METAL SPRAY PAINTER (MARKET COMPETITIVE)

The Metal Spray Painter (BPS-02) serves as a skilled tradesperson within the Federal Government Industrial Establishment, responsible for applying metallic and ceramic coatings onto machinery components, structural steel, and defense equipment using thermal spray processes such as flame, electric arc, and plasma spraying. The role directly supports the maintenance, rehabilitation, and corrosion protection of critical industrial assets, ensuring extended service life and operational readiness of heavy engineering plant and ordnance items.

Daily workflow involves interpreting work orders and engineering drawings to identify coating specifications, performing abrasive grit blasting to achieve Sa 2.5 or Sa 3.0 surface cleanliness profiles, masking non-coating areas, and setting up spray parameters (amperage, voltage, gas pressure, traverse speed) on oxy-acetylene wire flame, twin-wire arc, or plasma spray systems. The incumbent monitors coating thickness via calibrated DFT gauges, conducts bend/adhesion tests per ASTM/ISO standards, maintains spray booth ventilation and dust extraction systems, and logs all process parameters in the shop floor quality register for traceability.

Selection for this post is conducted strictly through a Practical Skill/Trade Test and Oral Viva Voce interview; no written examination is administered. Candidates must demonstrate hands-on proficiency in surface preparation, spray gun operation, coating application, and defect identification on test coupons before a technical board, followed by an assessment of theoretical knowledge and safety awareness.

• ✓Prepare substrate surfaces by operating abrasive blast cabinets and portable grit blasting equipment to achieve specified anchor profiles and cleanliness grades
• ✓Set up and operate thermal spray systems including oxy-acetylene flame spray, electric arc wire spray, and plasma spray units according to qualified spray procedures
• ✓Apply metallic coatings such as zinc, aluminum, and stainless steel, as well as ceramic coatings like chrome oxide and alumina-titania, maintaining consistent overlap, pass spacing, and interpass temperature
• ✓Inspect finished coatings for thickness uniformity, porosity, adhesion strength, and surface roughness using calibrated gauges and destructive test coupons
• ✓Perform routine preventive maintenance on spray guns, wire feeders, power sources, gas regulators, and dust collection units to ensure process stability
• ✓Enforce workshop safety protocols including proper respirator usage (PAPR/SAR), fire watch during hot work, hazardous material handling for spent grit and metal fumes, and lockout-tagout during equipment servicing

• 💡Expertise in abrasive blast cleaning standards (ISO 8501-1, SSPC-SP 5/10) and surface profile measurement using replica tape
• 💡Proficiency in operating and troubleshooting flame spray (wire/powder), twin-wire arc spray, and plasma spray equipment
• 💡In-depth knowledge of feedstock materials (wires, powders, rods) metallurgy and selection criteria for corrosion, wear, and thermal barrier applications
• 💡Ability to read and interpret engineering drawings, coating procedure specifications (CPS), and welder/sprayer qualification records (WPQR/SPQR)
• 💡Competence in coating quality control methods: dry film thickness (DFT) measurement, cross-hatch adhesion (ASTM D3359), bend testing, and porosity detection
• 💡Strict adherence to occupational health standards for metal fume fever prevention, silica exposure control, noise attenuation, and confined space entry permits