JPS - Drydocking Superintendent Training

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21/11/2024

DRYDOCKING
SUPERINTENDENT TRAINING
Bandung, 20 – 21 November 2024

Jotun Performance Coatings MC PC

Main Contents

1. Basic Corrosion

2. Paint Technology

3. Surface Preparation

4. Painting Application

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Jotun Performance Coatings MC PC

Global player with HQ in


Norway

More than 100 years in


paints and coatings industry

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DECORATIVE MARINE PROTECTIVE POWDER


PAINTS COATINGS COATINGS COATINGS

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40+
YEARS EXPERIENCE

10
BRANCHES

>500
EMPLOYEES

>4.000.000
LITERS PRODUCTION CAPACITY

HO, Jotun Paint Factory


MM2100 Cibitung Bekasi

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40+
YEARS EXPERIENCE

10
BRANCHES

>500
EMPLOYEES

>4.000.000
LITERS PRODUCTION CAPACITY

HO, Jotun Distribution Center


MM2100 Cibitung Bekasi

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40+
YEARS EXPERIENCE

10
BRANCHES

>500
EMPLOYEES

>4.000.000
LITERS PRODUCTION CAPACITY

Jotun Powder Factory


Legok Tangerang

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40+
YEARS EXPERIENCE

10
BRANCHES

>500
EMPLOYEES

>4.000.000
LITERS PRODUCTION CAPACITY

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A Wide Pool of Qualified Coating Advisors

PT. Jotun Indonesia currently supported by 67 Coating Advisor


for Performance Coating Segment certified as Inspector by
NACE, SSPC and FROSIO

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Tujuan pengecatan?

Perlindungan Estetika

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Gambar Apa ini?

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Apa itu Korosi?

Korosi adalah suatu PROSES dari reaksi kimia antara baja dengan
lingkungan sekitarnya menghasilakan KARAT

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Parameter yang mempercepat proses korosi

Kelemababan Suhu Polusi Garam

Semakin tinggi atau banyaknya nilai ke-empat parameter


diatas, semakin cepat baja akan mengalami korosi

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ISO 12944-2 Klasifikasi Lingkungan

Low DFT High DFT


Paint Paint
System System

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ISO 12944 Paints and Varnishes


Corrosion protection of steel structures by protective paint systems

Ketahanan
Low 0-7 tahun
Medium 7-15 tahun
High 15-25 tahun
Very High >25 tahun

*Persiapan permukaan minimum blasting ke Sa 2,5

Low DFT High DFT


Im1 = Terendam di Air Tawar
Im2 = Terendam di Air laut dengan Perlindungan katodik
Paint Paint
Im3 = Terendam di bawah Tanah System System
Im4 = Terendam Air laut dengan Perlindungan katodik/splash zone

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Perlindungan Korosi dengan Coating


Menciptakan penghalang yang
menghentikan arus ion (i.e. corrosion
Barrier effect / Efek Benteng current)
Contoh: epoxy-coatings

Passivasi dari cat di permukaan besi


Inhibitive/passivizing effect Contoh: cat dengan pigment anti korosi
(lead, chromates or phosphates)

Cat yang berfungsi sebagai anode


Cathodic effect (galvanic effect)
Contoj: zinc rich coatings

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Barrier Effect / Efek Benteng

Kebanyakan cat melindungi besi dengan


menciptakan penghalang dari lingkungan
sekitar

• Penghalang akan meningkatkan


ketahanan terhadap siklus galvanik

• Secara umum, penghalang yang tebal


memberikan perlindungan yang lebih
baik daripada yang tipis

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Inhibitor Effect / Efek Inhibitive


Dalam Cat inhibitive, kelembapan yang
pada akhirnya akan masuk penetrasi
hingga ke cat dasar yang telah memiliki
pigment reaktif dan diaktifkan, dimana
berubah menjadi passivasi dengan
permukaan logam di antara keduanya

Contoh pigment Inhibitive:


• Red Lead (not used)
• Lead/zinc chromate (not used)
• Zinc phosphate

Produk dengan pigment ini tidak sesuai


untuk area yang terendam.

