矿山机械镀锌件油漆施工工艺.doc

阿克苏诺贝尔防护涂料（苏州）有限公司Akzo Nobel International Paint（Suzhou）Co., Ltd.项目名称PROJECT NAMESANDVIK S11D Project ANIP文件编号ANIP DOC. No.页码 Page版次 REV1701文件编号DOC. No.ANIP-TSD-PWS20130906Painting Work Procedure for the Galvanized mesh镀锌构件涂装施工工艺01Issue for Approve2013-09-06Likun Li 版次REV说明Description日期Date编制PRED审核Review批准Approve日期Date审核Review批准ApproveCoating Supplier涂料供应商Akzonobel International Paint (Suzhou) Co., ltd1. Scope 范围This Painting Technology Specification covers surface preparation and painting specification. This document is organized on basis of International Protective Coatings Products Data Sheets of Akzonobel International Paint. It is composed of additional regulations and the detail descriptions in the above documents mentioned, and therefore is not to be the substitute of them. The specification is prepared with the reference of the Project Contract Specification.本技术工艺涵盖了表面处理及涂料技术规格。文件根据阿克苏诺贝尔防护涂料产品手册制定的，不是取代任何该项目的规范文件，而是对它们补充说明或细节性描述。此外，本文件服从于此项目合同技术规范中提到的要求。2. Standards, References, Definitions and Abbreviations 标准和参考文献SSPC the Society of Protective Coating 美国防护涂料协会NACE Nation Association of Corrosion Engineer 美国防腐工程师协会ASTM America Society for Testing and Materials 美国试验和材料协会ISO International Standard Organization 国际标准化组织DFT Dry Film Thickness 干膜厚度WFT Wet Film Thickness 湿膜厚度2.1 SSPC/NACE (Reference most current edition) Standard SSPC/NACE（现行的参考标准）标准SS PC-PA1 Paint Application Specification NO.1-Shop, Field, and Maintenance Painting of steel 油漆施工规范No.1-钢板表面在车间，现场和维修时的油漆施工规SSPC-PA2 Paint Application Specification NO.2-Measurement of Dry Coating Thickness with Magnetic Gauge 使用磁力测厚仪测量干膜厚度的操作规范SSPC-SP1 Solvent Cleaning 溶剂清理SSPC-SP7 Brush-off Blast Cleaning 扫砂级喷射清理SSPC-AB-1 Mineral and Slag Abrasives 矿渣磨料规范2.2 ISO Standard ISO 标准ISO 8501-1 Preparation of steel substrates before application of paints and related productsvisual assessment of surface cleanliness 涂装前钢基材的处理-表面清洁度的目测评估ISO 8502-3 Assessment of dust on steel surface 钢板表面灰尘的评估ISO 8503 Preparation of steel substrates before application of paints and related products Surfaceroughness characteristics of blast cleaned substrates. 喷射清理表面粗糙度特征 ISO 8504 Preparation of steel substrates before application of paints and related products-surface preparation methods 涂装前钢基材的处理表面处理方法ISO 4624 Paint and varnishes- pull-off test for adhesion 油漆和清漆拉开法测附着力ISO 2409 Paints and varnishes - Cross-cut test油漆和清漆划格法测附着力ISO 11126 Preparation of steel substrates before application of paints and related products Specificationsfor non-metallic blast-cleaning abrasives 涂装施工前钢材表面处理 非金属喷砂磨料的规定ISO 11127 Preparation of steel substrates before application of paints and related products - Test methodsfor non-metallic blast-cleaning abrasives 涂装施工前钢材表面处理 非金属喷砂磨料测试方法3. Coating Systems 油漆配套Coating涂层Product产品Mix ratio混合比（A:B;V/V）Thinner稀释剂DFT干膜厚度Primer底漆Intergard 2694:1GTA 22040mTop coat 面漆Interthane 9906:1GTA733100mTotal DFT 总膜厚 140m4. Surface Preparation for the galvanized mesh镀锌构件表面处理4.1 Removal of excessive zinc corrosion product e.g. zinc slats on the galvanizing or zinc sprayed layers prior to the application of specified primer is very important to ensure satisfactory adhesion and optimal performance. Surface should be clean, dry, abraded and free from zinc salts contamination.