fjarÐaÁl smelter project color matrix bechtel, …en 970: 1997 non-destructive examination of...

Fac.no. Description Color - RAL Color - IP Color description

All

supplied by Project Cladding MR. Two colors. Ref. to listed documents for breakdown by facilities.

RAL 9006 RAL 7022

Silver gray Gray Umber 24956-000-30X-A10D-00001

All Translucent panels in cladding No color Clear'

330GTC Main ventilation Pipe, excludes support structure RAL 1006 Ocher yellow 24956-000-30X-A10D-00001

810 / 820 Alumina Silos To be determined

330 GTC Stack To be determined

210 Vacuum Ship Unloader RAL 7022 Gray Umber

210 / 442

Alumina conveyor and Bath plant conveyor enclosures , excluding support structure and transfer tower cladding. RAL 1006 Ocher yellow

210 / 442Alumina and Bath plant conveyors; support structure and Alumina transfer tower RAL 7022 Gray Umber

710 / 720 / 730 Sub-stations (E-rooms) and Control rooms RAL 7022 Gray Umber

530 / 641/650/670

Pre-engineered buildings with Cladding not supplied by Project cladding MR. RAL 7022 Gray Umber

AllExterior Mech. Equipment and its structure, including support structures for piping. RAL 7022 Gray Umber

AllPiping and other mech. connection btw. ext.mech. equipment and buildings. RAL 7022 Gray Umber

All

Buildings structural steel, internal. Incl. girts, purlins, cross-bracing, crane girders and connecting items. RAL 9003 Grayish white

All Canopies RAL 7022 Gray Umber

Color Matrix

FJARÐAÁL SMELTER PROJECT

Ref. documents

Bechtel, In Association With HRV

p y

All Stairs, platforms and catwalks, interior RAL 9003 Grayish white

All Handrails, interiorAlcoa Safety Yellow. Listed as SW B54YZ37 (RAL 1023)

Alcoa Safety Yellow 24956-000-7EN-E01-00006

All Monorail girders and cranes Alcoa Safety Yellow. Listed as SW B54YZ37 (RAL 1023)

Alcoa Safety Yellow 24956-000-7EN-E01-00006

320 Claustra wallColor to be determined when vendor has been selected.

All Man doors, vehicle doors, frames and windows To be determined

All Electrical cabinets, switchboxes etc. Standard vendor colors*. Gray Umber

All Interior plant equipment Standard vendor colors*. Gray Umber

All External HVAC louvers on walls and roofs Same as adjacent cladding 24956-000-30X-A10D-00001

All Internal HVAC systems Standard vendor colors*. Gray Umber* When no standard color, RAL 7022 should be used

/ / 000 05/20/2005 HE 00C 03/23/2005 HE 00B 03/05/2005 HE 00A 02/21/2005 HE SH CL DVRev. Date BY CHECK EGS. PEM

P. 1 of 124956-000-30X-A10D-00002 DOCUMENT N°

Issued for approvalReason for Revision

IssuedColors for Pre-engineered buildings RAL # for Alcoa Safety Yellow


Electronic documents, once printed, are uncontrolled and may become outdated. Refer to the electronic documents in Infoworks for current revisions.

Bechtel Confidential © Bechtel Corporation 2004.

Contains confidential and/or proprietary information to Bechtel and its affiliated companies which shall not be used, disclosed or reproduced in any format by any non-Bechtel Party without Bechtel’s prior written permission. Notwithstanding the above, “Fjarðaál sf.” has the right to use the information contained in this document pursuant to Prime Contract between Bechtel Corporation and “Fjarðaál sf.”. All rights reserved."

SPECIFICATION

FOR

D - Concrete

REINFORCING STEEL AND EMBEDDED PARTS


Fjarðaál sf.

/ / / / 001 04/09/24 Add Client Com+50Ø Rebar 000 04/09/13 Issued for Construction C.B. E.V. C.L. D.V. 00A 04/05/21 Issued for Review C.B. E.V. C.L. D.V. Rev. Date Reason for Revision By Check EGS PEM SPECIFICATION No. 24956-000-3PS-DG00-00001 P. 1 of 11

FJARÐAÁL SMELTER PROJECT Furnishing and Fabricating Reinforcing Steel and No 24956-000-3PS-DG00-00001 Rev. 001 Embedded Parts

Bechtel Confidential © Bechtel Corporation 2004. Furnishing and Fabricating Reinforcing Steel and Embedded Parts 24956-000-3PS-DG00-00001 P.2 of 11

TABLE OF CONTENTS

1.0 GENERAL....................................................................................................................... 3

1.1 Scope ............................................................................................................................. 3

1.2 Related Work not Included ........................................................................................... 3

1.3 Referenced Codes and Standards............................................................................... 3

1.4 Quality Standards.......................................................................................................... 4

2.0 PRODUCTS.................................................................................................................... 4

2.1 Reinforcing Steel........................................................................................................... 4

2.2 Welded Wire Fabric....................................................................................................... 5

2.3 Miscellaneous Accessories.......................................................................................... 5

2.4 Joints ............................................................................................................................. 6

2.5 Steel Shapes and Plates ............................................................................................... 6

2.6 Anchor Bolts.................................................................................................................. 6

2.7 Headed Studs ................................................................................................................ 6

3.0 EXECUTION ................................................................................................................... 6

3.1 Detailing ......................................................................................................................... 6

3.2 Storage and Handling ................................................................................................... 7

3.3 Fabricating..................................................................................................................... 7

3.4 Marking .......................................................................................................................... 8

3.5 Welding .......................................................................................................................... 8

3.6 Shop Inspection and Testing ....................................................................................... 9

3.7 Special Provisions for Potroom Areas ........................................................................ 9

APPENDIX A – CONCRETE MATERIALS


Bechtel Confidential © Bechtel Corporation 2004. Furnishing and Fabricating Reinforcing Steel and Embedded Parts Document number P.3 of 11

1.0 GENERAL 1.1 Scope

This Specification contains the technical requirements, including materials, detailing, fabricating, and delivery, for the purchase and fabrication of reinforcing steel bars, welded wire fabric, anchor bolts, and embedded steel.

