Qualification Requirements for
Qualification Requirements for
Epoxy Coatings for Atmospheric Service
Epoxy Coatings for Atmospheric Service
Paints and Coatings Standards Committee Members
Paints and Coatings Standards Committee Members
Barouky, F.F.
Barouky, F.F., Chairman, Chairman Hammad, B.S.,
Hammad, B.S., Vice ChairmVice Chairmanan Al-Homayed,
Al-Homayed, M.A.M.A. Al-Khashram, Al-Khashram, M.S.M.S. Al-Nujaim,
Al-Nujaim, S.A.S.A. Al-Seba, Z.A Al-Seba, Z.A..
Suller, A.A. Suller, A.A.
Sa
Saudi
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Aramco De
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Top Standards
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Table of Contents Table of Contents
1
1 Scope...Scope...…... ....…... 22 2
2 Conflicts Conflicts and and Deviations....Deviations...….. ..….. 22 3
3 ReferenceReferences...s...…... ...…... 33 4
4 General General Requirements..Requirements...…... .…... 44 5
5 Qualification Qualification Tests Tests and and Requirements..Requirements...…... .…... 55 6
1 Scope
This Specification defines the minimum mandatory requirements for qualifying individual coating products for use in Saudi Aramco's approved protective coating systems APCS-1A through APCS-1F. It shall be used when any of the following situations occur:
1.1 Initial Product Approval
This specification shall be given to coating manufacturers, or other vendors of coating products, that wish to obtain initial approval for products that have not previously been qualified in accordance with this specification.
1.2 Purchase Requisitions/Purchase Orders
This specification shall be attached to Purchase Requisitions or Purchase Orders when those documents address the procurement of coating products that have not been previously qualified in accordance with this specification.
This specification does not apply and should not be included with Purchase orders or requisitions for coating products that have been previously qualified per this specification. This specification should also not be included with purchase orders or requisitions for coated items or equipment when a Saudi
Aramco approved protective coating system has been specified. 1.3 Periodic Product Compliance Checks
This specification may be used for periodic product compliance checks on previously approved coatings. It shall be given to the organization conducting
the compliance tests. 2 Conflict s and Deviations
2.1 Any conflicts between this specification and other applicable Saudi Aramaco Materials System Specifications (SAMSSs), Engineering Standards (SAESs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department, of Saudi Aramco, Dhahran.
2.2 Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Mangaer, Consulting Services Department, of Saudi Aramco, Dhahran.
3 References
Material or equipment supplied to this specification shall comply with the latest edition of the references listed below unless otherwise noted:
3.1 Saudi Aramco References
Saudi Aramco Engineering Procedure
SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement
Saudi Aramco Materials System Specifications
09-SAMSS-060 Packaging Requirements for Coatings 09-SAMSS-071 Inorganic Zinc Primer
Saudi Aramco Engineering Standards
SAES-H-101 APCS-1A Epoxy Coating System for Atmospheric Service (with Inorganic Zinc Primer)
SAES-H-101 APCS-1B Epoxy Coating System for Atmospheric Service (with Epoxy Primer)
SAES-H-101 APCS-1C Epoxy Coating System for Atmospheric Service (with Zinc-rich Epoxy Primer)
SAES-H-101 APCS-1D Epoxy/Polyurethane Coating System for
Atmospheric Services (with Inorganic Zinc Primer)
SAES-H-101 APCS-1E Epoxy/Polyurethane Coating System for Atmospheric Service (with Epoxy Primer) SAES-H-101 APCS-1F Epoxy/Polyurethane Coating System for
Atmospheric Service (with Zinc-Rich Epoxy Primer)
3.2 Industry Codes and Standards
American Society for Testing and Materials
ASTM A36 Structural Steel
ASTM B117 Salt Spray (Fog) Testing
ASTM D16 Definition of Terms Relating to Paints, Varnishes, Lacquers and Related Products
ASTM D523 Specular Gloss
ASTM D610 Evaluating Degree of Rusting on Painted Steel Surfaces
ASTM D660 Evaluating Degree of Checking of Exterior Paints ASTM D661 Evaluating Degree of Cracking of Exterior Paints ASTM D714 Evaluating Degree of Blistering of Paints
ASTM D822 Operating Light-and-Water Exposure Apparatus (Carbon-Arc Type) for Testing Paint, Varnish, Lacquer, and Related Products
ASTM D1640 Drying, Curing or Film Formation of Organic Coatings at Room Temperature
ASTM D1654 Method for Evaluation of Painted or Coated Specimens Subjected to Corrosive
Environments
ASTM D1849 Package Stability of Paint ASTM D2805 Hiding Power of Paints
ASTM G26 Operating Light-Exposure Apparatus (Xenon-Arc Type) With and Without Water for Exposure of Nonmetallic Materials
The Society for Protective Coatings
SSPC-PA2 Measurement of Dry Paint Thickness with Magnetic Gages
SSPC-Paint 20 Zinc-rich Primers (Type II, Organic)
SSPC-Paint 22 Epoxy-Polyamide Paints (Primer, Intermediate, and Topcoat) dated November 1, 1982
SSPC-Vis 1 Pictorial Surface Preparation Standards for Painting Steel Surfaces
Swedish Standard SIS 055900-Pictorial Surface Preparation Standard for Painting Steel Structures:
Sa 2-1/2 Very Thorough Blast Cleaning
4 General Requi rements
4.1 For purposes of this specification, the Buyer's Representative shall be the Responsible Standardization Agency Representative (RSA).