为了确保满意的附着性和最佳性能，在涂覆规定底漆之前，先清除镀锌或喷锌表面上的过量锌腐蚀物如锌盐，这一点是非常重要的。表面应清洁，干燥，经过打磨且无锌盐污染物。4.2 Usually, sweep blasting on galvanizing steel is a preferable method to coat. Prior to blasting the galvanizing or zinc sprayed layers, water rinse to remove all white zinc salts on the surface, and solvent clean according to SSPC SP 1 to remove any visible oil, grease, etc contaminants. Sweep blasting clean the zinc surface in order to obtain the proper surface profile in 20-30 microns in conformance with ISO 8501-1 Sa 1 or SSPC SP 7. A low air pressure (4-5 kg/cm2) shall be used and hold the nozzle at 1 meter far from the surface to and move it quickly in the operation of sweep blasting. Non-ferrous abrasive shall be used, e.g. copper slag, silica sand, aluminum oxide or garnet and etc fine grade (80 mesh) nonmetallic abrasive shall be recommended. 通常，对镀锌钢表面进行扫砂处理是最为理想的方法。在对镀锌或喷锌表面进行冲砂之前，须对表面存在的白色锌盐进行水冲洗，然后根据SSPC SP1的要求进行溶剂清理，以去除可见油脂等污染物。按照ISO 8501-1 Sa 1或SSPC SP 7的方法和标准对镀锌表面作扫砂处理，并获得20-30微米的表面粗糙度。进行扫砂处理时，所使用的压缩空气不应太高(4-5kg/cm2)。扫砂时喷枪距离表面保持约1米距离并快速移动。扫砂时应使用非铁质的细磨料(80目)，如铜矿渣，石英砂，棕刚玉或石榴石等可推荐使用。5. Application of Coatings油漆施工5.1 Stripe coating 预涂 Stripe coating is an essential part of good working practice. The number and sequence of stripe-coats shall be maintained as the same as the painting specification. Stripe-coats shall be applied to areas where it is difficult to get the required coverage, including mainly plate edges, welding seams, scallops, and difficult access areas.预涂是良好涂装施工的重要部分，预涂的道数要和涂层系统中的涂层道数一致，预涂一般在那些难以达到要求的覆涂处，主要是自由边，焊缝，扇形孔，管子，梯子，及难以触及的部位。5.2 Ambient Condition for Paint Application油漆涂装的环境条件要求Pay particular attention to the following items during painting application, stop painting except special require.在下列施工环境条件，除非涂料产品对施工环境有特殊要求，涂装施工应停止进行。n The temperature of steel surface or paint is less than 3 below the dew point temperature, or the ambient relative humidity is above 85%. 当构件表面温度不高于环境空气露点温度之差小于3，或者相对湿度大于85时n When steel surface temperature is higher than 40( except paint supplier specified). 当构件表面温度大于40（除非油漆供应商产品允许更高的温度）；n When air temperature is lower than 5当空气温度低于大约5时；n Predefine the bad weather in two hours when over-coating outdoor. 室外涂装施工，当开始涂覆两个小时内有可肯定的不良天气变化时；n When moisture formed on surface of structure under raining, condensation and frost etc.当因下雨、冷凝、霜冻等天气条件下，在构件表面形成潮气层时；n When the effective illumination less than 500lux during paint application. 当涂装施工环境光照有效发光流量低于500lux时。5.3 General Requirement of Painting油漆涂装的一般要求 5.3.1 Painting shall be carried out on daytime or under sufficient illumination.涂漆需在白天或有充分照明的环境下进行。5.3.2 The storage of paints shall meet with the requirements from MSDS of paint manufacturer. 油漆的存放环境应满足厂家MSDS对储存条件的要求。 5.3.3 Solidification or invalidated paint shall not be used during storage period and removed from the site. 在储存期间，已经凝结或变质的涂层材料不得使用，且要从现场搬走。5.3.4 It is important to ensure illumination, scaffolding which assure safe and convenient application of paint. The end of scaffolding shall be kept not less 30-40cm distance from coated surface at vertical. Illumination shall be shining over any working area and has sufficient intensity. Motioned lamp-house shall be equipped.