This article is about PROTECTIVE COATING ON CONCRETE USING AIRLESS SPRAY  and focusing to the engineers, technicians and supervisors. You will find lot of documents related to this article. Just navigate our website  and find more articles. Please! Do not forget to subscribe our You tube channel also. Thanks in Advance.



Surface Preparation

a. The purpose of surface preparation is to remove laitance, contaminants and others adhered compounds on the concrete like the curing agents, and to create an anchoring for coatings to be well adhered with the concrete structures.

b. Concrete surfaces shall be prepared for coating after they are adequately cured. The surface preparation methods of concrete structures can be done by mechanical cleaning, abrasive blasting, acid etching and water-jetting.

c. Concrete surface preparation prior to coating application shall include but not limited to: Repair of cracks, spalls, pop outs, and other irregularities, Removal of surface contaminants that inhibit coating adhesion or induce early coating deterioration, Roughen the smooth surfaces to improve coating adhesion, and Eliminating any weak surface layers to establish the strong base required for many coating system.

d. For surface profile use ICRI Guideline 03732 or equivalent document, which shall identify distinct profile levels for different generic coatings at different dry film thicknesses when a specific surface profile is required.
e. Cracks less than 1.0 mm wide and holes not exceeding 10 mm in diameter shall be filled using a qualified epoxy filler or grout before applying primer/sealer to the surface.

f. Expansion and construction joints shall be cleaned and masked off prior to coating. When coating application is completed, remove the masking tape for further civil works.

g. All voids shall be prepared, primed and filled using suitable and compatible epoxy filler prior to coating. The epoxy filler materials shall be approved by the company. h. Areas that do not meet the surface cleanliness requirements shall be marked with grease free chalk for correction.
i. Test for moisture is required and inspected prior to sealer application.

Concrete Coating Application

a. Surface temperature, humidity, and dew point readings shall be recorded. The work shall not proceed if the substrate temperature shall be less than 3°C (5°F) above the dew point, or any other deviations from the coating manufacturers’ data sheet.
b. A sealer/primer coat shall be applied directly after the concrete surface preparation prior to the application of the APCS-1B. The sealer/primer shall be compatible with the coating systems.

c. Sealer/primer, secondary and final coat shall be used in accordance with the manufacturer’s data sheet and shall be spray applied in a thin coat except for touch-up repairs.

c.1 – Penguard Sealer

c.2 – Penguard Express

c.3 – Penguard FCd. The coating shall be applied after the full curing time of concrete in accordance to SAES-Q-001(aramco standard). New concrete must have a moisture content of 4% or less before the coating applications commence.


1) All personnel will be issued with the following personal Protective equipment: a. Safety helmets with chin straps
b. Safety boots
c. Safety Goggles d. Hand Gloves
e. Dust Masks
f. Ear Defenders
g. Respirators (As Required)

i. Cotton overalls with full sleeves shall be worn on construction site
2) Airless spray guns shall never be pointed at anyone or at any part of the body. 3) The tip guard shall always be in place on the airless gun while spraying.
4) Leather gloves shall be worn by the operator whenever the airless spray gun is in

5) The trigger safety catch shall be engaged whenever the airless gun is left unattended.
6) Hoses, pumps, and accessories shall never be operated at pressures exceeding their rated pressure. In no case shall the working pressure in the paint line exceed 34.5 MPa (5000 psi). Safety pressure relief valves shall be used on discharge side of the pressure pump(s).
7) The pump shall be shut down and the fluid pressure in the system relieved before servicing or cleaning any components, including clogged spray tips.

8) Hoses shall be grounded, anti-static type. 9) Airless spray equipment shall not be operated unless all grounds (earths) are in place, connected, and in good condition. Grounding wire shall be AWG-4 or larger. 10) Air less spray equipment shall not be operated if any of the pressure system components is not in good condition.
11)Solvents shall not be flushed into containers that are hotter than 50°C.
12) Emergency medical care shall be obtained immediately if any high-pressure fluid from
the airless equipment penetrates the skin. (High pressure fluid injection injuries can be
extremely serious, including the need for amputation).

13) Emergency exit point, assembly area, emergency evacuation plan and emergency numbers shall be posted on the boards.
14) Subcontractors shall not enter or commence work in any deep Manhole or other enclosed confined space until a valid permit to work has been issued.
15) All personnel involved in the coating works shall have to undergo Safety Training being conducted by EPC Contractor.


1) All tools and equipment shall be inspected by  HSE department to ensure that the equipment is in good running condition. All damaged, unsafe or defective tools will be marked, tagged as Unsafe or with a Red Paint and shall remove from operation to assure that no one will use such tools on the job.
a) Roller Skins & Roller Frames
b) Serrated & Notched Squeegees

c) Paint Brush/Roller

d) Trowels
e) Mixing Tools & Buckets
f) Rags & Protective Gloves g) Safety Shoes
h) Concrete Grinders
i) Concrete Cleaners
j) Patching & Sealants
k) Non-Skid Additives
l) Threaded Poles
m) Mechanical Brush o) Compressor

p) Air Storage Drum
q) Airless Spray System
r) Paint Mixer

Please read also:  Procedure for Concrete Repair-CIVIL
Please read also: Civil Concrete Paving Work CIVIL
Please read also: Concrete Paving Hairline Crack Repair -CIVIL

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