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Cathodic Effect
• Some paints offer the same cathodic
protection effect as sacrificial anodes
• A zinc-rich primer reacts to protect the
steel substrate when the topcoat is
damaged
• The CP type of paints is not an inert
paint film as the barrier coatings
• The paints contain active, metallic
pigments
• The pigments react with moisture and
the steel and creates a calcareous
deposit on bare spots of the steel
substrate

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Apa itu Cat

• Cat adalah produk yang digunakan


untuk melindungi dan memperindah
(protective & decorative)
suatu objek atau permukaan dengan
melapisinya menggunakan suatu
lapisan berpigmen maupun tidak
berwarna (pernis).

*Dari wikipedia

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Komposisi Cat

BINDER

PIGMENT

EXTENDER

ADDITIVE

SOLVENTS

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Keterangan Komponen Cat

Binder Pigment
Fungsi :
•Menentukan Kualitas Cat Fungsi :
•Daya rekat permukaan •Pewarna
•Mengikat bahan baku lain •Bahan Pengisi
•Anti-Rust
•Daya Tutup “Hiding Power”
Extender
Fungsi :
•Bahan pengisi
•Penentu tingkat gloss
Solvent Additive
Fungsi : Fungsi :
•Melarutkan bahan baku •Mempercepat pengeringan
•Mengatur tingkat kekentalan/ •Katalis
“viskositas” •Biocide
•Memberikan kemudahan •dll
aplikasi

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Sifat dari sebuah cat ditentukan oleh jenis resin/binder

• Tiga jenis resin yang umum


seperti Alkyd, Epoxy,
Polyurethane
dibandingkan untuk
mengetahui masing-masing
sifatnya
• Diaplikasikan di panel
berbeda dan dijemur
dibawah sinar matahari,
direndam air dan direndam
pada larutan alkali tinggi
• Hasil ekspos dapat terlihat
untuk mengetahui sifat
resin-resin tersebut

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Bagaimana Cat dapat mengering ?

Sifat dari sebuah cat juga ditentukan dari bagaimana resin itu bereaksi untuk
mongering setelah diaplikasikan

Pengeringan sebuah cat dapat dikelompokan menjadi tiga bagian :

Pengeringan secara fisik Pengeringan dengan Reaksi ikatan kimia antara


(1K) oksidasi/oksigen (1K) resin dan hardener (2K)

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3 Layer Paint System 2 Layer Paint System


(total 300 mics) (total 300 mics)

Topcoat 100 mics

Midcoat 100 mics Topcoat 150 mics

Primer 100 mics Primer 150 mics

Steel Steel

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Pengeringan secara fisik


• Chlorinated rubber
• Vinyl
• Acrylic
• Silicone
• Bitumen
• Tar
• Antifoulings

 Ketahanan suhu antara 60-70°C


(semakin tinggi suhu semakin cat nya
melembut)
 Tidak bisa ditimpa dengan jenis cat
yang memiliki solvent yang lebih kuat
seperti (Alkyd, epoxy, polyurethane)
 Mudah diaplikasikan

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Pengeringan secara oksidasi/oksigen

• Alkyd

 Ketahanan cuaca yang baik


 Ketahanan solvent terbatas (hanya
bisa dicat ulang dengan alkyd)
 Sifat levelling (merata ke permukaan
yang baik)
 Tidak tahan terendam
 Ketahanan kimia yang buruk
(terutama pada alkali)
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Jotun’s Oxidative Drying Products

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Alkyd paint if applied too Thick

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Alkyd paint if underwater or overcoating zinc based paint

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Pengeringan secara reaksi kimia

 Memiliki daya lekat ke permukaan yang


sangat baik
 Memiliki ketahanan bahan kimia yang
sangat baik
 Beberapa binder seperti Epoxy tidak
tahan sinar matahari
 Pengeringan relatif lebih lama
 Sangat bergantung terhadap suhu
 Membutuhkan permukaan yang blasting

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Pengeringan secara reaksi kimia

• Epoxy (solvent and water borne)


• Zinc epoxy
• Epoxy Mastic
• Polyurethane
• 2-pack Acrylic
• Zinc Silicate
• Polysiloxane
• Polyester
• Vinylester

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Pengeringan secara reaksi kimia

Pengadukan yang tidak tepat


menghasilkan:

• Tidak kering

• Kualitas cat buruk

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Epoxy Paint Properties

Advantages Limitations

• Chemical curing • Chalking


• Very good chemical resistance • Temperature dependent
• High alkali resistance • 2 - component
• Moderate resistance to acids • Requires blast cleaning
• Good adhesion • Over-coating time
• Very low permeability
• High mechanical strength
• Dry heat resistant up to 120ºC

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Epoxy Paint Chalking due to UV Light (Sunlight)

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Epoxy Mastic Technology from Jotun

Epoxy yang dimodifikasi dengan resin hydrocarbon dan reaksi dengan hardener
berbasis amine, Memiliki besar molekul yang relatif lebih kecil dengan epoxy biasa.

Jotamastic

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Cat Surface Tolerance

Cat surface tolerance direkomendasikan


untuk permukaan yang tidak rata

• Dapat digunakan pada pekerjaan


perawatan pengecatan
• Persiapan permukaan minimum St2
sesuai ISO 8501-1
• Cat surface tolerant memberikan umur
yang lebih lama pada permukaan
tersebut

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Surface tolerant Simple surface Cost lebih


Jotamastic Jotamastic Premium
preparation rendah
Smart Pack HB 90
Excellent Adhesi kuat Perlindungan
Jotamastic penetration dengan substrat lebih optimal
Price

85
MCI tintable Pilihan warna Dapat mengikuti
Jotamastic Standard/
(khusus JM90) lebih banyak, selera customer
80 Medium
sebagai topcoat
Jotamastic 70
Jotafix Epoxy Mixing ratio 1:1 Simple Aplikasi lebih
Primer Commercial (khusus Smart application, part simple, tidak ada
Pack) mixing sisa cat
Performance
Thinner
no.17

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Jotun’s Polyurethane

 Ketahanan kilap yang luar biasa


 Ketahanan kimia yang sangat baik
 Ketahanan solvent yang sangat baik
 Ketahanan cuaca yang sangat baik
 Mengandung isocyanate (jangka
pendek, membuat efek iritasi kulit)
 Sensitif terhadap Kelembaban pada
saat proses pengeringan (penurunan
gloss dapat terjadi)

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Hardtop
Smart Pack Excellent Gloss & Warna & gloss Periode
Hardtop color retention tahan lama maintenance
Premium
Optima lebih lama
Hardtop AX Excellent Tahan terhadap Perlindungan
weathering cuaca & UV outdoor lebih
Price

resistance lama
Hardtop XP Standard/ MCI tintable Pilihan warna Estetika & sesuai
Medium sangat banyak pilihan customer
Futura Classic/
Jotafix PU TC Mixing ratio 1:1 Simple Aplikasi lebih
Commercial (khusus Smart application, part simple, tidak ada
Pack) mixing sisa cat
Performance

Thinner
no.10

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Polyurethane Properties

Advantages Limitations

• Very good weather resistance • 2-component


• Excellent gloss durability • May cause skin irritation
• Very good chemical resistance • Sensitive to moist in early
• Very good solvent resistance curing stage
• Cures down to 0ºC

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Surface Preparation (Persiapan Permukaan)

Kegagalan pengecetan paling banyak


dari:

• Persiapan permukaan yang buruk


• Teknik pengecatan yang buruk

Sebaik apapun produk cat, tidak bisa


menggantikan persiapan permukaan
yang benar

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Surface Preparation : Untuk mendapatkan daya lekat dan ketahanan cat yang maksimal

Steel dressing

Pretreatment

Surface Preparation

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Steel dressing – Pengecekan kondisi objek yang akan di cat

• Pengecekan secara visual adanya


cacat pada objek yang akan di cat

• Untuk menentukan tindakan


selanjutnya dalam memperbaiki objek
sebelum dilakukan pengecatan seperti
gerinda, sikat kawat, dempul, dan lain
lain

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Steel dressing - tepian tajam menyebabkan ketebalan tipis

Tepian tajam sebelum digerinda Tepian tajam setelah digerinda


Tidak OK OK
Sharp
edge,
low
Paint
DFT

Steel

Paint Steel

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Steel dressing – tipe cacat pada bagian yang di las


