NORSOK STANDARD
NORSOK STANDARDCOMMON REQUIREMENTSSURFACE PREPARATION AND PROTECTIVE COATINGM-CR-501Rev. 1, December 1994
Surface Preparation and Protective CoatingM-CR-501Rev. 1, December 1994CONTENTS1 FOREWORD. 22 SCOPE. 23 NORMATIVE REFERENCES. 24 DEFINITIONS AND ABBREVIATIONS . 35 GENERAL REQUIREMENTS . 45.1 General. 45.2 Planning . 45.3 Equipment protection and clean up . 45.4 Ambient conditions. 45.5 Coating materials. 55.6 Steel materials. 55.7 Unpainted surfaces . 55.8 Handling and shipping of coated items . 55.9 Prequalification of products, personnel and procedures. 55.10 Metal coating . 66 HEALTH, SAFETY AND ENVIRONMENT. 67 SURFACE PREPARATION. 67.1 Pre-blasting preparations . 67.2 Blast cleaning . 77.3 Final surface condition . 78 PAINT APPLICATION . 78.1 General. 78.2 Application equipment . 78.3 Application . 88.4 Repairs . 89 THERMALLY SPRAYED METALLIC COATINGS. 89.1 General. 89.2 Coating materials. 89.3 Application of thermally sprayed coating . 99.4 Field coating of pipes and coating of infill steel . 99.5 Repairs . 910 QUALIFICATION REQUIREMENTS . 910.1 Pre-qualification of products . 910.2 Qualification of personnel . 1010.3 Qualification of procedures . 1211 INSPECTION AND TESTING. 13ANNEX A - COATING SYSTEMS. 14ANNEX B - COLOURS . 18NORSOK Standard1 of 18
Surface Preparation and Protective Coating1M-CR-501Rev. 1, December 1994FOREWORDThis standard has been developed by the NORSOK Standardisation Work Group for thewidest possible national and international application.2SCOPEThis Standard gives the requirements for the selection of coating materials, surfacepreparation, application procedures and inspection for protective coatings to be appliedduring the construction and installation of offshore installations and associated facilities.The document covers both paints and thermally sprayed metallic coatings.The aim of the document is to obtain a system which ensures: Optimal protection of the installation with a minimum need for maintenance.That the coating system is maintenance friendly.That the coating system is application friendly.That health, safety and environmental impacts are evaluated and documented.The document is not applicable to pipelines and pipeline risers.3NORMATIVE REFERENCESASTM D823ASTM D1141ASTM D1650ASTM G8Method of producing films of uniform thickness of paint, varnish,lacquer and related products on test panels.Specification for Substitute Ocean Water.Method of sampling and testing shellac varnish.Test method for cathodic disbonding of pipeline coatings.BS 5493Code of practice for protection of iron and steel structures againstcorrosion.DIN 8566DIN 32521Zusätze für das termische SpritzenAcceptance test and quality control for thermal spraying equipment.ISO 1461Metallic coatings - Hot-dip galvanized coating on fabricated ferrousProducts - Requirements.Paints and varnishes - Examination and preparation samples fortesting.Paints and varnishes - Standard panels for testing.Paints and varnishes - Determination of volatile and non-volatilematter.Paints and varnishes - Determination of density.Paints and varnishes - Comparison of contrast ratio (hiding power) ofpaint of the same type and colour.ISO 1513ISO 1514ISO 1515ISO 2811ISO 2814NORSOK Standard2 of 18
Surface Preparation and Protective CoatingISO 4624ISO 4628ISO 6270ISO 7253ISO 8501ISO 8502-3ISO 8502-6ISO 8503ISO 8504-2M-CR-501Rev. 1, December 1994Paints and varnishes - Pull-off test for adhesion.Paints and varnishes - Evaluation of degradation of paint coatings Designation of intensity, quantity and size of common type of defects.Paints and varnishes - Determination of resistance to humidity(continuous condensation).Paints and varnishes - Determination of resistance to neutral saltspray.Preparation of steel substrates before application of paints and relatedproducts - Visual assessment of surface cleanliness.Preparation of steel substrates before application of paints and relatedproducts - Test for the assessment of surface cleanliness - Assessmentof dust on steel surfaces prepared for painting, pressure sensitive tapemethod.Preparation of steel substrates before application of paints and relatedproducts - Test for the assessment of surface cleanliness - Samplingof soluble impurities on surfaces to be painted - The Bresle method.Preparation of steel substrates before application of paints and relatedproducts - Surface roughness characteristics of blast cleanedsubstrates.Preparation of steel substrates before application of paints and relatedproducts - Surface Preparation Methods - Abrasive blast-cleaning.NACE TM0184Accelerated test procedures for screening atmospheric surface coatingsystems for offshore platforms and equipment.NACE RP0188Discontinuity (holiday) testing of protective coatings.NS 476Rules for the Approval of Surface Treatment Inspectors.RAL-1KFarbenübersicht.SSPC Vol.2Steel Structures Painting ManualS-DP-002NORSOK Standard Working environment.4DEFINITIONS AND ABBREVIATIONSFeathered:surface.A gradual taper in thickness from a coated surface to an uncoatedHoliday:MDFT:A discontinuity in a coating which exhibits electrical conductivitywhen exposed to a specific voltage.Minimum dry film thickness.NDFT:Nominal dry film thickness.NACE:National Association of Corrosion Engineers.NORSOK Standard3 of 18
