NES 764 Flame Metal Spraying and Hot Dip Galvanizing of Ships Structure and Fittings Category 2

Ministry of Defence
Defence Standard 02-764 (NES 764)

Issue 1 Publication Date 01 April 2000
Flame Metal Spraying And

Hot Dip Galvanizing Of
Ships Structure And Fittings
Incorporating NES 764 Category 2

Issue 3 Publication Date January 1988
AMENDMENT RECORD
Amd No
Date
Text Affected
REVISION NOTE
This standard is raised to Issue 1 to update its content.
HISTORICAL RECORD
This standard supersedes the following:
Naval Engineering Standard (NES) 764 Issue 3 dated January 1988.
Signature and Date
Ministry of Defence
Naval Engineering Standard
NES 764
Issue 3 (Reformatted)
January 1988
FLAME METAL SPRAYING AND

HOT DIP GALVANIZING
OF
SHIPS STRUCTURE AND FITTINGS
This NES Supersedes

NES 764 ISSUE 02
Record of Amendments
AMDT
1
2
3
4
5
6
7
8
9
10
INSERTED BY
DATE
NAVAL ENGINEERING STANDARD 764

ISSUE 3 (REFORMATTED)
FLAME METAL SPRAYING AND HOT-DIP GALVANIZING
OF SHIPS STRUCTURE AND FITTING
The issue and use of this Standard

is authorized for use in MOD contracts
by MOD(PE) Sea Systems and
the Naval Support Command
ECROWN COPYRIGHT
Published by:
Director of Naval Architecture
Procurement Executive, Ministry of Defence
Foxhill, Bath BA1 5AB
i
ii
NES 764
SCOPE
1.
This NES describes the application of metal by molten spray to protect steel structure and
fittings from corrosion where applicable on Surface Ships and Submarines.
2.
Guidance for the hot-dip galvanizing of structural steel is also included.
3.
The application of metal by molten spray for engineering purposes (eg the repair of machinery
parts) is not included.
iii
NES 764
iv
NES 764
FOREWORD
Sponsorship
1.
This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Deputy Controller Warships (DCW), Section NA 131.
2.
It is to be applied as required by any Procurement Executive, Ministry of Defence contract for

the flame metal spraying and hot-dip galvanizing of Surface Ships and Submarines structure
and fittings.
3.
If it is found to be technically unsuitable for any particular requirement the MOD(PE) is to

be informed in writing of the circumstances with a copy to Deputy Controller Warship
Equipment (DCWE), ME 241 for Ship Systems and Equipment.
4.
Any user of this NES either within MOD or in outside industry may propose an amendment
to it. Proposals for amendments which are:
a.
not directly applicable to a particular contract are to be made to the Sponsor of the NES
b.
directly applicable to a particular contract are to be dealt with using existing procedures
or as specified in the contract.
5.
No alteration is to be made to this NES except by the issue of an authorized amendment.
6.
Unless otherwise stated, reference in this NES to approval, approved, authorized or similar
terms, means by the Ministry of Defence in writing.
7.
Any significant amendments that may be made to this NES at a later date will be indicated
by a vertical side line. Deletions will be indicated by 000 appearing at the end of the line
interval.
8.
This NES has been reissued because of update to NES format.
Conditions of Release
General
9.
This Naval Engineering Standard (NES) has been prepared for the use of the Crown and of
its contractors in the execution of contracts for the Crown. The Crown hereby excludes all
liability (other than liability for death or personal injury) whatsoever and howsoever arising
(including but without limitation, negligence on the part of the Crown, its servants or agents)
for any loss or damage however caused where the NES is used for any other purpose.
10.
This document is Crown Copyright and the information herein may be subject to Crown or
third party rights. It is not to be released, reproduced or published without written permission
of the MOD.
11.
The Crown reserves the right to amend or modify the contents of this NES without consulting
or informing any holder.
MOD Tender or Contract Process

12.
This NES is the property of the Crown and unless otherwise authorized in writing by the MOD
must be returned on completion of the contract, or submission of the tender, in connection
with which it is issued.
NES 764
13.
When this NES is used in connection with a MOD tender or contract, the user is to ensure that
he is in possession of the appropriate version of each document, including related documents,
relevant to each particular tender or contract. Enquiries in this connection may be made of
the local MOD(PE) Quality Assurance Representative or the Authority named in the tender
or contract.
14.
When NES are incorporated into MOD contracts, users are responsible for their correct
application and for complying with contracts and any other statutory requirements.
Compliance with an NES does not of itself confer immunity from legal obligations.
Related Documents
15.
In the tender and procurement processes the related documents listed in each section and
Annex A can be obtained as follows:
a.
British Standards
British Standards Institution,

389 Chiswick High Road,
London W4 4AL
b.
Defence Standards
Directorate of Standardization and Safety Policy,

Stan 1, Kentigern House, 65 Brown Street,
Glasgow G2 8EX
c.
Naval Engineering Standards
CSE3a, CSE Llangennech, Llanelli,

Dyfed SA14 8YP
d.
Other documents
Tender or Contract Sponsor to advise.
Note: Tender or Contract Sponsor can advise in cases of difficulty.

