HOW SHOULD A PAINT OR COATING PROJECT BE MANAGED? THE BASICS YOU NEED TO KNOW

We are publishing the second and final part of our article series that we started in our previous issue. In this series, we examined in detail how a paints and coatings project should be managed.

Selection of Paints and Coatings Tools, Equipment and Techniques

Construction, manufacturing or printing and other industries use different tools, equipment and techniques for applying paints and coatings materials. The most frequently used tools and equipment can be listed as follows: • Brush, • Paint gloves, • Roller, • Air spray/conventional spray, • Airless spray, • Electrostatic spray, • Two-component spray, • Dip tank immersion, • Other methods

Industrial paints and coatings application equipment

Using these application tools and equipment correctly requires considerable experience, which can be gained from field work and professional training. For example, practical manual application together with spray application professional training can be obtained from international professional associations such as National Painting and Decorative Institute, TrainthePainter, ICATS and SSPC: As important as material selection and application processes is another matter — the preparation steps before beginning application, such as storage and straining, mixing, heating and cooling of paints and coatings. This information is contained in the product data sheet (TDS).

Communication / Team Management

In a typical industrial project, there is a group of people who carry out management, application and inspections, which can also be referred to as the Paints/Coatings Team. Members of this team may have very different experiences and different personalities. However, the following general approaches will serve as a guide for you to succeed in your relationships and the results you will achieve: • Do not be egotistical and stay calm: While techniques for staying calm vary from person to person, tips we frequently hear from psychologists such as counting backwards from ten, going to your happiest place, thinking of your loved ones/favourite places can be beneficial to you. • Before starting to work to find a solution to a disagreement, when time permits, know exactly and clearly what is being asked of you — and always remember that you need to focus on the main issue. This applies to any type of disagreement and compromise. A boxer knows why he enters the ring, and a child knows what he wants before asking his family for candy. For this reason, you need to know every detail about the project in a detailed and complete manner so that you can resolve the problem causing disagreement in a shorter and less problematic way. • Approach with a strategy to get what you want: Build personal connection or familiarity with the people you will work with and perhaps come into conflict with. Explain that, like everyone else, you have the same goals — serving the customer and making a living. "Let's overcome this business together like pulling a hair from butter! First and foremost, we all want the same thing. I promise you, I promise to always be kind and professional." Like a competing athlete, you are familiarizing yourself with potential rivals, and if a disagreement arises, you will have some understanding of their personality and needs to get what you want. • As much as possible, let the data speak: Refer to written specifications, test results or other legal documents that strengthen your position. • Be empathetic and sincere: Putting yourself in someone else's shoes can lead you to see the situation from different perspectives. Also, the solution may be in others' hands, and what you think right now may not be part of the solution. For this reason, being empathetic and speaking sincerely can break the ice and be a good problem-solving opportunity. • Ask questions: To find a way out of the issue you face, you need to gather as much information as you can. As a result, the solution may be a collection of answers you have gathered up to that point. • As a last resort, be firm: You have been kind and patient so far. However, if someone becomes overly aggressive, stay calm. But still have some prepared statements on your behalf, for example "Can we agree to stick to the facts and data, and stay away from personal opinions?" or "Do you think we could discuss this matter with each other calmly and in a professional manner?" • If you are wrong, sincerely own your mistake: You know this global saying, "Nobody Is Perfect!" In this context, you may make an error or think incorrectly during a paints/coatings project. This is quite normal and if you are a humble and mature professional, you acknowledge your error in front of others. If they shout criticism, stay calm and listen. Remember, this is probably not personal. Although we want a problem-free work life, we should know that potential technical and personal problems can occur in real life and be prepared to resolve them in the ways mentioned above.

Quality Matters

Another important topic for a successful paints and coatings project is Quality Management through Quality Control (QC) and Quality Assurance (QA) methods. In the QC phase, the quality of processes (such as surface preparation, painting or coating) or raw materials to be used are controlled through Inspection Test Plans (ITP), which contain inspection/testing devices, standards, procedures/techniques and acceptance criteria.