照明、脚手架非常重要，不仅保证安全，还要保证没有不可到达的部位，并施工方便。脚手架与涂装表面的垂直距离至少保持在3040cm。照明应达到任何施工部位，且有足够的强度，并配备移动的光源。5.3.5 Power agitator in good condition shall be used to ensure even and thorough mixing of paint. Continuous stirring shall be kept during application of zinc-rich primer. 使用工作状态良好的动力搅拌器，保证油漆混合均匀、彻底。富锌漆在施工过程中需不停的搅拌.5.3.6 Protect the non-coated surface from contamination of paint. e.g. electric, electronic, instruments, nameplates, rubber pads, screws etc.喷涂时，对于电气、电子、仪表、铭牌、橡皮垫、螺丝等非涂漆面应进行保护，防止其受污染。5.3.7 Type of thinner shall be selected in according to paint category and paint instruction book from paint manufacturer. 稀释剂的类型应根据油漆的种类，并按照油漆厂家的使用说明书进行选择。5.3.8 Thinner shall be added into during mixing and stirring when thinning is allowed. When suitable viscosity of paint has been obtained, no more thinning. Whole thinning process must be monitored by a supervisor who should be familiar with thinning proportion and thinner type.当允许使用稀释剂时，稀释剂应在搅拌混合过程中加入。油漆稀释到合适的稠度后，不要再加稀释剂。所有稀释过程必须在一个熟悉加入量和加入类型的监工的监督下进行。5.3.9 The underneath coating must be hard dry and qualified and over-coated in the interval time. Prior to over-coating, surface of previous paint shall be cleaned to remove spray mist, dust, oil and other chemical contaminations.后道涂层必须在前道涂层硬干并检查合格后，并在油漆厂说明书要求的覆涂间隔时间范围内进行覆涂，覆涂前，应对上道涂层表面进行清洁，除去上道涂层表面的漆雾、灰尘、油污和其它化学污染物，以保证下道涂层良好的外观和附着力。5.3.10 Strip coating shall be applied onto each coat prior to spray. The position of strip coat should include: backside of bars, plates edges, scallops, rough welding seam, surface knaggy, seam cracking, undercutting, free edges, handrail and ladders, screw and bolts, complex position that is hard to spray. 每层油漆喷涂前都要进行预涂。预涂的部位包括：型材反面、板材边口、各种孔、粗糙的焊道、表面的凹凸不平、焊道裂缝、咬口、自由边、扶梯和扶手、螺丝和螺栓、结构复杂难以喷涂的部位。5.3.11 Spray equipment shall be sufficient tidy and cleaned thoroughly with solvent prior to using and after using. Equipment shall be wash cleaned with suitable thinner, eve if various paints sprayed.喷涂设备足够干净，用前和用后都要把设备中的溶剂彻底清除干净。设备要用能与喷涂油漆相溶的稀释剂清洗。在喷涂不同种类的油漆时，也要将喷涂设备清洗干净。5.3.12 High pressure line for airless spray shall be suitable in length. Pump shall be wash cleaned prior to use. Seal the airtight ball valve and sucker to avoid pump inhaling air.无气喷涂喷漆高压管长度适当，泵须彻底清洗后才能使用。封闭严密球阀和吸管，避免泵空吸。5.3.13 When spray paint, each spray fan shall be overlapped 50% at least to obtain correct paint thickness.油漆喷涂时，为保证较均匀的涂层厚度，应保持喷涂时搭接宽度为50%。5.3.14 Spray shall be tested prior to full spray. Spray gun should be kept 300-500mm away from coated surface at vertical. 在喷涂之前应先试枪，喷枪应与被喷涂构件表面保持垂直，喷涂距离一般在300500mm之间。5.3.15 Suitable protection shall be applied to wet paint film to ensure proper touch-dry and prevent contaminate by dust or other foreign matters.对于刚喷涂完毕的湿油漆，在未表干前，要予以适当的防护，以防沾染上灰尘或被其它物质所污染。The painting powder, dust, and other contaminations on the surface to be painted shall be cleaned thoroughly with sandpaper, before every painting application. The oil and grease shall be cleaned completely according to SSPC SP1: Solvent Cleaning. 每道油漆施工前，要用砂纸打磨清除待喷涂表面上的油漆粉尘，可能飘落的灰尘，以及其他污染物，如有油污，根据SSPC-SP1要用溶剂反复清除干净。