16.
All applications to Ministry Establishments for related documents are to quote the relevant
MOD Invitation to Tender or Contract Number and date, together with the sponsoring
Directorate and the Tender or Contract Sponsor.
17.
Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.
Health and Safety

Warning
18.
This NES may call for the use of processes, substances and/or procedures that may be injurious
to health if adequate precautions are not taken. It refers only to technical suitability and in
no way absolves either the supplier or the user from statutory obligations relating to health
and safety at any stage of manufacture or use. Where attention is drawn to hazards, those
quoted may not necessarily be exhaustive.
vi
NES 764
CONTENTS
Page No
TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOD Tender or Contract Process . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
v
v
v
v
vi
vi
vi
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
SECTION
1.
MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 1.1 MATERIALS AND EQUIPMENT . . .
1.1
1.1
SECTION
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . .
Flame Pistols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas and Oxygen Cylinders . . . . . . . . . . . . . . . . . . . .
Gas and Air Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation Supply and Exhaust . . . . . . . . . . . . . . . .
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
2.1
2.1
2.2
2.2
2.2
2.2
2.3
SECTION
3.
3.1
3.2
EXTENT OF METAL SPRAYING . . . . . . . . . . . . .

Internal Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
3.1
3.1
SECTION
4.
SURFACE PREPARATION . . . . . . . . . . . . . . . . . . .
4.1
SECTION
5.
5.1
5.2
5.3
METAL SPRAYING . . . . . . . . . . . . . . . . . . . . . . . . .
Sprayed Metal Systems . . . . . . . . . . . . . . . . . . . . . . .
Application of the Coatings . . . . . . . . . . . . . . . . . . . .
Repair of Metal Sprayed Coatings . . . . . . . . . . . . . .
5.1
5.1
5.1
5.2
SECTION
6.
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
SECTION
7.
QUALITY ASSURANCE . . . . . . . . . . . . . . . . . . . . .
7.1
SECTION
8.
8.1
8.2
TREATMENT OF METAL SPRAYED SURFACES

Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
8.1
8.1
SECTION
9.
HOT-DIP GALVANIZING . . . . . . . . . . . . . . . . . . . .
TABLE 9.1 COATING WEIGHT . . . . . . . . . . . . . .
9.1
9.1
vii
NES 764
ANNEX
A.
RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . .
A.1
ANNEX
B.
DEFINITIONS AND ABBREVIATIONS . . . . . . . .
B.1
ANNEX
C.
METHOD OF CHECKING THE ADHESION OF

THE ZINC SPRAY TO THE STEEL SURFACES .
C.1
PROCUREMENT CHECK LIST . . . . . . . . . . . . . . .
D.1
ANNEX
D.
ALPHABETICAL INDEX
viii
NES 764
1.
MATERIALS
a.
References to zinc in this NES mean zinc in accordance with Zn2 (99.95% zinc)
or Zn3 (99.5% zinc) as given in BS 3436.
b.
References to aluminium for metal spraying in this NES mean aluminium in

accordance with G1B (99.5% Al) or G1C (99% A1) as given in BS 1475.
c.
The particulars of the materials and equipments to which this NES refers are
as follows:
Quantity
Material
Specification
3.2mm, 12kg coil

3.2mm, 25kg coil
Wire,, spray
p y gun,
g ,
aluminium
2.0mm, 12kg coil
Cylinder
y
propane
p p
Acetylene
y
technical
BS 1475
3439995264189
3439995264190
3439995264191
3.2mm, 12kg coil
3439995264194
2.0mm, 12kg coil
Cylinder
y
oxygen
yg
3439995264188
2.0mm, 25kg coil

3.2mm, 25kg coil
Wire,, spray
p y gun,
g ,
zinc
NATO Stock No
BS 3436
3439995264195
3439995264196
2.0mm, 25kg coil
3439995264197
20 cu ft
110 cu ft
6830999422250
220 cu ft
6830999422251
10 lb
6830992245324
24 lb
6830992245326
28 lb
6830992245327
42 lb
6830992245329
50 lb
75 lb
6830992245328
100 lb
6830992245325
10 cu ft cylinder
6830992203828
100 cu ft cylinder
6830999422218
200 cu ft cylinder
6830992240439
Metal spraying
p y g
equipment
q p
(p
(pistols,,
nozzles,, regulators,
g
,
flow meters,,
stands, etc
Proprietary
p
y
Concentrated
General Purpose
p
cleaner
DG Ships
p 305
Metallic zinc-rich
priming paint
Bituminous Solution
BS 4652
5 gallon
TS 10195A
TABLE 1.1 MATERIALS AND EQUIPMENT
1.1
7930992346817
8010995432432
8010999429290
NES 764
1.2
NES 764
2.
SAFETY PRECAUTIONS
a.
2.1
2.2
The danger of explosion or fire is ever present during the setting up of the
equipment and carrying out the metal spraying work, and until the equipment
has been removed from the work area. It is therefore essential that precautions
are taken throughout these periods. Guidance on precautions which experience
has shown to be necessary to guard against the risk of fire and explosion is given
in the following Clauses in this section.
Flame Pistols
a.
Flame pistols and associated equipment must be used and maintained in