Steel preparation sebelum cuci: Laminations,
undercuts, welding seams

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Karat pada tepian tajam dan


las-lasan

• Pengecatan baru saja dikerjakan


• Terekspos angin, hujan, cuaca
sekitar 2 minggu

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ISO 8501-3 Preparation grade of welds, cut edges and other areas with surface
imperfections

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ISO 8501 - 3
Preparation grades of welds, cut edges and other areas with surface
imperfections: Three grades of preparation

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ISO 8501 - 3

Preparation grades of welds, cut edges and other areas with surface
imperfections: C5 requires preparation Grade P3

Preparation grade Type of corrosive environment (ISO 12944)


P1 - Light preparation C1 and C2 Very low - low
P2 – Thorough preparation C3 and C4 Medium - High

P3 – Very through C5, CX, IM Very high


preparation
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Minyak dan Gemuk


Minyak dan gemuk menyebabkan daya
lekat cat menjadi buruk

Cek kontaminasi minyak dan gemuk


• Basahi permukaan yang dengan air

• Air pada permukaan akan timbul


Pelangi, jika ada minyak

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Pre-treatment

Cuci dengan deterjen

• Cuci dengan deterjen dari


bawah ke atas
• Cuci secara sistematis ke
seluruh permukaan
• Biarkan detergen bereaksi
selama 3-5 menit
• Bilas dari bawah ke atas
• Bilasan terakhir dari atas ke
bawah

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Pre-treatment
Cuci dengan detergen, bilas dengan air bersih

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Menghilangkan kontaminasi

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Blister disebabtkan oleh garam atau solvent yang terjebak saat


pengecatan

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Osmotic blistering caused by salt contamination

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Osmotic blistering caused by salt contamination


Formation of blisters
as a function of salt concentration on substrate (1 of 2)

Salt: 0 mg/ m² Salt: 60 mg/ m²


Film: 150 microns Film: 150 microns

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Osmotic blistering caused by salt contamination


Formation of blisters
as a function of salt concentration on substrate (1 of 2)

Salt: 100 mg/ m² Salt: 200 mg/m²


Film: 150 microns Film: 150 microns

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Osmotic blistering caused by welding smoke


Welding smoke is water soluble and can only
be removed by water

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Osmotic blistering caused by welding smoke

Blisters close to weld


• Welding smoke is water soluble and will create osmotic blistering if not removed
• Galvanic difference between steel plate and weld may aggravate the attack

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Guide for Salt Concentration Levels


AREA / POSITION MAX. SALT CONCENTRATION

Under water areas: 80 mg/sq.m.


Ballast tank (general): 80 mg/sq.m.
Ballast tank (PSPC): 50 mg/sq.m.
Cargo oil tank (PSPC): 50 mg/sq.m.
Cargo tank: 50 mg/sq.m.
Fresh / Potable water tank: 50 mg/sq.m.
(20 mg/sq.m. for elevated temp)
NORSOK specification: 20 mg/sq.m

1 µg/sq.cm. = 10 mg/sq.m.
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Persiapan Permukaan
Dry abrasive blast cleaning Hand and Power tool cleaning

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Dry abrasive blast cleaning

• Memberikan surface profile


yang baik
• Permukaan tetap kering
• Proses cepat
• Beberapa pilihan tingkat
kebersihan sesuai standar
dapat dicapai

• Tidak menghilangkan
minyak, gemuk dan garam
• Membuat debu

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Sikat kawat

• Mudah digunakan untuk maintenance


pada permukaan yang telah dicat

• Tidak bisa melandaikan tepian cat

• Tidak bisa menghilangkan mill scale

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Manual and Rotating Wire Brushes

• Standar st2 dan st3 bisa dicapai


• Sikat kawat manual lebih lambat
• Sikat kawat listrik mempercepat
proses
• Beresiko membuat permukaan licin
• Permukaan licin membuat daya lekat
cat buruk

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Disc sanding and grinding

Mirip seperti sikat kawat bertenaga

Beresiko membuat permukaan licin

Cocok untuk melakukan pelandaian


untuk spot repair/touch up

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Permukaan licin setelah gerinda

