The Technological Instruction for applying of the weather-resistant of organisilicate compositions OC-12-03 different colors, OC-12-01 green color on the steel surface

Approve

““Morozovskiy khemicheskiy zavod” ZAO”

General Director

Shnajder D. G.

The Technological Instruction

for applying of the weather-resistant of organisilicate compositions

OC-12-03 different colors, OC-12-01 green color on the steel surface

1. General Instructions

1.1. The technological instruction spreads, as the recommendation, on the anticorrosion, protective-decorative painting of steel structures and constructions by organosilicate compositions OC-12-03 different colors, and OC-12-01 green color.

1.2. The instruction includes the operations for the preparation of the surface, the preparation of the composition, the paint coating rules, the quality control and safety rules.

1.3. During the working process the correction of the instruction is possible. The changes to the instructions are added by the developers of the document or the changes must be conformed to them.

1.34. The instruction was crated on the basis TУ “The Organosilicate Compositions. The Technical Conditions”, the instructions for applying of the organosilicate compositions, GOST 9.402-80 “The paint-and-lacquer coatings. The preparation of the steel surfaces before painting”.

2. Preparation of Surface

2.1. The surfaces of details, subjecting to the painting, mist not have any nick-and-burrs, any sharp edges (with radius not less than 0.3mm), any sharp peaks along the welding joints, and any welding splashes.

2.2. There must not be any residue flux and any molding sand, any scales, any rust, and any oil and mechanical impurity on the surface. The product preparation before painting must be done as per the scheme No.3 of the table 4 GOST 9.402-80 (degreasing by the solvent, mechanical treatment, blasting). The mechanical treatment of the surface from the oxides is done up to the degree Sa 2½ or St 3 as per ISO 85010-1:1988 or in accordance with the table 3 GOST 9.420-80 up to the second degree, i. e. there must not be any scales, any rust, any burn-on, any molding sand and other not steel coats. The air, which is used for the dust removal, must not contain the oil and the water.

2.3. After the dust removing the surface must pass the removing grease by toluol, xylol, acetone, solvents P-4, P-5, P-646. The removing of grease on the surface is done directly before painting and not later than 6 hours after the mechanical treatment during the work on the open air, and not later than 24 hours during the work inside of building.

2.4. The removing of grease on the surface as per the conclusion of the supervisor it is not allowed to execute.

2.5. It is not allowed to apply the compositions to the wet surface.

2.6. The applying of the compositions do not required the prior primer coating of the steel surface.

2.7. In the case of the necessity it is allowed primer coats VL-02, VL-023, GF-021, FL-02, FL-03K on the steel surfaces before painting by organosilicate compositions. The method of applying, the thickness and time of the primer hardening is executed in accordance with the instructions for their applying. The applying of the primer coats is possible only with the exploitation of coats with the temperature up to 100ºC.

2.8. For leveling of the surface the automobile coatings, the coatings НЦ, ЭП in accordance with the recommendations for applying. The usage of such materials is possible only with the exploitation of coatings with the temperature up to 100ºC.

3. Preparation of Composition

3.1. The organosilicate composition before the applying must be mixed by the mixer of the vertical type not less than 10 minutes in the tare of the manufacturer before the complete loss of sediment and uniformity along the whole volume, after it is keeping during about 10 minutes before loss of bubbles.

3.2. The composition OC-12-01 green color, OC-12-03 all colors can be used as coats of cold (without injection of hardener) and hot curing.

3.3. The work viscosity of a composition, before coating, must be within:

18-25 with during air-injection;

25-35 with during coating with the brush and roller;

30-45 with during airless spray.

3.5. The viscosity of the composition is mentioned in the quality certificate. In case of necessity the measurement for viscosity is executed by viscosimeter ВЗ-246 with a nozzle with diameter 4mm with the temperature 20ºC.

3.6. With the necessity the delution of composition to the necessary viscosity is done directly before usage by the addition of one from the next solvents: toluol with the temperature of composition applying from minus 30 to plus 10ºC, xylol with the temperature from 10 to 35 ºC with the next mixing in the tare of the supplier.

3.7. For gaining of the qualified coating the temperature of the composition during the applying must be closer to the temperature of the surface of the painting detail.

3.8. During the breaks in the work process the composition must be storage in the closed tight tare, before the starting of work the composition must be mixed and kept not less than 10 minutes.

4. Painting Process

4.1. The coating of the composition is done not less than in two coats by methods of the airless spray, the pneumatic spray, a brush, and a roller.

4.2. The coating process is done with the temperature:

- from minus 30ºC to + 35ºC – for spray methods;

- from minus 30ºC to +20ºC – a brush and a roller;

It is forbidden to execute painting during rain, and also when the speed of wind is more than 10m/second by the spay methods.

4.3. During the painting, when the temperature is negative, for avoiding the formation of the hoar frost and the ice crust it is necessary to make sure that the temperature of the painting surface will be not less than for 3ºC higher the dew point.