Surface Preparation and Protective CoatingRAL:Shop primer:Stripe Coat:SSPC:M-CR-501Rev. 1, December 1994Colour definitions issued by RAL Deuches Institut für Gütesicherungund Kennzeichnung e.V.A thin protective coating for protection during transport and storageapplied at the steel suppliers facilities.Coat of paint applied to welds, edges, etc. by brush, to ensureadequate film thickness of areas of difficult access.Steel Structures Painting Council.5GENERAL REQUIREMENTS5.1GeneralSelection of coating systems and application procedures shall be made with dueconsideration to conditions during fabrication, installation and service of the installation.5.2PlanningAll activities shall be fully incorporated in the fabrication plan.Details of management, inspectors, operators, facilities, equipment and qualifiedprocedures shall be established and documented before commencing work.Steel surfaces shall be blast cleaned and coated, i.e. metal sprayed or coated with primerand the succeeding coat of the applicable system, prior to installation.5.3Equipment protection and clean upAll equipment and structures shall be fully protected from mechanical damages, ingress ofabrasives and dust from blast cleaning. Sags, droplets and paint overspray (incl. dryspray)shall be avoided. Adjacent areas not to be painted or already finished, shall be protected.On completion of the work in any area, all masking materials, spent abrasives, equipmentetc. shall be removed.5.4Ambient conditionsNo final blastcleaning or coating application shall be done if the relative humidity is morethan 85 % and when the steel temperature is less than 3 C above the dew point. Nocoating shall be applied or cured at temperatures below 0 C.The coating manufacturer shall specify the maximum and minimum application and curingtemperature and other relevant limitations regarding application and curing conditions foreach product in any coating system.NORSOK Standard4 of 18
Surface Preparation and Protective Coating5.5M-CR-501Rev. 1, December 1994Coating materialsThe selected coating materials shall be suitable for the intended use and shall be selectedafter an evaluation of all relevant aspects such as: Corrosion protective properties. Requirements to health, safety and environment. Properties related to application conditions, equipment and personnel. Availability and economics of coating materials.All coating materials and solvents shall be stored in the original container bearing themanufacturer's label and instructions. Each product shall have a batch number showingyear and month of manufacture and giving full traceability of production. Shelf life shallbe included in the technical data sheet.Applicable coating systems are tabulated in Annex A. Alternative coating systems may beused if the requirements of this document are fulfilled.Top coat colours should be in accordance with Annex B.5.6Steel materialsSteel subject to surface preparation on site shall as a minimum requirement be inaccordance with Rustgrade B according to ISO 8501-1. Shop primer applied by the steelmanufacturer shall be regarded as temporary corrosion protection and shall be removedprior to the application of the coating systems herein.5.7Unpainted surfacesThe following items shall not be coated unless otherwise specified: 5.8Aluminium, titanium, stainless steel, chrome plated, nickel plated, copper, brass,lead, plastic or similar.Jacketing materials on insulated surfaces.Handling and shipping of coated itemsCoated items shall be carefully handled to avoid damage to coated surfaces. No handlingshall be performed before the coating system is cured to an acceptable level. Packing,handling and storage facilities shall be of non-metallic type.5.9Prequalification of products, personnel and proceduresPrequalification requirements as described in clause 10 of this document shall be fulfilledand documented prior to commencement of any work in accordance with this document.NORSOK Standard5 of 18
Surface Preparation and Protective Coating5.10M-CR-501Rev. 1, December 1994Metal coatingHot-dip galvanising shall be in accordance with ISO 1461. When hot-dip galvanised itemsare painted, coating system 6 in this document shall be used.Metal spraying shall be in accordance with the requirements in this document.6HEALTH, SAFETY AND ENVIRONMENTThe following documentation shall be provided and used when evaluating coating systems: Chemical name of organic solvent, OAR number (Occupational Air Requirements)according to Norwegian regulations and VOC content (Volatile Organic Componentsg/l).Percentage of low molecular epoxy (molecular weight 700).Content of hazardous substances. Ref. S-DP-002.Specification of hazardous thermal degradation components.Combustibility.Special handling precautions and personal protection.All coating products as applied, shall as a minimum, be in accordance with relevantNorwegian regulatory requirements regardless of where the coating operation takes place.Content of quartz and heavy metals in blast cleaning media (ISO 8504-2) shall be given.7SURFACE PREPARATION7.1Pre-blasting preparationsSharp edges, fillets, corners and welds shall be rounded or smoothed by grinding(min R 2 mm).Hard surface layers, e.g. resulting from flame cutting, shall be removed by grinding priorto blast cleaning.The surfaces shall be free from any foreign matter such as weld flux, residue, slivers, oil,grease, salt etc. prior to blast cleaning.Any oil and grease contamination shall be removed by solvent or alkali cleaning prior toblasting operations, ref. SSPC-SP-1.Any major surface defects, particularly surface laminations or scabs detrimental to theprotective coating system, shall be removed by suitable dressing. Where such defects havebeen revealed during blast cleaning, and dressing has been performed, the dressed areashall be reblasted to the specified standard. All welds shall be inspected and if necessaryrepaired prior to final blast cleaning of the area.NORSOK Standard6 of 18
