(b) Mark off the acceptable sprayed area.
(c) Call the TSC inspector to observe and evaluate the error, notify the purchaser or his agent, and
record the deficiency and the actions taken to resume the job in the JCR.
(5) The TSC shall meet the system requirements and acceptance tests cited in Section 6.
Use QC Checkpoint #7 to validate proper TSC application process.

286
 SSPC-CS
SSPC-CS 2300(1)
23.00(I)
March
March 1,2000

QC
Q C Checkpoint
C h e c k p o i n t #7
#7 - TSC
T S C Application
Application
7.1. Measure/confirm
Measure/confirm substrate surface temperature with contract pyrometer to be 2 > 3°C [5°F] above the dew
point:
a) Air temperature
a) °F L[ °C].
b) Relative Humidity (RH) %..
c)
C) Dew Point ° F °F [ °C].
d) Substrate surface temperature
d) °F [ C°].
e) {Surface temperature (D)} 2> {5°F above the dew point}: (Yes/No)
f) If Yes 9"-) Continue.
g)
g) If No -)
" ) STOP. Wait for proper conditions andfor
and/or adjust the work-area space temperature and humidity
conditions so that the steel temperature is 2
> 5°F above the dew point.

7.2. Observe the spraying process as specified

specified in Section E.6:
a) Preheat to 250°F [120°C] when flame flame spraying.
b) Proper spray gun adjustment and spraying process (:I:
(± 30°
30 ° from the
perpendicular, thickness/pass, and crossing passes).
c) No rust bloom on prepared steel during spraying.
d) No degraded TSC.

7.3. Specified
Specified TSC thickness. Ensure proper coating thickness in the contour transition areas (see Step 7.5
below).
7.4. Measure the total TSC thickness:
3)
a) One measurement spot every 100 to 200 it2 fi2 [10-20 m2]
m 2]
of applied TSC.
b) Take the average value of of 5 readings per measurement
. fl
. . .fl
line or spot. p_@l__fi
. . . ._-_ _ =t-fi
m .@
= _-fl
1) Use a measurement line for flat fiat surfaces. Take _
5 in line at about 2.5~crn [1-in. ] intervals
the average value of
of 55 readings taken in line at 11
in. [2.5 cm] intervals. The line measurement will
measure the peaks and valleys ofof the TSC. 5 in a spot of about 10 cm2
cm 2 [1.6
[1.6 inF’]
in. 2]
2) Use a measurement spot for complex geometries
and geometry transitions. The measurement spot
should be approximately 1.6 in.2in. 2 [10 cmz].
cm2]. The
spot measurement will not measure the peaks and
valleys of the TSC.

7.5. Measure TSC thickness in surface plane changes and attachments (brackets, angles, plates, studs, etc.)
welded or permanently attached to the substrate.
7.6. If too thin, continue spraying to the specified
specified thickness range.
7.7. If within the contract specified
specified thickness range, go to Step 7.9.
7.8. If too thick, perform the TSC cut test.
a) If PASS, reapply the TSC over the TSC cut and go to Step 7.9.
b) If FAIL, remove defective coating and reapply the specified
specified TSC. Record discrepancies and remedial action
in the JCR.
7.9. Record the locations and values of
of the TSC thickness measurements in the JCR.

287
287
SSPC-CS 2300(1)
SSPC—CS 23.000)
March 1, 2000

E.7 Low T
E7 Low e m p e r a t u rre
Temperatu Spraying
e Spraying
40°° F [5°C] must:
Thermal spraying in low temperature environments, less than 40
(1) Meet the substrate surface temperature and holding period of E42. No moisture
of Section E.4.1 and E.4.2.
condensation on the surface is permissible during thermal spraying.
(2) Be qualified
qualified with a bend test or portable tensile bond test, or both.
Note: TSCs are mechanically bonded to the substrate. Substrate preheating may be required to improve the
TSC tensile bond to the substrate and reduce internal stresses. Validate the preheating requirement, or non-
E6 (1)).
requirement, during preparation ooff the JCR (see E.6
Sealer and
E3 Sealer
E.8 Topcoat
and Topcoat
Sealers and topcoats for TSCs shall be applied in accordance with SSPC-PA 1, the paint manufacturer's
specified TSC, and/or the purchasing contract.
instruction for sealing and topcoating the contract specified
If moisture is present or suspected in the TSC pores, the steel may be heated to 120°F [50°C] to remove
the moisture prior to the seal coat application. When possible, the steel from the of the TSC
reverse side of
shall be heated to minimize oxidation and contamination of the TSC prior to sealing.
E.8.1
E.8.1 Sealer Application
Sealer Application
The seal coat shall be thin enough when applied to penetrate into the body of of the TSC and seal the
porosity. Added thickness to porous TSC should not be measurable. Typically the seal coat is applied at a
film thickness.
spreading rate resulting in a theoretical 1.5 mils [38 microns] dry film
field work, sealers should be applied as soon as possible after thermal spraying and
For shop and field
preferably within eight hours.
If sealer cannot be applied within eight hours, verify that the TSC (a) has not been contaminated by
8502-3), before applying the
visual inspection and (b) is dust free using the clear cellophane tape test (ISO 8502-3),
sealer.
Use QC Checkpoint # 8 to validate proper application.

QC Checkpoint #8 - Sealer Application

8.1. During application of the seal coat, visually validate complete coverage. The seal coat shall be thin enough
8.1.
when applied to penetrate into the body of the TSC and seal the porosity. Added thickness to the porous TSC should
not be measurable.
E.8.2 Topcoat Application
specified in the purchasing contract. Do
manufacturer’s instructions or as specified
Topcoats shall be applied per manufacturer's
not apply a paint coating over an unsealed TSC.
Use QC Checkpoint # 9 to validate proper application.

QC Checkpoint #9 -— Topcoat Application & Thickness

9.1 During application of the topcoat, visually validate complete
complete coverage.
fixed-probe
9.2 If required by the contract, measure the thickness of the topcoat per SSPC-PA 2 using a Type 2 fixed-probe
gage. The measurement
measurement may be made on (a) companion coupon or (b) the sealed TSC if the TSC thickness has
been previousl~¢
previously measured.
measured.

288