Table 1. (Information in yellow cells can optionally be included when preparing an ITP.)

On ITP preparation, you can obtain a comprehensive information resource called "SSPC Guide for Planning Coatings Inspection" free of charge from the internet. On the other hand, in the QA phase, quality is ensured by checking that inspection reports, product/personnel certificates and other project documents are in compliance with the project specification, contract or another document approved in the project.

Compatibility of prepared documents with project specifications or other approved project documents is checked using checklists.

Finally, to successfully carry out QA and QC steps, authorized personnel working on the project must know the most commonly used international standards (for example, ISO, EN, and others) or industry-accepted standards, specifications and regulations (API, ASTM, DNV, NACE, SSPC and others). You can find a quite comprehensive list that may be useful to you on this subject in the References section. *Since the number and content of these standards is quite large, detailing the subject is beyond the scope of this article and may be the subject of another article related to inspection and protective paints and coatings sector in the future. However, through training and certification programs opened by professional institutions such as FROSIO, NACE, SSPC, TWI and similar operating around the world in the field of paints and coatings, these standards can be learned in detail.

Identification, Remedies and Repair of Paints and Coatings Defects

Like people, animals or machines, paints and coatings materials will eventually experience an error* or defect*. In a Paints/Coatings project, you need to know the source and causes of the defects/errors that occur. This way, you can easily plan the solution and subsequent repair work. (*A paints and coatings error/defect is defined as deterioration that occurs in shorter time than the expected service life under normal operating conditions of the materials.)

These errors/defects can result from:

1. Design-related issues: (For example, sharp edges, corners, weld spatter, water traps, overlapping seams, etc.). 2. Surface preparation operations: (For example, abrasive and dust contamination, insufficient surface profile and cleanliness, etc.). 3. Paints and Coatings Types and Formulations (For example, selection of paints and coatings not suitable for project conditions, inappropriate resin, pigment, filler and additive formulation-related issues, incompatible paints and coatings with substrate, for example oil-based paints for surfaces painted with galvanized or zinc-rich primers). 4. Paints and Coatings Application (For example, excessive wet coating thickness, incorrect application equipment selection, incorrect application techniques, etc.) 5. Paints and Coatings Drying/Curing (For example, high humidity, excessively high/low temperature, non-uniform heating, etc.) 6. Unexpected service conditions (For example, unexpected weather conditions, disasters such as earthquakes and hurricanes, aggressive chemical spills, etc.) Sagging, colour fading, cracking, scratching, colour change, wrinkling are some of the paints and coatings errors frequently experienced in the protective paints and coatings sector. To prevent these errors and defects, the following actions can be followed as remedies: • Selection of the correct high-performance paints and coatings system fully suited to a specific environment, location and service, • Preparation of a work specification containing the requirements needed to achieve long-term paints and coatings performance, • Proper surface preparation before application of paints and coatings, in accordance with the environment and service conditions recommended by the paints and coatings manufacturer, • Application of paints and coatings as recommended by the manufacturer, with inspection included in this process to ensure that project specification requirements are met. • Defective/faulty surfaces should be evaluated using ASTM D714 or ISO 4628 standards and the quantity and extent of the errors/defects that occur should be determined. • Planning quick corrective actions addressing deviations from recommendations and early signals of paints and coatings defects.

Paints and Coatings Defects and Errors

For more detailed information on the subject, you can examine books, technical data sheets or bulletins published by paints and coatings professional communities, chemical manufacturers and professionals working on this subject. For example, a booklet published by Dr. Richard W. Drisko, a U.S. Navy paints and coatings expert, will be quite useful for you. You can find links to this and similar publications in the References section at the end of our article.