5.3.16 During spraying, all knaggy spots of wet paint shall be smooth with brush promptly. Any sagging or runs shall be removed with brush.在喷涂过程中，所有的凸点和凹陷应立即刷平。若出现流挂，立即用刷子带平。5.3.17 Inspection shall be undertaken prior to apply the nether coat to correct bulge spots, over-spray, rough, pinholes, cissing(fresh eyes), holiday etc, coating defects which should be repaired or re-coated in accordance with the recommended methods from paint manufacturer. 在进行下一涂层之前，都要进行检验。发现有凸点、多喷、粗糙、针孔、凹陷、漏涂或其它非正常痕迹的地方，按油漆生产厂推荐方法来修补或重新喷涂。5.3.18 Compressed air shall be filtered via oil/water separator that is in good condition to ensure dry, non of oil/water air, if air spray has been allowed to use.如涂料允许采用有气喷涂，其压缩空气必须经过工况良好油水分离器进行过滤，以确保压缩空气干燥，无油、水。5.3.19 Ventilation of confined space e.g. pipe/tank/vessel/container 管道、储罐或容器等密闭空间内部通风 Good ventilation shall be ensured when painting in the confined space of pipe, tank or container. Good ventilation shall be helpful for: 管道、储罐或容器内部封闭的空间内进行涂装施工，必须保证良好的通风。良好的通风有利于： Discharge organic steam and toxic, harmful gas.及时排出有机溶剂蒸汽和有毒有害气体； Ensure air on surface of paint film to flow, via to volatilize the solvent of paint and develop curing of film.保证漆膜表面空气流动，有利于油漆漆膜溶剂的挥发，促进漆膜固化。 Ensure sufficient fresh air to make applicators safety work inside tank.确保足够的新鲜空气量，保证储罐内部施工人员的安全。5.3.20 In general, paint application in pipe/tank/container shall be carried out when whole welding and other procedures that would destruct coats finished completely. For some partial area that should be welded until painting finished, 50 mm width around seam shall be covered by adhesive tape to avoid any coating that would affect welding quality.总体来说，管道、储罐或容器内部涂层施工应在所有的焊接和涂层破坏性施工结束后进行，对于局部必须在涂层施工完进行焊接的部位，在油漆涂装前，焊缝边缘50毫米的范围内应该被粘贴覆盖以免被涂装上油漆，影响焊接质量。5.3.21 Touching up of whole paint system in pipe/tank/container shall be reduced as possible when whole welding and other destructive working completed. The integrity of coats shall be important for the whole paint system. 管道、储罐或容器内部涂层应在所有的焊接和其它破坏性施工结束后，对涂层进行整体施工，应尽量减少涂层的修补工作。涂层的完整性对涂层的整体质量和功能很重要。5.3.22 Coated steelwork shall be put in service until coats had been cured completely. The detailed curing time shall refer to TDS of International paint.涂装好的钢结构涂层在涂层充分固化后，才能投入使用，具体的固化时间请参阅我公司该产品的说明书要求。5.3.23 Coatings shall be applied onto steel surface that had been prepared properly and over-coated with itself in the interval time of over-coating. As if the interval had been exceeded, the previous coat must be abraded thoroughly and qualified.涂料只能涂覆在经过基层表面处理的钢材表面和自覆涂，并要求在规定的覆涂间隔时间内进行覆涂，如超过最大覆涂间隔时间范围，必须对上道涂层表面进行“拉毛”处理并检查合格后，才能进行自覆涂。5.3.24 The soft wrapping should be used to protect the coat during carriage, lifting and installing of the finished components.完工构件应有保护措施，在运输、吊装时应使用软质包扎物。5.4 Application of Tie coat Intergard 269 Intergard 269的施工5.4.1 Mixing 混合Mixing ratio: Part A: Part B = 4: 1(by volume)The power agitating should be employed. Agitate part A at first, combine entire contents of Curing Agent part B with part A and mix thoroughly with power agitator. The suitable quantity thinner may be added if necessary. Once the unit has been mixed it must be used within the working pot life specified.混合比例 A组分 B组分 = 41（体积比）应采用机械搅拌，先搅拌均匀A组分，然后把B组全部加入A组分并搅拌均匀。搅拌均匀的油漆应在混合使用寿命内喷涂完毕。