accordance with the manufacturers instructions. Cleanliness and leak free
connections are essential. Ignition is only to be within gas free areas.
b.
The spraying pistol is always to be lit up, adjusted, and shut off strictly in
accordance with the manufacturers instructions. When in use the pistol is not
to be pointed at other persons, combustible materials or gas cylinders.
c.
If the pistol back fires in use, close the pistol valve to prevent major damage to
the unit, then shut off the fuel gas cylinder valve. Immediately reopen the pistol
valve, allowing air to flush nozzle ports for about half a minute. If, on relighting
correctly, the back fire is repeated, shut off as above and ascertain the cause.
d.
When the spraying unit is to be laid aside after use, both the fuel gas and oxygen
cylinder valves are to be closed and the hoses and pistol purged of all residue gas
by a reverse flow of compressed air (using suitable adaptors) from the gun end
of the hoses to open air.
Gas and Oxygen Cylinders

a.
The following precautions are to be taken when using or storing gas and oxygen
cylinders.
b.
On no account are oxygen and fuel gas cylinders to be stored in the same area
and near compartments in which metal spraying is being undertaken, and care
is to be taken to see that full and empty cylinders are clearly distinguishable and
kept well apart.
c.
When cylinders have to be stored or sited out of doors, they are to be protected
from rain, and the direct rays of the sun. Gas cylinders in particular, are to be
treated with care, and not subject to knocks, blows or excessive heating, and are
to be kept in an upright position at all times.
d.
If by arrangement with the Shipbuilders or Ship repairer, they are permitted to

be placed on the ship, they are never to be sited between decks.
e.
It is important that no oil, grease, or fatty substances are allowed to come into
contact with oxygen cylinders, regulators, or filters. Oil and grease in the
presence of oxygen are EXTREMELY EXPLOSIVE. It is also important that no
grit or other foreign matter is allowed to enter, or remain on fittings carrying
combustible gases or oxygen.
f.
Keys of gas cylinders must always be a perfect fit on the spigot, and maintained
in good condition. When not in use the reducing valve fittings and the outlet
valve control are to be removed taking care to ensure that the cylinder valve is
fully closed before removal.
g.
All cylinders are to be fitted with Non Return Valves.
2.1
NES 764
2.3
Gas and Air Hoses

a.
Only British Standard approved reinforced rubber hoses and connectors of

correct distinguishing colours and adequate internal diameter are to be used for
gas and air supplies to the metal spraying pistol. The British Standard
distinguishing colours for the hoses are:
Orange for propane gas
Red for acetylene
Blue for oxygen
Green or Black for compressed air.
2.4
2.5
2.6
b.
Care is to be taken to ensure that hoses are securely attached to connectors by

means of suitable approved hose clips. When two lengths of hose require to be
coupled together, special couples only are to be used.
c.
All hoses supplying fuel gas to the spraying pistol are to be supported and
secured in such a manner that they are free from kinks, and not exposed to
possible damage from heat, sharp edges, footwear or heavy objects.
d.
The hoses are to be frequently inspected to ensure that they have not become
cut or cracked. Hoses that show any defects are to be replaced immediately.
Ventilation Supply and Exhaust

a.
It is important that an efficient system of flameproof ventilation providing at

least 15 volume air changes per hour is installed and maintained in
Compartments where metal spraying work is being carried out.
b.
The ventilation trunkings are to be constructed of suitable sound

non-flammable material adequately secured and protected from damage.
c.
The exhaust ventilation trunking within the compartment is to be positioned

at the highest and lowest points in the compartment to dispose of any possible
accumulation of gases.
Cleanliness
a.
Accumulations of zinc and aluminium spray dust with abrasive blasting dust
arisings are potentially explosive and fire hazardous. Therefore regular cleaning
operations to avoid such accumulations are to be carried out. Particular
attention being paid to the inside of exhaust ventilation where heavily oxidized
abrasive blasting dust is likely to settle and mix with the sprayed metal dust
arisings.
b.
Arisings from cleaning operations are to be removed from the ship and safely
disposed of.
c.
On no account is the dust exhausted during abrasive blasting and metal

spraying to be collected in the same container.
d.
Likewise zinc and aluminium dust will react with water and give off hydrogen,
which produces an explosive mixture in the presence of air. In view of this on
no account is the metal powder arisings to be discharged into water traps, for
collection purposes.
Lighting
a.
Adequate flameproof and dust proof lighting giving a high standard of

illumination is to be provided during the whole course of abrasive blasting and
metal spraying work.
2.2
NES 764
2.7
Protective Clothing
a.
All operators are to be issued with, and wear overalls, gloves, tinted goggles, and
respirators either fed with a clean filtered air supply, or fitted with dust and
fume cartridges.
2.3
NES 764
2.4
NES 764
3.
EXTENT OF METAL SPRAYING