Health and Safety at Work, Environmental Protection (HSE)

Surface preparation and paints and coatings application in paints and coatings projects inherently contain certain risks and hazards. However, these inherent risks and hazards can be minimized by using some precautions and protective equipment. Some of the risks arising from the nature of paints and coatings projects are: • Fire and/or explosion, • Solvent emissions, • Tripping and falls, • Working at heights, • Dust and chemical inhalation, • Confined spaces, • Noise/hearing loss, • Radioactivity, • Electrical-related risks, • Static electricity, • Etc. If risks cannot be eliminated or minimized due to the nature of the operations, personal protective equipment (PPE) must always be used during applications. A good resource on HSE and Environmental Protection is Safety Data Sheets (SDS), which must be provided by suppliers for all chemicals used in a project. These sheets contain the risks and hazards involved in storage, handling and application of surface preparation and paints and coatings chemicals used in the project, as well as the PPE equipment that must be used in these processes.

Safety Data Sheets (SDS) for each chemical used are mandatory legal documents that must be provided in industrial projects.

Additionally, HSE and environmental matters can be discussed together with the site safety manager at the project kickoff meeting, and the safety and environmental rules in the project can be clearly understood. Moreover, professional organizations worldwide such as CPCA, OSHA, NIOSH, SSPC, SWA and HSWA publish bulletins along with training on safety and health for painting and coating work. As a side note, you can find the "Painting Work Checklist" document published by the Turkish Ministry of Environment and Occupational Safety free of charge on the internet.

Conclusion

Paints and coatings projects involve multiple disciplines. For this reason, they require technical knowledge and field experience in different areas such as substrates, surface preparation, paints and coatings materials, team management, quality matters, occupational safety and environmental issues. In summary; for successful project management, the tips we briefly mentioned above will help you manage your project in the most economical, safest and healthiest way. 1. Plan the Paints/Coatings Project in detail: As mentioned above, this is the first and most vital step of this project, as all success comes from here. This step also includes preparing a "Work Plan" and "PCP" (commonly known as Procedures) documents in compliance with the project specification. 2. Ensure proper Surface Preparation is carried out before beginning paints and coatings application: This step is the most important step for any paints and coatings application to be successful, and can significantly differentiate the quality of one project from another. 3. Selection of the correct paints and coatings material: Success or failure of a Paints/Coatings project depends largely on this. However, by asking the questions mentioned above and effectively using international standards accepted by the industry, you can easily overcome this issue successfully. 4. Selection of the correct painting/coating equipment application tools, equipment and techniques: After selecting the correct paints and coatings materials, the next step is selection of the correct painting/coating techniques. This decision often comes the hard way; field experience or trial and error… Alternatively and more healthily, you can make this decision through industry-accepted professional training and certification programs. On the other hand, there is great benefit in checking the equipment to be used before proceeding to the field — to prevent unnecessary time loss. Additionally, keeping spare parts for this equipment will also prevent time loss in unexpected breakdowns that may occur. 5. Establish "Correct Communication" and "Team Management". In any project, communication is the key to everything. Some things can change very quickly in the field. Here, the key to success is keeping those responsible informed of every development in the field and developing good relationships. The universal principles of personal behavior and approach mentioned above will support you in managing a smooth and successful project. 6. Document every step of operations and manage quality matters efficiently. From beginning to end, you can find some critical points for correctly and healthily managing processes in the Quality Matters section above. For example, the ITP, CAPA, NCR and other project quality documents you will use and international standards will help you succeed. However, ensuring that QC and QA documents in the project specification are completed is also quite critical. Additionally, taking plenty of photos at the site is also a good idea. 7. Handle paints and coatings defects, remedies and repairs correctly. In every Paints/Coatings project, you will eventually encounter such an unwanted situation. But fortunately, you are not alone on this. As mentioned above, there are step-by-step guidelines and principles you can follow on this matter. You can obtain much more detailed information on this subject from the links in the References section at the end of our article and apply them to your work.