5.4.2 Pot life after mixing混合使用寿命Temp. 温 度10C15C25C40CPot life可使用寿命17hrs12hrs8hrs3hrs5.4.3 Application. 施工方法Before application of airless spray, the stripe coat with brush must be carried out to edges, welding seems, holes, dead corner and any hard to reach areas to ensure the thickness and avoid holidays. 在喷涂前，应用毛刷进行预涂，包括自由边、扇形孔，拐角角钢反面的及死角等不易喷到的部位。Airless-spraying would be preferred, Pump radio will be 32 1 or 451. The input pressure should be above 3.5/, total output pressure at spray tip is not less than 141/, tip size 0.38 - 0.53mm.本产品应采用高压无气喷涂施工，泵压比32:1或45:1，进气压力为3.5 - 5kg/cm2，喷嘴压力至少141/cm2，喷嘴口径：0.38-0.53mm.、5.4.4 Dry time and over coating intervals: 表干、硬干、覆涂时间间隔Surface temp.表面温度Touch Dry表干Hard Dry硬干Over-coating Interval覆涂间隔Minimum最小Maximum最大10C40min分钟16hrs小时16hrs小时Extended无限制15C35min分钟12hrs小时12hrs小时Extended无限制25C30min分钟8hrs小时8hrs小时Extended无限制40C15min分钟1hrs小时4hrs小时Extended无限制This product will not cure adequately below 5C. For maximum performance ambient curing temperature should be above 10C. 本产品在5 C以下时，不能充分固化，在10 C以上是适宜的温度。5.4.5 DFT limitation 干膜厚度限制 Care should be exercised to avoid the excessive dry film thicknesses. Due to excessive film thickness may lead to splitting of the film when overcoated with high build systems of high solid Interseal 670HS. Intergard 269施工时应小心，漆膜不宜过厚，否则用厚浆型的环氧涂料Interseal 670HS涂覆时，有可能导致漆膜开裂。u For more information about this product, pls. refer to the PDS.关于该产品更详细的信息，可参考产品说明书。5.5 Application of Polyurethane Interthane 990聚氨酯面漆施工5.5.1 Mixing 混合Mixing ratio Part A : Part B = 6:1 (by volume)Material is supplied in two containers as a unit. Always mix a complete unit in the proportions supplied. Once the unit has been mixed it must be used within the working pot life specified.(1) Agitate Base (Part A) with a power agitator.(2) Combine entire contents of Curing Agent (Part B) with Base (Part A) and mix thoroughly with power agitator. 混合比 A 组分B组分61（体积比）涂料分两个包装，记着一定要按比例混合一套涂料，一套涂料混合好后，必须在规定的混合使用寿命内用完。先使用机械搅拌器搅拌A组分，把全部的固化剂倒入基料A组分，机械搅拌均匀。5.5.2 Thinning 稀释Thinning with GTA 733 ratio will be adjusted according to temperature, spray pump pressure. The excess thinning will affect coats performance i.e. sags. Using thinner shall not disobey the local regulations.稀释剂GTA733的用量将根据温度，喷漆泵压力进行调整。稀释量不能过度而影响涂层性能，引起流挂等，不能违反当地的环境保护法规。5.5.3 Pot life 混合使用时间Temp. 温度 5 152540Pot-life,使用时间，小时 12 hrs4 hrs2 hrs45 minThe paint cannot be used once the pot life exceeds.如果超过规定的混合使用寿命，涂料将不可以再使用。5.5.4 Application Methods 施工方法Maximum film build in one coat is best attained by airless spray.高压无气喷涂是通过一道涂层获得最大膜厚的最佳方法。Tip size: 0.33 .0.45 mm (13”18”) 枪嘴孔径：0.33.0.45 mm(13”18”);Total output fluid pressure at spray tip not less than 155 kg/cm2 (2200 psi)喷嘴处油漆压力不得低于155 kg/cm2 (2204 psi)5.5.5 Drying and over-coating干燥和重涂Temperature温度Touch Dry表干，小时Hard Dry硬干，小时Over-coating Interval 重涂间隔, 小时Min. 最小Max. 最大55 hrs小时24 hrs小时24 hrs小时Extended 无限制152.5 hrs小时10 hrs小时10 hrs小时Extended 无限制251.5 hrs小时6 hrs小时6 hrs小时Extended 无限制401 hrs小时3 hrs小时6 hrs小时Extended 无限制u For more information about this product, pls. refer to the PDS.关于该产品更详细的信息，可参考产品说明书。