Removing Coatings and Cleaning Masonry Substrates

1. Removing Coatings and Cleaning Masonry Substrates Kenneth A. Trimber KTA-Tator, Inc.

2. Identify SSPC/NACE, ASTM, and ICRI standards and guidelines applicable to cleaning and the removal of paint from CMU and brick substrates Describe various methods of paint removal and cleaning, including advantages and disadvantages of each Removing Coatings and Cleaning Masonry Substrates- Webinar Learning Objectives

3. Questions to Ask During Project Design The following questions help to identify candidate coating cleaning or paint removal methods for the project: • Does all coating have to be removed, or just loose coating? • If all coating must be removed, can small amounts still be permitted to remain in the porosity of the block?

4. Questions to Ask During Project Design (con’t) • Can roughening of the block or brick be tolerated. If so, can it be heavy or only slight? • Can large volumes of water be tolerated (environmentally and in terms of potential water intrusion into the substrate)? • Can airborne dust be tolerated?

5. Industry Standards and Guides

6. Industry Standards and Guides (SSPC) • SSPC-SP13/NACE No. 6, Surface Preparation of Concrete • More of a Guide than a Standard • Frequently references other SSPC and ASTM Standards • Describes cleaning methods from air blow down and vacuum cleaning to power tool cleaning, water jetting and abrasive blast cleaning • Standard will be revised in a joint effort between the SSPC Surface Preparation Committee and the SSPC Commercial Coatings Committee

7. Industry Standards and Guides (SSPC) • SSPC-SP12/NACE No. 5, Surface Preparation and Cleaning of Metals by Water Jetting Prior to Recoating – replaced with: • SSPC-SP WJ-4/NACE WJ-4, Waterjet Cleaning of Metals – Light Cleaning • SSPC-SP WJ-3/NACE WJ-3, Waterjet Cleaning of Metals – Thorough Cleaning • SSPC-SP WJ-2/NACE WJ-2, Waterjet Cleaning of Metals – Very Thorough Cleaning • SSPC-SP WJ-1/NACE WJ-1, Waterjet Cleaning of Metals – Clean to Bare Substrate

8. SSPC Visual Guides for Surface Cleanliness – Steel (not Concrete) • SSPC Visual Reference Photographs are well established for the cleaning of steel, but none exist for the cleaning of concrete • The SSPC Commercial Coatings Committee will be filling this void and developing reference photographs for the preparation of concrete-both cleanliness and roughness

9. Industry Standards and Guides (ICRI) • ICRI Guideline No. 310.2 (formerly 03732), Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, and Polymer Overlays • Addresses water and detergent cleaning, acid etching, a variety of power tool methods, abrasive blast cleaning, and flame blasting • ICRI 310.2 – 9 Concrete Surface Profile (CSP) Coupons

10. Industry Standards and Guides (ASTM) • ASTM D4258, Surface Cleaning Concrete for Coating • Broom cleaning, vacuum cleaning, air blast cleaning, water cleaning, detergent cleaning, steam cleaning • ASTM D4259, Abrading Concrete • Power tool, water blast, and wet/dry abrasive blast cleaning • ASTM D4260, Liquid and Gelled Acid Etching of Concrete • ASTM D4261, Surface Cleaning Concrete Masonry Units for Coating • Same as D4269 with the addition of mechanical tool cleaning for the removal of mortar spatter and efflorescence

11. Surface Preparation/Cleaning Methods in Standards/Guides • Detergent Cleaning • SSPC-SP13/NACE No. 6 • ICRI Guideline No. 310.2 • ASTM D4258, ASTM D4261 • Air Blast Cleaning, Water Cleaning, Steam Cleaning, Vacuum Cleaning • SSPC-SP13/NACE 6 • ASTM D4258, ASTM D4261 • Chemical Stripping • Effective method of paint removal, but not addressed in the standards/guides