4.2 In order to qualify a coating system as acceptable under this specification, the coating supplier shall submit a certified test report documenting that the
proposed coating system meets the qualification tests and requirements of this SAMSS. Preparation and testing shall be performed and/or witnessed by an independent laboratory or inspection agency. This report shall be submitted to the Saudi Aramco RSA for review. The RSA shall decide if the data presented by the Supplier satisfies all the requirements.
4.3 All initial product qualification tests shall be carried out at no cost to Saudi Aramco.
5 Qualifi cation Tests and Requirements
5.1 Tests Applicable to Specific Generic Types of Coatings
5.1.1 Epoxy coatings (except zinc-rich primers) supplied in accordance with this Specification shall meet the requirements of SSPC-Paint 22 except as modified below:
a) Paragraphs 2.2, 2.3 and 2.4: Should read "percent by weight," not "percent by volume."
b) Paragraph 4.3, Composition: Base component of topcoats need not contain anti-corrosion pigments.
c) Paragraph 5.5, Pot Life: Shall be replaced by paragraph 5.2.3 of this Specification.
d) Paragraph 5.7, Test Panels: Shall be replaced by paragraph 5.3 of this Specification.
e) Paragraph 5.8, Elcometer Adhesion Test: Shall be replaced by paragraph 5.4.2 of this Specification.
f) Paragraph 5.9, Salt Spray Resistance: Shall be replaced by paragraph 5.4.1 of this Specification.
g) Paragraph 6, Labeling: Shall be replaced by section 6 of this Specification.
h) Paragraphs 7 (Inspection) and 8 (Safety): Delete requirements. 5.1.2 Zinc-rich epoxy primers for APCS-1C and APCS-1F, in addition to
meeting the requirements of Section 5.2, shall meet the requirements of paragraphs 1, 2, 3, and 4 of SSPC-Paint 20 (Type II, Organic). The
vehicle shall be a catalyzed epoxy
5.1.3 Inorganic zinc silicate primers for APCS-1A and APCS-1D shall meet the requirements of 09-SAMSS-071.
5.1.4 Urethane coatings supplied in accordance with this Specification shall be Type V Polyol-cured Aliphatic as defined in ASTM D16.
a) Specular gloss of the urethane coatings, when tested at a 60 degrees angle in accordance with ASTM D523, shall be at least 85.
b) When tested in accordance with ASTM D2805, the minimum contrast ratio of the polyurethane coating shall be 0.94 except for red colors which shall be 0.88 minimum.
5.2 Physical Property Tests Applicable to All APCSs 5.2.1 Package Stability of Paint
When stored at 52 ± 1ºC for 6 months in accordance with ASTM D1849, the sample shall meet the following requirements:
a) Weight loss – 0.
b) Skinning, pressure and corrosion – 10. c) Settling - 6 or better.
d) Grains, lumps, or streaks - 8 or better. 5.2.2 Spray Properties
The ready mixed paint shall be easily applied to a vertical surface at the following dry film thicknesses with no tendency to orange peel, sag, creep or run:
Inorganic zinc : See 09-SAMSS-071
(APCS-1A and APCS-1D)
Zinc-rich epoxy primers : 75 micrometers (3 mils) (APCS-1C and APCS-1F)
Epoxy primers : 100 micrometers(4 mils) (APCS-1B and APCS-1E):
Epoxy topcoats : 150 micrometers (6 mils) (All APCSs)
Polyurethane (APCS-1D, : 65 micrometers (2.5 mils APCS-1E and APCS-1F)
5.2.3 Usable Potlife
At 40°C, the viscosity of the ready-mixed paint shall remain within the range recommended by the manufacturer for sprayability without
additional thinning for not less than 1 hour. 5.2.4 Drying Times
When tested in accordance with ASTM D1640, the Dry-Through (or Dry-To-Handle) Time shall be 8 hours or less (2 hours or less for the zinc-rich epoxy primers) and the Dry-To-Recoat Time shall be in accordance with suppliers published data sheets.
5.3 Test Panel Preparation
5.3.1 Test panels shall be ASTM A36 hot-rolled steel approximately 100 mm X 150 mm. Prior to preparing the surface, the condition of the test panel shall be equivalent to SSPC-Guide to Vis 1 Rust Grade A, Adherent Mill Scale. The minimum thickness of the test panel shall be 5 mm.