a.
3.1
Internal Areas
a.
3.2
The areas selected for metal spraying will be listed in Contract Documents. The
extent of metal spraying is to be kept to the minimum consistent with adequate
protection of structure and fittings against corrosion. DCW will provide
guidance when proposed omissions are under discussion.
Internal areas to be metal sprayed include inner bottom; wet bilges; upper
surfaces of all longitudinals in machinery spaces; bathroom, laundry and galley
structures except where neoprene polymeric epoxy, latex or ceramic deck
coverings will be laid; inaccessible structure; any other areas considered to
require this standard of preservative treatment.
External Areas
a.
External areas to be metal sprayed include all steel decks and the bottom 75mm
of all adjacent superstructures, edgestrips and coamings excluding those of
aluminium. Helicopter landing decks and aircraft Flight Decks ARE NOT to be
metal sprayed.
3.1
NES 764
3.2
NES 764
4.
SURFACE PREPARATION
a.
The following requirements are to be met before the structure concerned is

prepared for the application of the metal sprayed coatings.
(1)
All welding required to be carried out on surfaces and the reverse side of
surfaces including the securing of minor fittings and attachments is to be
completed.
(2)
All welds are to be continuous, and ground flat and smooth, and
surrounding weld spatter removed.
(3)
All portable items which might otherwise obstruct free access for the
preparation, coating, and subsequent inspection of areas of structure, are
to be removed whilst the work is in progress.
(4)
Sharp edges on attachments, seatings etc are to be slightly rounded off to

approx 2mm radius.
(5)
Where the work is of necessity and is required to be carried out in the open
air in wet or cold weather conditions, suitable weatherproof covers are to
be erected over the areas being treated as protection from the weather
elements.
b.
When all the above requirements have been satisfactorily complied with, the
structure and fittings are to be prepared in the following manner.
c.
All the surfaces are to be initially washed and cleaned of all oil, grease, dirt and
other foreign matter by washing and scrubbing with general purpose detergent
to DG Ships 305 and then abrasive blasted to the BS 4232 1st Quality (SA 3)
standard of finish using Grade G 24 chilled iron grit, to produce a blast cleaned
surface profile 100 microns. On no account is copper slag, or other forms of
abrasive to be used for the purpose.
d.
The initial washing and abrasive blasting of the surfaces is to be carried out
following all the instructions with respect to procedures, precautions,
environmental conditions, and Quality Assurance requirements contained in
Sections 5 and 6 of NES 755.
e.
Where the abrasive blasting is carried out by open circuit blasting methods,
suitable screens are to be erected to confine the spread of abrasive to within the
working area, so as to avoid contamination of equipment, and injury to persons
working in the vicinity.
f.
After an area has been abrasive blasted in preparation for the application of the
coating, it is to be thoroughly cleaned of all spent abrasive grit, and residue dust
particles using a suitable vacuum cleaner fitted with a brush attachment for the
final clean.
g.
Thereafter the prepared surface is not to be allowed to become contaminated in

any way before the metal coating is applied. Personnel employed on final
cleaning of the abrasive blasted areas and the application of the metal sprayed
coatings, are to wear clean overshoes and gloves, where it is necessary to walk
on, or handle the areas being treated.
4.1
NES 764
h.
The abrasive blasting is to be so arranged for an area abrasive blasted during

a working shift, to be coated with the full specified sprayed metal thickness
before the cessation of the working shift. In any event the abrasive blasted
surface is not to be allowed to remain bare for more than 6 hours before being
overcoated.
i.
If despite these requirements areas abrasive blasted show signs of deterioration

before being overcoated the areas affected are to be reabrasive blasted to the
required standard before the sprayed metal coating is applied.
4.2
NES 764
5.
METAL SPRAYING
5.1
Sprayed Metal Systems

a.
5.2
The sprayed metal systems to be applied to structure are as follows:

(1)
Exterior Weatherdecks. A duplex sprayed metal system consisting of

50 microns of zinc, overcoated with 100125 microns of aluminium, to
produce a total thickness of not less than 150 microns.
(2)
Weatherdecks to be fitted with wood decking. 150 microns of zinc.
(3)
Internal Structure (except Feed Water Tanks). Zinc to a total

thickness of not less than 150 microns.
(4)
Feed Water Tanks.Where Feed Water Tanks are specified to be metal

sprayed the coating is to consist of 200 microns of aluminium.
Application of the Coatings

a.
The application of the sprayed metal coatings is generally to be in accordance

with BS 2569 Part 1 except where augmented or modified in the aforementioned
or following Clauses.
b.
The metal to be sprayed is to be in wire form of no more than 3.2mm diameter,

and applied using a suitable flame metal spraying pistol as mentioned in Clause
6.a. On no account is metal in powder form to be used.
c.
The metal coating thickness is to be built up in one continuous operation, by