12. Surface Preparation/Cleaning Methods in Standards/Guides (con’t) • Acid Etching • SSPC-SP13/NACE No. 6 • ICRI Guideline No. 310.2 • ASTM D4260 • Flame Cleaning • SSPC-SP13/NACE No. 6 • ICRI Guideline No. 310.2 • Power Grinding/Sanding • SSPC-SP13/NACE No. 6 • ICRI Guideline No. 310.2 • ASTM D4259

13. Surface Preparation/Cleaning Methods in Standards/Guides (con’t) • Impact Power Tool Cleaning • SSPC-SP13/NACE No. 6 • ICRI Guideline No. 310.2 • ASTM D4259 • Scarifying/Grinding/Scabbling/Milling • ICRI Guideline No. 310.2 • ASTM D4259 • Water Cleaning/Water Jetting • SSPC-SP13/NACE No. 6 • ICRI Guideline No. 310.2 • ASTM D4259

14. Surface Preparation/Cleaning Methods in Standards/Guides (con’t) • Wet Abrasive Blast Cleaning • SSPC-SP13/NACE No. 6 • ASTM D4259 • Dry Abrasive Blast Cleaning • SSPC-SP13/NACE No. 6 • ICRI Guideline No. 310.2 • ASTM D4259

15. Candidate Paint Removal Methods for CMU/Brick • Dry Abrasive Blast Cleaning • Wet Abrasive Blast Cleaning • Sodium Bicarbonate Blast Cleaning • Water Cleaning (Low Pressure <5,000 psi; High Pressure 5000 -10,000 psi) • High Temperature Pressure Water Cleaning (<5,000 psi) • Water Jetting (High Pressure 10,000 – 30,000 psi; Ultra-High Pressure (>30,000 psi) • Power Tool Cleaning • Chemical Stripping

16. Abrasives propelledby compressed air Very dusty – typicallyrequires containment system Dry Abrasive Blast Cleaning

17. Boiler slag, copperslag, nickel slag,garnet, crushed glass,sponge, walnut shells, others Dry Abrasive Blast Cleaning

18. Difficult to selectivelyremove loose coating Elastomeric coatings canbe difficult to removedue to bounce back ofthe abrasive Potential for very heavyroughening of thesubstrate and damageto mortar joints, especially when trying to remove all coating Dry Abrasive Blast Cleaning (con’t)

19. Variation of dryabrasive blastcleaning Water is mixed with the abrasiveto control dusting Same potential toroughen the substrate as dryabrasive blast cleaning Wet Abrasive Blast Cleaning

20. Expendable abrasive,same as dry blastcleaning Water is mixed withabrasive using: Water collar Special injection nozzle Special equipmentthat creates a slurry Wet Abrasive Blast Cleaning (con’t)

21. Wet Abrasive Blast Cleaning (con’t)

22. Variation of wet or dryabrasive blast cleaning Sodium bicarbonate (baking soda) is the abrasive Larger particle size thanhousehold baking soda Good for removing surface contamination,graffiti, and efflorescence Sodium Bicarbonate Blast Cleaning

23. Sodium Bicarbonate Blast Cleaning – efflorescence (wet)

24. Sodium Bicarbonate Blast Cleaning – fire restoration (dry)

25. Pressure categoriesdefined in SSPC-SP WJ-4/NACE WJ-4 SSPC-SP WJ-3/NACE WJ-3 SSPC-SP WJ-2/NACE WJ-2 SSPC-SP WJ-1/NACE WJ-1 Despite the titles, the methods are suitable for CMU/brick Water Cleaning Low Pressure <5,000 psi High Pressure 5,000 to 10,000 psi

26. Will effectively removeloose coating Zero degree rotatingtip improves efficiency Can remove all coatinggiven ample dwell time Generally 5.0 to 10.0gal/min Water Cleaning (con’t) Low Pressure <5,000 psiHigh Pressure 5,000 to 10,000 psi

27. Potential for using largeamount of water, especially for total coatingremoval Increased dwell time for total removal can lead to water intrusion and wetting of interior surfaces Water Cleaning (con’t) Low Pressure <5,000 psi High Pressure 5,000 to 10,000 psi