5.3.2 The test panel shall be abrasive blast cleaned to near white metal (SP-10 or Sa 2-½).
5.3.3 Profile of blasted surface shall be as follows:
40-65 micrometers (1.5 - 2.5 mils) for APCS-1A, APCS-1B, APCS-1D, and APCS-1E
25-40 micrometers (1.0 - 1.5 mils) for APCS-1C and APCS-1F. The profile shall be determined with replica tap e.
5.3.4 Coatings shall be mixed, applied and cured in accordance with the Vendor's recommendations. The temperature of the test panel shall be 63 ± 2ºC during coatings application. Dry film thickness shall be
measured and recorded in accordance with SSPC-PA2 and shall meet the requirements in Table 1.
Table 1 - Dry Film Thickness (DFT) Requirements Intermediate Total
Primer Coat (1 or Topcoat (2 or Topcoat System(Min (1 coat) more coats) more coats) (1 coat) 3 coats) DFT in DFT in Max. DFT in DFT in DFT in Micrometers Micrometers Micrometers Micrometers Micrometers APCS Min-Max Min-Max Min-Max Min -Max APCS-1A 65 - 100 N/A 150 N/A 275 - 400 APCS-1B 50 - 100 N/A 150 N/A 275 - 400 APCS-1C 40 – 75 N/A 150 N/A 250 - 375 APCS-1D 65 - 100 100 - 150 N/A 25 - 65 190 - 315 APCS-1E 50 - 100 100 - 150 N/A 25 - 65 175 - 315 APCS-1F 40 – 75 125 - 175 N/A 25 - 65 175 - 290
5.4 Performance Tests
5.4.1 Weather-o-Meter and Salt Fog Performance Tests
Each panel shall be scribed in accordance with ASTM D1654 and exposed alternately in a Weather-o-Meter in accordance with ASTM D822, Procedure B, or ASTM G26, Method B, and a salt fog cabinet in accordance with ASTM B117. Panels shall be rotated every 100 hours until a total of 500 hours in each device has been achieved. At the conclusion of the test, each coating will be evaluated for and meet the criteria in Table 2.
Table 2
Standard Acceptable Rating ASTM D714 No blisters
Evaluating Degree of Blistering of Paints
ASTM D660 No checking Evaluating Degree of
Checking of Exterior Paints
ASTM D661 No cracking Evaluating Degree of
Cracking of Exterior Paints
ASTM D610 9 or better for APCS-1B and Evaluating Degree of APCS-1E.
Rusting on Painted 10 for APCS-1A, APCS-1C, Steel Surfaces System APCS-1D, and APCS-1F. ASTM D1654 Rating of Failure at Scribe
Standard Evaluation of shall not exceed:
Painted or Coated 9 for APCS-1B and APCS-1E. Specimens Subjected to 10 for APCS-1A, APCS-1C, Corrosive Environments APCS-1D, and APCS-1F.
N/A No more than 10% of the total
Erosion average thickness has been removed. ASTM D 523 The reduction in gloss of the
Specular Gloss tested sample shall not exceed
(Polyurethane Coatings Only) 20% compared to an untested sample.
5.4.2 Adhesion Test
a) Test panels shall be prepared in accordance with paragraph 5.3 except that the coatings shall be cured as shown in Table 3.
Table 3
Coating Drying Time at 25 ± 1ºC Inorganic zinc primer 14 days
Zinc rich primer 24 hours Epoxy primer 72 hours Epoxy intermediate coat 72 hours Epoxy topcoat 5 days Polyurethane topcoat 5 days
b) Determine the adhesion of the prime coat to the substrate,
intercoat adhesion, or cohesion of any coat of the painting system by using an adhesion tester, 450 kg capacity. Lightly sand the
coated surface and aluminum dolly and apply an epoxy adhesive. Allow the adhesive to cure as directed by adhesive supplier. Scribe the coating and adhesive around the dolly prior to testing. Make a minimum of three trials and report the average. The average shall be at least 2750 kPa (400 psi).
5.4.3 Maximum Service Temperature
The maximum service temperatures of the coating systems shall be as follows:
• For APCS-1A, APCS-1B, and APCS-1C: 150ºC • For APCS-1D, APCS-1E, and APCS-1F: 80ºC
To verify compliance with these requirements, conduc t adhesion tests on coated panels that have been prepared in accordance with paragraph 5.4.2 and then exposed in an oven for 14 days at the appropriate temperature listed above. The adhesion shall be at least 90% of that obtained on samples prepared and tested in accordance with paragraph 5.4.2 but not subsequently exposed in an oven.
6 Method of Packaging
Coatings shall be packaged in accordance with 09-SAMSS-060.
Revision Summary
31 October, 2004 Revised the "Next Planned Update". Reaffirmed the contents of the document and reissued with no other changes.