successive passes over the surface in one direction, and considerably
overlapping each pass in order to produce an even overall thickness and avoid
corrugations in the coating finish.
d.
On no account is an initial thin flash coat of metal to be applied to abrasive

blasted surfaces to serve as a holding coat whilst the remaining surfaces are
being abrasive blasted prior to applying the full thickness of the metal.
e.
When applying the duplex zinc aluminium metal coating system no more than
2 hours are to be allowed to lapse between the completion of the application of
the zinc and overcoating with the aluminium.
f.
During application of the metal coatings it is important that every effort is made
to constantly keep the spray nozzle at the distance from the surface
recommended by the manufacturer of the equipment and to direct the sprayed
metal vertically on to the surface being coated. The speed to which the pistol is
passed over the surface during application is also to be taken in relationship to
the rate to which the wire is melted and atomized.
g.
Care is also to be taken to ensure that the metal spraying wire is kept free of
kinks, and passes freely through the spraying pistol.
h.
The metal sprayed coatings are to be of fine texture free from lumps, coarse
areas and loosely adherent particles, and of even thickness.
i.
On no account are surfaces to be allowed to become contaminated whilst tests

are being applied. Personnel employed on the application work are to wear
gloves and clean overshoes whilst walking on or cleaning the surfaces. The
surfaces being metal sprayed are also to be continuously cleaned of metal dust
arisings using a vacuum cleaner during application.
5.1
NES 764
5.3
j.
When an area abrasive blasted and metal sprayed adjoins areas still to be
treated, the finished area is to be protected against damage from abrasive
blasting and abrasive given inbedment by covering with suitable sheeting, but
allowing a sufficient uncovered margin for overlapping with the metal for
joining up purposes when the adjoining area is subsequently coated.
k.
The metal sprayed coating is to be sealed by overcoating with the first coat of
the specified paint system immediately the application has been completed.
Repair of Metal Sprayed Coatings

a.
Areas of damaged metal sprayed coatings are to be repaired by reabrasive

blasting and remetal spraying the affected areas, following the procedures and
to the standards already mentioned for the preparation and metal spraying of
surfaces. Where circumstances prevent the use of abrasive blasting equipment,
the areas in question are to be carefully scraped back to sound surrounding
edges, and then power abrasive disced to the SVENSK STANDARD SIS 05 59 00
(Swedish C St 3 pronounced metallic sheen appearance), followed by making
good by over coating with multiple coats of zinc rich epoxy paint Type 3 to
BS 4652 to produce a total dry film thickness of at least 100 microns before
touching up with the specified paint system.
5.2
NES 764
6.
EQUIPMENT
a.
The approved process for metal spraying is by the use of wire fed proprietary fuel
gas/oxygen spray guns. Electric arc spray processes are not approved.
b.
The makers instructions for the use, handling and maintenance of equipment
must be complied with. These instructions will detail the type of fuel gas and
pressures of gas, oxygen and compressed air required, type of flame, angle of
operation and distance of gun nozzle from the prepared surface.
c.
If the makers instructions are not provided a test area is to be sprayed starting
with fuel gas at 1.7 bar, oxygen at 1.38 bar and compressed air at 4.14 bar with
the gun nozzle square to and approx 300mm from the surface. Pressures, angle
of spray and distance from surface are then to be adjusted until the trial area
is satisfactorily sprayed.
Note:
The fuel gas pressure quoted is for propane; considerable alteration may
be necessary for other fuel gases or gun nozzle sizes employed.
d.
If the equipment is fitted with flow meters the test spray is first to be tried with
minimum flows, gradually increasing the flows until optimum spray
performance is achieved.
e.
Fluctuations of pressures of fuel gas, oxygen and compressed air will result in
non-uniform spray application.
f.
Moisture and/or oil in the compressed air will have a deleterious affect on the
metal sprayed coatings. Only dry compressed air is therefore to be used.
g.
Large gauge wires produce coarse finishes.
h.
Too rapid a feed of wire produces lumpy finishes and too slow a feed an
exceptionally fine oxidized coating.
6.1
NES 764
6.2
NES 764
7.
QUALITY ASSURANCE
a.
The Quality Assurance Representative (QAR) is to be satisfied that all the

requirements listed in Clause 4.a. have been met before the commencement of
the surface preparation and application of the metal sprayed coatings, and that
the equipment intended for use is efficient, safe for use, and maintained in a
serviceable condition.
b.
The QAR is to satisfy himself that the abrasive grit, and metal wire intended for
use are of the grade and quality called for.
c.
The Contractor undertaking the work is to provide evidence that the operators
to be employed have been properly trained in the operation and use of all the
main associated ancillary equipment and are fully conversant with all the
requirements.
d.
The surface preparation, and application of the metal coatings is not to be

carried out when the relative humidity is above 70% nor where the steel
substrate temperature falls less than 3 C above the dew point.
e.
If necessary these conditions are to be brought about by using suitable

flameproof dehumidifiers set to work at least 24 hours before the
commencement of the abrasive blasting and metal spraying work operation
during the whole course of the blasting and metal spraying work, and until the
sprayed metal surface has been sealed with the first coat of the specified paint
system.
f.
Relative humidity, ambient temperature and substrate temperature readings