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Perbaikan yang direkomendasikan untuk permukaan yang


terpoles licin – menggunakan non woven grinder

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Perbaikan yang direkomendasikan untuk permukaan yang


terpoles licin – menggunakan non woven grinder

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Surface Preparation Standards (ISO & SSPC)

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ISO 8501-1 Rust Grades

Rust Grade A : 100% Mill scale


Rust Grade B : Mulai muncul karat, Mill
……………………….scale mulai pecah
Rust Grade C : Permukaan diselimuti karat.
…………………….…Mulai muncul “pitting”
……………………….sedikit
Rust Grade D : Permukaan diselimuti karat.
…………………….…”Pitting” menyebar
……………………….diseluruh area

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ISO 8501-1 Preparation grades blast cleaning

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Blast cleaning grades description Sa 1 & Sa 2

Putty knife

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Blast cleaning grades description Sa 2½ & Sa 3

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Contoh hasil blasting permukaan carbon steel


beserta kualitasnya

Rekomendasi dari
Poor ISO 12944-5
Best

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Blasting test area

• It may be difficult to evaluate a


surface according to a standard

• Test areas are often put up on the site


to make sure that the actual standard
specified is followed

• Agreement before the work starts will


help to avoid later disagreements

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Hand and power tool cleaning grades

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Hand and power tool cleaning grades (ISO 8501-1)

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St3 prepared by disc grinding

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Pelandaian tepian pada perbaikkan spot

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Hasil tanpa pelandaian setelah perbaikan spot

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Prosedur perbaikan sistem pengecatan (1)

Yang harus diperhatikan


 Bersihkan dari segala kontaminasi
 Pelandaian dan sanding
menggunakan gerinda min 70 mm
dari sekeliling area yang rusak
 Aplikasikan cat diarea tersebut

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Prosedur perbaikan sistem pengecatan (2)

Low DFT
Untuk low DFT
 Amplas ringan, bersihkan/vacuum,
aplikasikan sesuai spesifikasi
High DFT

Untuk high DFT


 Amplas sampai didapatkan DFT
sesuai spesifikasi

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Parameter kondisi cuaca untuk pengecatan


sesuai ISO 8502-4

• Relative humidity dibawah 85%


• Suhu objek(minimum) 3˚C above
Dew Points

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Environmental Check

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Pengaruh Suhu lingkungan dan Suhu baja

Suhu lingkungan akan Suhu baja akan


memengaruhi : memengaruhi:
• Shelf life (penyimpanan) • Penguapan solvent
• Pot life • Waktu pengeringan
• Induction time • Tingkat kematangan cat
• Viscosity / sprayability • Interval recoating
• Suhu baja

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A case of ventilation in a confined space

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Amine Sweating/Blooming – Sticky and Milky Surface


Application Epoxy Amine cured at High Humidity

Amine Sweating Blooming


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Rain on fresh polyurethane – loss of gloss

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Hal yang harus diperhatikan dalam sebelum aplikasi


Cat 2 komponen
Harus perhatikan hal berikut:
1. Pastikan cat dalam kondisi baik tidak expired (Self Life)
2. Pastikan comp A dan Comp B sesuai pasangannya
3. Jika mixing sedikit-sedikit, pastikan Mixing Ratio nya benar Comp A : Comp B
4. Gunakan mixer
5. Pastikan memahami Potlife
6. Pastikan memahami Induction Time
7. Pastikan memahami recoating intervals

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Chemically curing ?

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Pencampuran cat 2 komponen

• Component B dituang ke Component A


• Component B dapat memiliki kekentalan
yang tinggi, pastikan tuang seluruhnya
• Pastikan mixing ratio benar
• Gunakan mixer

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Pengadukan yang cepat (gelembung pada cat)

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Cat 1 komponen
Untuk cat 1 komponen, pastikan teraduk secara merata
sebelum aplikasi

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Preparation of 2 Component Paint

• Untuk cat 2 komponen, pastikan komponen B


(hardener) sesuai dengan pasangannya

• Aduk komponen A dan B secara terpisah. Selalu


bersihkan mixer setelah mengaduk

• Tuangkan komponen B secara perlahan ke


komponen A dalam takaran yang sesuai (lihat
kaleng)

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Persiapan aplikasi cat 2 komponen