4.4. The distance from the nozzle of the spray gun to the painting surface must be 200-300 mm, the air pressure 1,5-2,5 kgs/cm² (during the pneumatic spray), the coating operations are clarified in every concrete case in dependence of the work conditions and type of apparatus for applying.

4.5. The applying of the composition as “line coat” by a brush on the welding joints, edges, nooks before painting.

4.6. The applying of the second coat and, if it is necessary, next coats is executed during the positive temperature of the air not earlier than in 60 minutes during the spraying, and in 120 minutes during the applying by the brush or by the roller; during the negative temperature of the air the hold time is increased for 2-3 times.

4.7. The quantity of coats is determined by the thickness of the one-layer coating, which is got experimentally in every separate case in dependence on the method of applying, the common thickness of the coating and on the polymerization conditions.

During the coating process with the temperature lower than 0 ºC the thickness of one coat becomes lower minimum for two times, naturally the quantity of the painting coats is increasing.

4.8. It is recommended to cover the second coat on the horizontal surface not earlier than after 24 hours, or by sections in accordance with p.4.5, which except the waking on the applied coating.

4.9. The transportation and erection of constructions and equipment can be executed not earlier than after 3 days after the painting in dependence on the thermal regime of the polymerization coating.

4.10. The compositions OC-12-01 green color and OC-12-03 all colors are applied as the coats of the cold curing. For the coats, which are exploited with the temperature higher than 100ºC, it is recommended to execute the polymerization in the regime of the hot curing.

4.11. The hot curing of the compositions OC-12-01 green color and OC-12-03 all colors coats are executed in the next regime: the soaking on the open air after the applying with the temperature of the air during not less than 1 hour, then the rising of temperature up to the temperature of exploitation with the speed not more than 3,5ºC per a minute and the soaking with this temperature during not less than 3 hours.

4.12. The temperature of coating exploitation for the composition OC-12-03 of red, yellow, blue color – up to 200ºC, for OC-12-01 of green and OC-12-03 of other colors – up to 300ºC.

4.13. The location places on the supports, other not painted parts or damages of the coating are painted manually according to the regimes, which were described above.

4.14. The flow of the composition with the thickness of the coat (dry coat) 100mkm is 350g/m² (without the technological losses, which depending on the way of coating, the degree of spraying, the used equipment, the qualification of workers, and the characteristics of surface).

5. Quality Control

5.1. There must be the quality certificate for organosilicate composition, which can approve its correspondence to the requirements of the standards.

5.2. The preparation quality of the surface is controlled by the contractor. The control is done in accordance with the point 5 in GOST 9.402-80, after the cleaning rags must not have any track from the rust, dust, moisture, oil and other pollutions.

5.3. The quality control of the composition preparation is executed by the contractor for absents of deposition, the uniformity of the composition and the conformance of viscosity to the present instruction requirements.

5.4. The compressed air control, which is supplied for the dust removal, to the sand-blasting apparatus, for the pneumatic spraying, is checked by the contractor for absents of water condensate and oil.

5.5. The painting quality is controlled by the contractor. During the applying by spraying on the surface in the moment of applying must be formatted the “wet” uniform film, there must not be the dry coating in form of the dry particles of the composition. After the drying of the coating there must not be any skips, runbacks, and “pits”. The measurement of the coating thickness is done on five spontaneous chosen points, for the result the average figure is taken. During the measurement of the coating thickness the device have to register the roughness of steel after the mechanical treatment before the applying.

6. Safety Requirements

6.1. The job safety rules are fulfilled as per the technical documents of the contractor with taking for the account the properties of the special fast compositions.

6.2. The toxicity and the flammability risk of the organosilicate compositions are specified the presents of solvents toluol and xylol in their content.

6.3. The toluol and xylol as per the degree of their impact to the human organism are categorized to the 3d class of the danger as per GOST 12.1.007-76, PDK in the work area air – 150/50mg/m³.

6.4. During the applying on the open air, it is necessary to watch, that the work area has the proper lighting. The workers, which do the applying of the composition, should use the rubber gloves, the protective pasts like “biological gloves”. For the protection of the respiratory organs people have to use gas - and dustproof breathing masks.

6.5. It is expressly forbidden to produce the applying of the composition in the close places, pits, manholes without the individual protective means. For the protection of the respiratory organs the isolating airline respirator has to be used.

6.6. The compositions refer to the flammable liquids in connection with presents of toluol and xylol. The temperature of the toluol flash is 4ºC, flash of xylol is 24ºC, the temperature of the spontaneous ignition of toluol is 536ºC, and xylol is 494ºC. Therefore during the applying of the composition it is necessary to follow the requirements of the fire safety: to have the fire-extinguishing means on the work place, to use the tool and devices made of the spark-proof material, not to use the open fire on the work places, do not smoke.

6.7. IN the case of fire of the composition it is necessary to use the next measures for firefighting: sand, felt mat, asbestos quilt, foam fire extinguisher or carbon dioxide extinguisher, foam apparatuses, and thin defused water.