Surface Preparation and Protective Coating7.2 M-CR-501Rev. 1, December 1994Blast cleaningBlasting abrasives shall be dry, clean and free from contaminants which will bedetrimental to the performance of the coating.Size of abrasive particles for blast cleaning shall be such that the prepared surface profileheight (anchor pattern profile) is in accordance with the requirements for the applicablecoating system. The surface profile shall be graded in accordance with ISO 8503.The cleanliness of the blast cleaned surface shall be as referred to for each coating system,i.e. Sa 2 1/2 or Sa 3 in accordance with ISO 8501-1.7.3Final surface conditionThe surface to be coated shall be clean, dry, free from oil/grease and have the specifiedroughness and cleanliness until the first coat is applied.Dust, blast abrasives etc. shall be removed from the surface after blast cleaning such thatthe particle quantity and particle size do not exceed rating 2 of ISO 8502-3.The maximum content of soluble impurities on the blasted surface as sampled using ISO8502-6 and distilled water, shall not exceed a conductivity corresponding to a NaClcontent of 20 mg/m2. Equivalent methods may be used.8PAINT APPLICATION8.1GeneralContrasting colours shall be used for each coat of paint.The coating manufacturer shall provide a Coating System Data Sheet (CSDS) for eachcoating system to be used, containing at least the following information for each product: 8.2Surface pre-treatment requirements.Wet film thickness/dry film thickness (max, min. and specified).Maximum and minimum recoating intervals at 5 C, 10 C and 23 C.Information on thinners to be used (quantities and type).Mixing, handling and application requirements/recommendations.Hiding power of top coat for specified colours according to ISO 2814. Contrast ratioshall not be less than 94% at the specified top coat thickness.Application equipmentThe method of application shall be governed by the coating manufacturer'srecommendation for the particular coating being applied.Roller application of the first primer coat is not acceptable. When paints are applied bybrush, the brush shall be of a style and quality acceptable to the coating manufacturer.NORSOK Standard7 of 18
Surface Preparation and Protective CoatingM-CR-501Rev. 1, December 1994Brush application shall be done so that a smooth coat, as uniform in thickness as possibleis obtained.8.3ApplicationPrior to the application of each coat, a stripe coat shall be applied by brush to all welds,corners, behind angles, sharp edges of beams etc. and areas not fully reachable by spray inorder to obtain the specified coverage and thickness.Edges of existing coating shall be feathered towards the substrate prior to overcoating.Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and dripsshall be avoided. Each coat shall be free from pinholes, blisters and holidays.Contamination of painted surfaces between coats shall be avoided. Any contaminationshall be removed.8.4RepairsAll repair of coating shall be conducted in accordance with the original surface preparationand coating application requirements.9THERMALLY SPRAYED METALLIC COATINGS9.1GeneralRelevant requirements provided in this Standard are applicable for thermally sprayedmetallic coatings. Specific requirements valid for thermally sprayed metallic coatings areprovided below.9.2Coating materialsThe materials for metal spraying shall be in accordance with the following standards:Aluminium:Type Al 99.5 of DIN 8566/2 or equivalent.Aluminium alloy: Aluminium alloy with 5 % Mg, DIN 8566/2 AlMg5 or equivalent.All coating metals shall be supplied with product data sheets and quality controlcertificates, and be marked with coating metal manufacturer's name, manufacturingstandard, metal composition, weight and manufacture date.The materials for sealing the metal coating shall be in accordance with BS 5493 (1977),chapter 11, table 4C. Type CP3-6 shall be used below 60 C and type CP7 above 60 C.NORSOK Standard8 of 18
Surface Preparation and Protective Coating9.3M-CR-501Rev. 1, December 1994Application of thermally sprayed coatingEach coat shall be applied uniformly over the entire surface. The coat shall be applied inmultiple layers and shall overlap on each pass of the gun.Application should follow guidelines given in DIN 32521.For items that will be welded after spraying, 5-10 cm measured from the bevel area shallbe left uncoated.The coating shall be firmly adherent. The surface after spraying shall be uniform and freeof lumps, loosely adherent spattered metal, bubbles, ash formation, defects and uncoatedspots.Before application of any further coat, any damage to the previous coat shall be repaired.9.4Field coating of pipes and coating of infill steelBefore the metal spraying operation starts, the metal coated area 30-40 cm in distance fromthe weld zone shall be sweepblasted to ensure that all contaminations are removed. Theuncoated welding zone shall be blast cleaned as specified for coating system no 2. Themetal coating shall be performed accordi
ASTM D823 Method of producing films of uniform thickness of paint, varnish, lacquer and related products on test panels. ASTM D1141 Specification for Substitute Ocean Water. ASTM D1650 Method of sampling and testing shellac varnish. ASTM G8 Test method for cathodic disbonding of pipeline coatings.
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