6 .QC & QA质量控制和保证6.1 The painting contractors duty 涂装承包方的责任 Painting subcontractors have the responsibility to make detailed Painting Schedule & QC Procedure and establish a Quality Control System. The Contractor shall have control of the means and methods utilized to meet all QC and painting activities.涂装承包商应有责任制订涂装质量控制程序，并建立完善的质量控制体系。总承包方应控制应用的方式方法以达到质量控制和涂装的要求。6.2 Check points检查要点：6.2.1 Steel work and cleaning check points结构性处理及清洁度检查要点：Spatters； laminations；sharp undercuts； rough welds； sharp edges；welding smoke；oil and grease to be removed.飞溅、叠片、咬边、粗糙焊缝、锐边、焊烟、油污。6.2.2 Surface preparation Check Points表面处理检查要点：Degree of cleaning；roughness profile (40-75 microns)；Dust cleaning (Rating 2)；oil & grease；Ambient conditions (air temperature, relative humidity, steel temperature, dew point). 清洁度、粗糙度（40-75微米）、灰尘清洁度（2级）、油污、环境条件（气温、相对湿度、表面温度、露点）。6.2.3 Check points during application施工检查要点：Application equipments； ventilation；mixing；thinning；stirring； paint storage； stripe-coat or touch-up；W.F.T；Ambient condition (air temp,/relative humidity,/steel temperature, dew point). 施工设备、通风、混合、稀释、搅拌、涂料储置、预涂或补涂、湿膜厚度、环境条件（同上）。6.2.4 Check points for final inspection完工检查要点:Finish coat (Topcoat): uniform color & gloss, no sagging, running, spraying dust, no contamination. 完工面漆：色泽均匀，无流挂、无漆雾、无污染。Imperfection: full coverage, no pinholes, holidays & cavities, no rusty spots. 缺陷：无针孔、无气泡、无漏喷、无锈斑DFT: according to min /max DFT in specification. 干膜厚度：根据规定的最低/最高厚度。6.3 Site ambient condition control现场环境条件控制No final blast-cleaning or painting application shall be done if the R. humidity is more than 85% and when the steel temperature is not more 3 above the dew point. For inspection frequency shall be at the beginning of work of every day (including surface preparation), thereafter one inspection every 2 hour. If the weather changes acutely the QC shall inspect immediately, and tell the working team to stop blasting or painting operations, when the weather does not meet specified requirement. 如果相对湿度超过85%或者钢板温度不高于露点3，不要进行最终的喷砂或油漆施工。检查的频度，一般是施工的（包括表面处理）每天都要检查，从施工开始时，每隔2小时检查一次，当天气剧烈变化或明显变恶劣时，检查人员应时刻检查现场环境条件，当环境条件不能满足施工要求时，应及时通知施工人员停止施工。6.4 WFT and DFT inspection湿膜厚度与干膜厚度检测6.4.1 Measure the wet film thickness regularly using a wet film gauge (comb gauge). Make sure to have cleaning towels are available to clean the comb gauge. WFT must be measured immediately after application since evaporation of solvents will affect the reading if not performed at once. WFT measurements are specified to be carried out alongside checking of paint consumption. These should take into consideration specified dry film thickness and volume solids of the paint.施工过程中应采用湿膜仪(湿膜梳)定期测量涂层的湿膜厚度，而且，确保附近有干净的毛织物来擦拭刚使用过的湿膜卡。湿膜厚度在施工开始时和施工过程中应及时检测，因为不及时执行，溶剂的挥发将影响读数。湿膜厚度的检测可反映油漆用量，同时也有助于控制干膜厚度。6.4.2 DFT measurement shall be carried out after completion of and sufficient drying of each coat applied. Recommended, non-destructive methods for the determination of DFT on metallic, magnetic and non-magnetic substrates are described in SSPC PA2.干膜厚度应当在每一涂层完成，干燥（硬干）后进行。对于金属，磁性和非磁性表面的干膜测定，非破坏的方法可参照SSPC中PA2的方法和要求。6.5 Sufficient Luminance足够的照明Checking should be done under good lighting conditions no less than 500lux. Keep lights clean free from paint. A general rule-of-thumb is to be able to read normal newspaper print u