• Untuk pencampuran parsial, gunakan gelas ukur,
gelas, penggaris , dan sebagainya untuk takaran
yang pas
• Lihat TDS untuk mixing ratio antara Comp A dan
Comp B yang benar
• Pengadukan dilakukan min 2 menit atau terlihat
pencampuran merata
• Selalu gunakan mixer

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Persiapan aplikasi cat 2 komponen

• Mixing Ratio A : B = 4 : 1

A A A A B

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Preparation of 2 Component Paint

• Mixing Ratio A : B = 4 : 1

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Mixing ratio beberapa produk cat dari Jotun


Typical Primers Coat

Typical Finish Coat

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Induction time dan Potlife berdasarkan dokumen Technical


Datasheet
Induction Time 15 Menit @23°C
• Induction Time
10:00 10:15
Periode waktu cat 2 komponen bereaksi
antara setelah pengadukan dan sebelum Waktu tunggu sebelum aplikasi
aplikasi (berbeda tiap produk)

• Pot Life Potlife 2 Jam @ 23° C


Periode waktu cat 2 komponen setelah 10:00 12:00
dicampur dan diaduk sampai cat tersebut Potlife <2 Jam @ > 23° C
tidak bisa digunakan lagi (mengeras
dalam kaleng) (berbeda tiap produk 10:00 12:00

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Drying and Curing Time

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Pengenceran
Cat dibuat dalam kekentalan yang
optimal

• Biasanya tidak ada alasan untuk


mengencerkan cat

• Cat dibuat dalam kondisi kekentalan


yang optimal

• Kebanyakan pengenceran dapat


membuat masalah yang buruk

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Penambahan thinner

Jangan pernah menambahkan thinner


yang tidak sesuai diperuntukan untuk cat
yang dipakai, dapat menimbulkan hasil yang
buruk

Penambahan thinner sesuai yang


diperuntukan sangat direkomendasikan
(jika ada penambahan maksimal 5-10 %

(Campuran 10 Liter Cat, maksimal


penambahan thinner 0,5 – 1 L)

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Application

• Brush
• Roller
• Stripe-coating
• Airless spray

Kebersihan dan beberes dan bersih bersih sebelum, saat dan sesudah pengecatan
adalah faktor yang paling penting untuk mendapatkan hasil pengecatan yang
maksimal

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Application by Brush

• Kuas dapat menekan cat ke dalam permukaan


sehingga membuat daya lekat cat yang
maksimal

• application Cat khusus seperti epoxy mastic


dibuat khusus untuk jenis pengecatan dengan
kuas

• Selalu cek TDS untuk jenis aplikasi pada


produk

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Stripe Coating

• Stripe coating adalah pengecatan


tambahan yang diaplikasikan pada
sudut, lasan dan tepian tepian

• Area dimana tidak bisa dijangkau


oleh spray

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Stripe Coating

• Kuas sangat cocok untuk stripe coating

• Membasahi permukaan dengan baik

• Tepian , lasan, dan sudut harus dilakukan


stripe coat

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Application by Roller

• Banyak pilihan dari jenis roller,


pastikan sesuai dengan kebutuhan

• Tidak direkomendasikan untuk lapisan


pertama / 1st coat

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Application by Airless Spray


• Sangat cocok untuk pengecatan anti-korosif dan cat
performa tinggi untuk struktur besar seperti kapal,
jembatan, tangki, dan sebagainya
• Gambar disamping adalah ilustrasi pengecatan
Airless spray
• Sangat popular untuk aplikasi pengecatan industri-
industri berat

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Airless Spray

• Jarak spray gun ke objek adalah 30-60 cm


• Sudut tegak lurus
• Jarak yang terlalu jauh akan menimbulkan dry spray dan over spray

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Teknik Airless Spray pada bidang kompleks dan sempit

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Dryspray/overspray when gun too far away from object

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Sagging and Orange peel occur when gun too short from
object

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Proper tip sizing – same fan width/different orifice size

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Signs of tip wear.

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Tailing / Fingering

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Pastikan diri anda terlindungi..

Full faced air respirator


Solvent resistant gloves

Coverall/Boiler suit

Safety Glass

Safety Shoes
Safety helmet

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