28. When used for surface cleaning, operator discipline is required to assure the complete cleaning is achieved Water Cleaning (con’t) Low Pressure <5,000 psi High Pressure 5,000 to 10,000 psi

29. Water temperature 250ºF and pressures <5,000 psi High temperature improves cleaning efficiency when removing all coating High temperature softens paint during removal High Temperature Low Pressure Water Cleaning (<5,000 psi)

30. High Temperature Low Pressure Water Cleaning (<5,000 psi) - con’t

31. Typically less water volume than low pressure cleaning methods Efficiently removes existing coating, but can roughen substrate Water Jetting High Pressure 10,000 to 30,000 psi Ultra -High Pressure >30,000 psi

32. Integral vacuum recovery system improves housekeeping and cleanup Water Jetting (con’t)High Pressure 10,000 to 30,000 psi Ultra -High Pressure >30,000 psi

33. Water Jetting (con’t) High Pressure 10,000 to 30,000 psi Ultra -High Pressure >30,000 psi

34. Power sanding, power grinding, needle gunning, rotopeening Vacuum shrouding available Power Tool Cleaning

35. Sanding and grinding remove paint with less damage to substrate than impact methods Power Tool Cleaning

36. Power tool cleaning best used for localized removal Sanding methods good for feathering Power Tool Cleaning (con’t)

37. Chemical stripping effectively removes existing paint Biodegradable strippers are available that do not contain methylene chloride or caustic materials Chemical Stripping

38. Stripper is first applied to the surface by brush, roller, or spray Dwell time depends on coating type, temperature and thickness, but typically overnight Chemical Stripping – con’t

39. Stripper and coating are removed by scraping, bucket and sponge, or pressure washing Chemical Stripping – con’t

40. Depending on results, a second application may be necessary Chemical Stripping – con’t

41. Second application essentially removes all coating Chemical Stripping

42. Original Project Design Questions • Does all coating have to be removed, or just loose coating? • If all coating must be removed, can small amounts still be permitted to remain in the porosity of the block? • Can roughening of the block or brick be tolerated. If so, can it be heavy or only slight? • Can large volumes of water be tolerated (environmentally and in terms of potential water intrusion into the substrate)? • Can airborne dust be tolerated?

43. Practical Use of Candidate Surface Preparation Methods 1 – This table represents the practical application of the various methods when used under normal operations, but it is not absolute. For example, abrasive blast cleaning can partially remove existing coating from CMU or brick, and low pressure water (5k) can remove all coating, but they are not commonly used in these ways. 2 – Sodium bicarbonate is best suited for surface cleaning rather than paint removal. It can be used wet or dry. If used dry, a large quantity of airborne dust is created. When used wet, little to no dust is generated. 3 – Slight to heavy roughening may occur. Vacuum shrouding will significantly reduce the volume of water. Without vacuum shrouding, the volume is greater, but typically not as high as pressure washing at < 10,000 psi. 4 – Roughening created by power tool cleaning is dependent on the tool being used, ranging from slight to no roughening with power sanding to heavy roughening with power impact tools. 5 – A large volume of water is generated if the stripper is removed by pressure washing. Much less water is involved if removed by scraping and sponge/water to flush the surface, but this is only practical for small localized areas.

44. Productivity Production rates for some of the methods can be found in: • Painting and Decorating Contractors of America (PDCA) Estimating Guide, Volume 2, Rates and Tableswww.PDCA.org (314-514-7322) • ICRI Guideline No. 310.2 (formerly 03732), Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, and Polymer Overlayswww.icri.org (847-827-0830)

45. Additional Information • A paper associated with the information in this webinar was published in Durability + Design Magazine – March/April 2011 • Sources of equipment and materials can be found in the Durability + Design on-line Painting Equipment and Supplies Buying Guide (under the Buying Guides tab on the home page)

46. Removing Coatings and Cleaning Masonry Substrates - Questions Kenneth Trimber 412-788-1300,x204 ktrimber@kta.com