are to be taken before, midway, and at the end of each shift and the relevant
details recorded and documented.
g.
Each stage of the surface preparation and application of the coatings is to be

inspected both during and after completion and any descrepancies rectified
before the next stage is commenced.
h.
On no account are abrasive blasted or sprayed metal coated surfaces to be

allowed to become contaminated in any way before being overcoated. The
overcoating time constraints mentioned in Clauses 4.h., 5.2e., and 5.2k. are to
be strictly observed.
i.
When flat surfaces such as decks are being treated personnel employed on the
removal of spent abrasive grit, and dust after abrasive blasting and the
subsequent application of the sprayed metal and sealing of the coating on
completion, are to wear gloves and clean overshoes whilst carrying out the work.
Supervisors and Quality Assurance Representatives are also to be likewise
dressed. Foot traffic by persons other than mentioned above, over areas being
treated is to be prohibited whilst the work is in progress and until finally
completed.
j.
The thickness of the metal coating being applied is to be frequently measured

both during and on completion to ensure that the specific thickness is deposited.
Areas found lacking in this respect are to be further metal sprayed until the
required thickness is achieved.
k.
The thickness is to be measured using suitable commercially available

electro-magnetic type instruments calibrated and operated strictly in
accordance with the manufacturers instructions for the purpose required. On
no account are magnetically operated type instruments such as the Microtest,
Tinsley, pull off, or elcometer 101 thickness gauges to be used for the purpose.
7.1
NES 764
l.
The finished metal sprayed surface is to be inspected for uniformity of texture,

and fine matt appearance, free from coarse areas, and loosely adherent
particles. In addition the adhesion of the sprayed metal coating to the
underlying steel substrate, and the intercoat adhesion between the zinc and
aluminium is to be tested to the procedures and instructions contained in Annex
C.
m.
Areas where the adhesion or surface finish is found to be unsatisfactory are to

be blast cleaned free of the defective coating, and re-metal sprayed to the
required standards.
n.
The QAR is to record and document all the relevant details concerning the work.
Such details are to include relative humidity, ambient and surface temperature
readings, standards of abrasive blasting and metal spraying achieved, method
of abrasive blasting, and type of metal spraying equipment and size of wire used,
together with the total thickness measurement readings of the sprayed metal
deposited.
o.
For the zinc and aluminium system the thickness of the zinc and aluminium
coatings are to be measured and recorded separately.
7.2
NES 764
8.
TREATMENT OF METAL SPRAYED SURFACES
8.1
Internal
a.
8.2
Where abrasive blasted steel surfaces have been sprayed with metal to the full
thickness specified, the first coat of the appropriate paint system in accordance
with and or NESs, 753, 763, 765, 774, or as otherwise specified in the Contract
Documents, is to be applied before deterioration or contamination occurs.
Dehumidification and temperature control is to be provided as stated in
NES 755 (Section 5 Clause 0511).
External
a.
Steel weatherdeck surfaces which have been abrasive blasted and sprayed with
the full thickness of zinc, ie 150 microns and are subsequently to be covered with
wood decking, in accordance with NES 156, are to be sealed, before
deterioration or contamination can occur, with a coat of bituminous solution to
TS 10195A.
b.
Where weatherdeck surfaces and the bottom 75mm of steel superstructure have
been abrasive blasted and sprayed with zinc followed by aluminium to a finished
total thickness of 150 microns, the appropriate paint system specified in
NES 753 and Class or Ship drawings is to be applied before deterioration or
contamination occurs. Dehumidification and temperature control is to be
provided as stated in NES 755 (Section 5 Clause 0511).
8.1
NES 764
8.2
NES 764
9.
HOT-DIP GALVANIZING
a.
Hot-Dip Galvanizing is to be carried out in accordance with BS 729 or BS 2989,

whichever is appropriate for the article or structural material being galvanized.
b.
The coating weight determined by dividing the total weight of the deposited
galvanizing by the total surface area treated is to produce the ratios as shown
in TABLE 9.1:
Category
Steel structurals and

articles which are not
centrifuged
Thicknesses
Coating Weight
5mm and over
not less than 610g/m2
under 5mm
under 5mm
Grey and malleable iron

castings
Threaded work and other
articles which are
centrifuged
Steel sheet and coil
TABLE 9.1 COATING WEIGHT

c.
Tubes on which screw threads are required are to be galvanized before the
threads are cut.
d.
NES 155 is to be referred to for certain areas where galvanizing is prohibited

or mandatory.
e.
NES 507 is to be referred to for information on galvanizing requirements

specifically applicable to electrotechnical equipment.
9.1
NES 764
9.2
NES 764
ANNEX A.
RELATED DOCUMENTS
A.1
Reference is made to:

Referred to in
Clause
BS 729
Hot-dip galvanized coatings on iron and

steel articles
Wrought aluminium and aluminium alloys
for general engineering purposes: wire
Sprayed metal coatings Pt 1. Protection of
iron and steel by aluminium and zinc
against atmospheric corrosion
9.a.
BS 2989
Continuously hot-dip zinc coated and ironzinc alloy coated steel: wide strip, sheet/
plate and slit wide strip
9.
BS 3436
Ingot zinc
1., TABLE 1.1
BS 4232
Surface finish of blast-cleaned steel for

painting
Metallic zinc-rich priming paint (organic
media)
Paint systems, bitumen, for defence equipment types I, II and III
4.c.
BS 1475
BS 2569 Pt 1
BS 4652
TS 10195A
1.b., TABLE 1.1

5.2
5.3, TABLE 1.1

TABLE 1.1, 8.2
SVENSK
Standard
SIS 05 59 00
Pictorial Surface Preparation Standards for 5.3

Painting of Steel Surfaces
NES 155
Structural Practices in Steel Surface Ships
9.d.
NES 156
Wood Decking
8.2
NES 507
NES 753
Materials and Finishes for Electro-technical 9.e.

Equipment
WeatherdecksPreparation and Painting
8.1, 8.2b.
NES 755
Abrasive Blasting of Steel
NES 763
Preservation and Painting of Compartments 8.1, Annex D.

in Surface Ships
Requirements for Painting of Machinery
8.1, Annex D.
Compartments in Steel Hulled Surface
Ships
NES 765
NES 774
DG Ships 305
4.d., 8.1, 8.2b.
Requirements for Preparation and Painting 8.1

of Submarines
General Purpose Cleaning Liquid Detergent TABLE 1.1, 4.c.
A.1
ANNEX A.
NES 764
ANNEX A.
A.2
NES 764
ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1
There are no Definitions and Abbreviations for this NES.
B.1
ANNEX B.
NES 764
ANNEX B.
B.2
NES 764
ANNEX C.
METHOD OF CHECKING THE ADHESION OF THE ZINC SPRAY TO THE STEEL
SURFACES
EQUIPMENT REQUIRED
C.1
Straight edge.
C.2
Hardened steel scriber ground to a sharp 30 point.
METHOD
C.3
Using a straight edge and a hardened steel scriber, score two parallel lines in the
coating at a distance apart equal to approximately ten times the average coating
thickness. The cuts are to penetrate through the full depth of the coating to the base
metal and, by the application of sufficient pressure, be achieved in the minimum
number of strokes.
C.4
Should any part of the coating between the lines break away from the base metal it
is to be deemed to have failed the test.
C.5
The items or areas selected for this test is to be agreed between the Contractor and
the responsible Quality Assurance Authority.
C.6
The test is destructive and the damaged area must be locally reblasted and re-metal
sprayed in accordance with this NES.
C.1
ANNEX C.
NES 764
ANNEX C.
C.2
NES 764
ANNEX D.
D.1
PROCUREMENT CHECK LIST

TITLE .....................
REFERENCE .....................
Notes:
1. This Check List is to ensure that certain aspects of this Naval Engineering
Standard are consulted when preparing a Statement of Technical
Requirements for a particular application.
2. Clauses where a preference for an option is to be used or where specific
data is to be added are included in the Check List.
3. Each item is to be marked either:
p
NA
=
=
included
not applicable
CLAUSE
CHECK
CHECK
No
No
1.
The areas selected for metal spraying are to be 3.a.
listed
2.
Where abrasive blasted steel surfaces have been 8.1
sprayed with metal to the full thickness specified, the first coat of the appropriate paint system in accordance with NES 763, 765 or Contract Documents is to be applied
3.
4.
Only approved type of metal spraying equipment and abrasive grit to be specified
Metal not to be used in powder form
D.1
p or
NA
5.2b., 6.a.
5.2b.
ANNEX D.
NES 764
ANNEX D.
D.2
NES 764
ALPHABETICAL INDEX
A
Air hoses, 2.2
Application, 5.1, 5.2
Areas, external, 3.1, 8.1
Areas, internal, 3.1, 8.1
Areas, selected, 3.1
C
Cleanliness, 2.2
Coating weight, 9.1
Cylinders, 2.1
D
Dehumidification, 7.1, 8.1
Discharge, ventilation, 2.2
E
Electrotechnical equipment, 9.1
Environmental conditions, 4.1, 7.1
Equipment, 1.1, 2.1, 2.2, 6.1, 7.1
F
Flame pistols, 2.1
Flameproofing, 2.2
Flow meters, 6.1
G
Gas cylindersprecautions, 2.1
Gas hoses, 2.2
H
Hoses, 2.2
Hot-dip galvanizing, 9.1
L
Lighting, 2.2
INDEX.1
INDEX
NES 764
M
Materials, 1.1
O
Operators requirements, 7.1
P
Paint system, 5.2, 7.1, 8.1
Preparation, cleaning, 4.1, 5.1
Preparation, protection, 4.1, 5.1, 7.1
Preparation, welds, 4.1
Pressures, fuel gas, oxygen, air, 6.1
Protective clothing, 2.2
Q
Quality control, 7.1, 7.2
R
Regulators, 2.1
T
Temperature control, 7.1, 8.1
Thickness of coatings, 5.1, 7.1
Trunking, 2.2
Tubes, 9.1
V
Ventilation supply and exhaustprecautions, 2.2
W
Wood decking, 8.1
INDEX
INDEX.2
Inside Rear Cover
Crown Copyright 2000