Health, Safety and Environment (HSE)

As mentioned above, in all operations within paints and coatings projects (such as Surface Preparation and Paints/Coatings applications), you may encounter situations that could give you a headache and cause inefficiencies, lead to possible work losses, or even create legal issues. To resolve these issues before they occur, you can find the information and methods you can use in the relevant paragraph above. For more detailed and comprehensive information on the topics covered in this article, please refer to the References section below.   PCS. Tolga Dıraz Chemical Engineer / Protective Paints and Coatings Specialist Chairman, TUCSA TK-4 Surface Protection Committee    

References 1. Work Plan: Use It or Lose It – Joseph Brandon, Michael Damiano –JPCL 2011 2. Effect of Humidity on Surface Preparation and Coating Application – R. Prasanna, Essar Projects (India), Ltd. – Material Performance, Jan 2016 3. Mind Your Business How To Effectively Manage Conflict – Warren Brand, W Brand Consulting – JPCL, January 2014 4. How To Manage a Successful Coating Project – Tatsuya Nakagawa 5. Good Painting Practice – SSPC Painting Manule Volume 1 – Fourth Edition 6. Handbook of Corrosion Engineering – Pierre R. Roberge – 1999 7. Corrosion Prevention by Protective Coatings – Charles G. Munger &Louis D. Vinceny – Second Edition 8. Selecting Coatings for Industrial and Marine Structures – SSPC - The Society for Protective Coatings and Pamela Groff, 2008 9. Corrosion Protection, Inspector's book of refence – Dag Kjernsmo, Kjell Kleven, Jan Scheie – FROSIO 2003 10. SSPC-VIS 1 – SSPC Dry Abrasive Blasting Steel Surface Preparation Guide and Visual Photographs – http://www.sspc.org/ PB-00212_4 11. SSPC-VIS 3 – SSPC Hand and Power Tools Steel Surface Preparation Guide and Visual Photographs http://www.sspc.org/PB- 00407_3 12. Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, Polymer Overlays, and Concrete Repair - Guideline and Concrete Surface Profile chips (set of 10)https://icri.site-ym.com/store/ViewProduct.aspx?id=5569335 13. SSPC-Paint standards and specifications that can be used in paints/coatings selection: http://www.paintsquare.com/standards/?fuseaction=subcat&catid=1&subcatid=6 14. SSPC environmental zones and paints/coatings systems http://www.sspc.org/site/images/standards/std-vol2intro.pdf 15. NACE standards that can be used in paints/coatings selection https://nace.org/uploadedFiles/Committees/NACEStandards_ Detailed.pdf 16. Selecting Coatings for Industrial and Marine Structures - http://www.sspc.org/PB-00801_2 17. Paint and Coatings: Applications and Corrosion Resistance - https://www.crcpress.com/Paint-and-Coatings-Applications-and-CorrosionResistance/PE/p/book/9781574447026 18.http://onlinelibrary.wiley.com/book/10.1002/9783527611867 19. Paints, Coatings and Solvents, Second, Completely Revised Edition - http://onlinelibrary.wiley.com/book/10.1002/ 9783527611867 20. Some of the international standards used in paints and coatings industry: http://www.corrosionclinic.com/corrosion_resources/list%20of%20Coatings%20standards%20for%20the%20oil%20and% 20gas%20industry.html 21. http://ponderosapaintco.com/techdata/7.pdf 22. http://www.sspc.org/Marketplace/Books/Paint-and-Coating-Failures 23. http://onlinelibrary.wiley.com/doi/10.1002/9780470744673.ch10/summary 24. https://www.naaa.com/standards/Identifying_and_Correcting_Paint_Defects.pdf 25. http://www.sspc.org/trn-crs-icsmc 26. https://www.osha.gov/Publications/OSHA3897.pdf 27. https://www.cdc.gov/niosh/docs/2004-101/chklists/n40spr~1.htm 28. https://www.csgb.gov.tr/media/3738/boya.docx 29. https://painters.edu.au/Training-Courses/Applying-Paint-by-Spray.htm 30. http://trainthepainter.com/ 31. http://www.icats-training.org/ 32. http://www.sspc.org/trn-crs-appc12-option1