Professional Hand Passivation Services for Precision Weld Treatment
Not every passivation job requires full-system circulation. Weld repairs, small-bore piping, field modifications, and spot contamination call for a hands-on approach. CXP Solutions delivers localized treatment for areas too small, too isolated, or too specific for system-wide methods—from heat tint removal to post-weld touch-ups, with complete documentation and ASTM A967 compliance.
Choose Your Hand Passivation Approach
Four specialized techniques for localized stainless steel surface treatment—each optimized for specific geometries and access conditions.
Most VersatileThixotropic Gel Application
Pharmaceutical-grade citric acid gel that adheres to vertical surfaces and complex geometries. The thixotropic formula maintains position during extended contact times, ensuring consistent treatment across weld zones, tank walls, and overhead surfaces.
Fastest CoverageAtomized Spray Application
High-pressure atomized citric solution for rapid coverage of larger surface areas and pipe interiors. Ideal when speed matters and surfaces are accessible for spray application with proper containment.
Most PrecisePrecision Swab & Wipe
Lint-free applicators saturated with passivation chemistry for surgical-precision spot treatment. Maximum control for confined spaces, delicate surfaces, and areas requiring exact coverage boundaries.
Fastest ResultsElectrochemical Treatment
Controlled electrical current accelerates passivation on localized weld zones. Combines cleaning, descaling, and passivation in a single operation for maximum efficiency on heat-affected zones.
Why Welds Demand Hand Passivation
Welding creates the highest-risk zones for corrosion. Heat input depletes chromium, embeds iron, and creates oxide scale that compromises protection.
Chromium Depletion Zone
Temperatures above 800°F cause chromium to combine with carbon, forming carbides at grain boundaries. This "sensitization" depletes chromium available for passive layer formation.
Embedded Free Iron
Welding redistributes iron to the surface. Without passivation, this free iron rapidly oxidizes, creating corrosion initiation sites and contaminating downstream systems.
Heat Tint Oxide Scale
The colorful discoloration around welds indicates thick, chromium-poor oxide providing no corrosion protection. This scale must be removed before passivation.
Porosity & Microcrevices
Weld porosity creates micro-environments where chlorides concentrate and pitting initiates. Proper passivation ensures microscopic features develop protective coverage.
CXP Weld Treatment Process
ASTM A967 compliant procedure
Surface Preparation
Mechanical cleaning with stainless steel brushes. Solvent wipe to eliminate oils and organic contamination.
Gel Application
Apply 6-8% citric acid gel to entire heat-affected zone (HAZ), extending 1-2 inches beyond visible discoloration.
Contact Time
Maintain chemistry contact for 30-60 minutes at ambient or elevated temperature (120-140°F for accelerated treatment).
Neutralization & Rinse
Neutralize with sodium bicarbonate solution, then rinse with DI water until pH returns to 6.5-7.5.
Verification
Perform water break test and/or copper sulfate test per ASTM A380 to confirm successful passivation.
Weld Types We Treat
Orbital Welds
ASME BPE tube weldsManual TIG
GTAW process weldsSocket Welds
Fitting connectionsTank Seams
Vessel longitudinal weldsField Repairs
On-site modificationsHeat Tint Color Spectrum
Understanding heat tint colors helps identify the severity of chromium oxide degradation and required treatment intensity.
Understanding Heat Tint
Heat tint colors indicate oxide thickness and chromium depletion. Darker colors mean higher temperatures were reached, creating thicker oxides with less protective chromium content. Our heat tint removal guide explains the science behind each color zone.
ASME BPE Requirement
ASME BPE requires heat tint removal for high-purity systems. Our hand passivation services meet pharmaceutical-grade requirements, ensuring welds achieve the specified surface finish and corrosion resistance for bioprocessing applications.
Heat Tint Removal Process
Systematic approach for complete chromium restoration
Color Assessment
Evaluate heat tint severity to determine chemistry strength and contact time requirements.
Oxide Removal
Apply gel or electrochemical treatment to dissolve chromium-depleted oxide layer.
Re-Passivation
Fresh citric acid application builds new chromium-rich passive layer on exposed base metal.
Visual Confirmation
Verify complete color removal and uniform surface appearance across treatment zone.
Surface Correction Applications
Hand passivation addresses localized surface issues that compromise system integrity without requiring full system treatment.
Chemical Staining & Buildup
Process residues and chemical deposits create localized contamination zones that harbor bacteria and compromise product purity.
Grease & Organic Contamination
Lubricants, oils, and organic residues trapped in valve bodies and fittings create biofilm-friendly environments and contamination sources.
Flange & Sensor Contamination
Contamination rings around flanges and instrument connections indicate gasket degradation and process fluid intrusion into crevices.
Pitting Corrosion
Localized treatment of pit sites to halt propagation and restore surface
Rouge Spots
Targeted derouging of localized iron oxide contamination
Grind Marks
Post-grinding passivation to restore protection after mechanical work
Weld Repairs
Immediate post-weld passivation for field modifications
Small-Bore Piping Solutions
Hand passivation techniques designed for tubing and small-diameter piping where circulation methods cannot achieve adequate flow or contact.
Gel Injection Method
Syringe-applied gel for complete internal coverage. Ideal for dead legs and instrument tubing where flow-through isn't possible.
Pull-Through Swab
Saturated lint-free swabs pulled through tubing with retrieval wire. Provides mechanical contact plus chemical treatment.
Static Fill
Fill tubing with passivation solution, cap ends, and allow extended contact time. Simple approach for accessible runs.
Micro-Spray Insertion
Extended spray wand inserted into tubing for atomized coverage. Effective for longer runs with accessible entry points.
Common Applications
Size Range Capabilities
Biopharmaceutical Hand Passivation
cGMP-compliant localized passivation for pharmaceutical manufacturing systems requiring validated surface treatment.
WFI Loop Welds
Post-modification passivation for Water For Injection systems. Maintains loop integrity after tie-ins, repairs, and equipment additions.
Vessel Repairs
Reactor and tank weld repairs requiring localized treatment. Minimizes downtime while maintaining validated surface conditions.
CIP/SIP Systems
Clean-in-place and steam-in-place system modifications. Hand passivation ensures new connections meet existing system specifications.
Complete Documentation Package
Every hand passivation service includes comprehensive cGMP documentation for audit readiness and validation compliance.
Passivation Verification Testing
Every hand passivation treatment includes appropriate verification testing per ASTM A380 to confirm successful surface passivation.
Water Break Test
DI water sheeting confirms absence of oils and organic contamination. Continuous water film indicates clean, passive surface.
ASTM A380 §7.3Copper Sulfate Test
Acidified copper sulfate solution detects free iron. No copper plating after 6 minutes confirms successful passivation.
ASTM A380 §7.2Ferroxyl Test
Potassium ferricyanide solution identifies embedded iron particles. Blue spots indicate contamination requiring retreatment.
ASTM A380 §7.4Visual Inspection
Magnified examination confirms uniform surface appearance, complete heat tint removal, and absence of contamination.
ASTM A380 §7.1Ready for Precision Hand Passivation?
From single weld repairs to comprehensive surface correction programs, CXP Solutions delivers ASTM-compliant hand passivation with complete documentation. Let's discuss your specific requirements.