Copying Only as Agreed with DStan
Defence Standards are Published by and Obtainable from:

Defence Procurement Agency
An Executive Agency of The Ministry of Defence
Directorate of Standardization
Kentigern House
65 Brown Street
GLASGOW G2 8EX
DStan Helpdesk
Tel 0141 224 2531/2
Fax 0141 224 2503
Internet e-mail enquiries@dstan.mod.uk
File Reference
The DStan file reference relating to work on this standard is D/DStan/69/02/764.
Contract Requirements
When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with
a Defence Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards
Defence Standards are revised as necessary by up issue or amendment. It is important that
users of Defence Standards should ascertain that they are in possession of the latest issue or
amendment. Information on all Defence Standards is contained in Def Stan 00-00 Standards
for Defence Part 3 , Index of Standards for Defence Procurement Section 4 Index of Defence
Standards and Defence Specifications published annually and supplemented regularly by
Standards in Defence News (SID News). Any person who, when making use of a Defence
Standard encounters an inaccuracy or ambiguity is requested to notify the Directorate of
Standardization (DStan) without delay in order that the matter may be investigated and
appropriate action taken.

NES 764 Flame Metal Spraying and Hot Dip Galvanizing of Ships Structure and Fittings Category 2

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

NES 764 Flame Metal Spraying and Hot Dip Galvanizing of Ships Structure and Fittings Category 2

Uploaded by

Copyright:

Available Formats

Ministry of Defence

Defence Standard 02-764 (NES 764)

Flame Metal Spraying And

Incorporating NES 764 Category 2

Signature and Date

Naval Engineering Standard

FLAME METAL SPRAYING AND

This NES Supersedes

NAVAL ENGINEERING STANDARD 764

The issue and use of this Standard

Guidance for the hot-dip galvanizing of structural steel is also included.

It is to be applied as required by any Procurement Executive, Ministry of Defence contract for

If it is found to be technically unsuitable for any particular requirement the MOD(PE) is to

No alteration is to be made to this NES except by the issue of an authorized amendment.

This NES has been reissued because of update to NES format.

MOD Tender or Contract Process

British Standards Institution,

Directorate of Standardization and Safety Policy,

Naval Engineering Standards

CSE3a, CSE Llangennech, Llanelli,

Tender or Contract Sponsor to advise.

Note: Tender or Contract Sponsor can advise in cases of difficulty.

Health and Safety

EXTENT OF METAL SPRAYING . . . . . . . . . . . . .

TREATMENT OF METAL SPRAYED SURFACES

DEFINITIONS AND ABBREVIATIONS . . . . . . . .

METHOD OF CHECKING THE ADHESION OF

PROCUREMENT CHECK LIST . . . . . . . . . . . . . . .

References to aluminium for metal spraying in this NES mean aluminium in

3.2mm, 12kg coil

2.0mm, 12kg coil

3.2mm, 12kg coil

2.0mm, 12kg coil

2.0mm, 25kg coil

2.0mm, 25kg coil

TABLE 1.1 MATERIALS AND EQUIPMENT

Flame pistols and associated equipment must be used and maintained in

Gas and Oxygen Cylinders

If by arrangement with the Shipbuilders or Ship repairer, they are permitted to

All cylinders are to be fitted with Non Return Valves.

Gas and Air Hoses

Only British Standard approved reinforced rubber hoses and connectors of

Care is to be taken to ensure that hoses are securely attached to connectors by

Ventilation Supply and Exhaust

It is important that an efficient system of flameproof ventilation providing at

The ventilation trunkings are to be constructed of suitable sound

The exhaust ventilation trunking within the compartment is to be positioned

On no account is the dust exhausted during abrasive blasting and metal

Adequate flameproof and dust proof lighting giving a high standard of

EXTENT OF METAL SPRAYING

The following requirements are to be met before the structure concerned is

Sharp edges on attachments, seatings etc are to be slightly rounded off to

Thereafter the prepared surface is not to be allowed to become contaminated in

The abrasive blasting is to be so arranged for an area abrasive blasted during

If despite these requirements areas abrasive blasted show signs of deterioration

Sprayed Metal Systems

The sprayed metal systems to be applied to structure are as follows:

Exterior Weatherdecks. A duplex sprayed metal system consisting of

Weatherdecks to be fitted with wood decking. 150 microns of zinc.

Internal Structure (except Feed Water Tanks). Zinc to a total

Feed Water Tanks.Where Feed Water Tanks are specified to be metal

Application of the Coatings

The application of the sprayed metal coatings is generally to be in accordance

The metal to be sprayed is to be in wire form of no more than 3.2mm diameter,