1.2 Related Work Not Included

1.2.1 Furnishing and Delivering Ready-Mix Concrete 24956-000-3PS-DB01-00001

1.2.2 Concrete Work

24956-000-3PS-DB00-00001 1.3 Referenced Codes and Standards 1.3.1 The editions of the codes and standards referred to in this Specification are those in

effect at the time of contract award. European standards (EN/ENV) with accompanying Icelandic National Application Documents (NAD), and Icelandic building regulation (Byggingareglugerð 1998) shall apply. (Referenced codes and standards shall apply unless an equivalent code or standard is submitted for review and approval).

EUROCODE 2: Design of concrete structures including the following additions/modifications from the Icelandic National Application Document (NAD): NS3575:1990 Tests of reinforcing steel NS3576:1997 Reinforcing steel, Dimensions and properties

1.3.2 EN 206-1: 2000 Concrete – Performance, production, placing and compliance criteria

ENV 13670-1: 2000 Execution of concrete structures – Part 1: Common

PrEN 10080: 1999 Steel for the reinforcement of concrete – Weldable ribbed reinforcing steel Part 1 – Part 6

EN ISO 4066: 1999 Construction drawings – Bar scheduling EUROCODE 3: Design of steel structures EN ISO 4014: 1992 Hexagon head bolts: grade 8.8 EN ISO 4016: 1992 Hexagon head bolts: product grade 4.6



EN 24032: 1992 Hexagon nuts, style 1: product grades a and b

EN ISO 7089: 2000 Plain washers – Normal series – Product grade A EN ISO 7090: 2000 Plain washers, chamfered – Normal series – Product grade A EN ISO 7091: 2000 Plain washers, chamfered – Normal series – Product grade C EN 10025: 1993 Hot rolled products of non-alloy structural steels: technical delivery conditions EN 287-1: 1992 Approval testing of welders. Fusion welding. Part 1: Steels EN 288 Specification and approval of welding procedures for metallic materials EN 970: 1997 Non-destructive examination of fusion welds – Visual examination EN 22553:1994 Welded, brazed and soldered joints. Symbolic representation on drawings DIN 4099 Welding of reinforcing steel; execution of welding work and testing NS 3576-3 Steels for reinforcement of concrete – Dimensions and properties – Part 3: Ribbed bars B500C BS 4449:1997 Specification for carbon steel bars for the reinforcement of concrete

1.4 Quality Standards

1.4.1 The quality of items and services shall be controlled to meet the requirements of this Specification, applicable codes and standards, and local regulations.

1.4.2 Seller shall submit the Quality Control program that will be followed during execution of

the work to the Buyer for approval prior to fabrication. The program for reinforcing steel shall include dimensional checks and visual inspection for cracks at bends.

2.0 PRODUCTS

2.1 Reinforcing Steel

2.1.1 Materials and workmanship shall comply with ENV 13670.



2.1.2 Reinforcement shall be uncoated grade B500A or B500B, with characteristic yield strength of 500 MPa conforming to ENV 10080, except stirrups and ties 16 mm diameter and less, which shall be grade B500C, conforming to NS 3576. See section 2.6 for potroom anchor bolts fabricated from reinforcing steel.

2.1.3 With each shipment of reinforcing steel, the Seller shall provide certified mill test reports

showing chemical and physical analysis for each heat of each size of reinforcing steel delivered.

2.2 Welded Wire Fabric

Conform to ENV 10080. 2.3 Miscellaneous Accessories

2.3.1 Refer to Standard Potroom Drawings and Section 3.7, Special Provisions for Potroom Areas, for special provisions for potroom reinforcing steel and embedded parts.

2.3.2 Reinforcing steel bar supports shall be provided. 2.3.3 Bar supports, including chairs, bolsters, spacers, and tie wire shall be standard products

from a reputable manufacturer of such items. Properly sized supports shall be furnished in sufficient numbers, manufactured to serve their intended purpose, and capable of carrying imposed loads without measurable deflection or displacement of the reinforcing steel.

2.3.4 Size 1.5 mm (minimum) annealed tie wire shall be used for tying reinforcing steel. 2.3.5 The size and shape of bar supports shall be selected so that the bar is maintained in

proper position with minimal movement during concrete placement. If concrete blocks are used for support, the compressive strength of the blocks shall equal or exceed the strength of the concrete being placed.

2.3.6 Metal bar supports shall not be used to support reinforcing steel in concrete placed

against earth. Driving steel rods into the subgrade to support reinforcing steel or other methods of support, which may conduct an electrical current between the reinforcing steel and subgrade are prohibited. Metal bar supports may be used for elevated slabs, except in potroom areas where, for safety reasons, electrically nonconductive supports must be used.

1



2.3.7 Embedded surfaces of insets and sleeves shall be unpainted. Pipe sleeves shall be either Schedule 40 black steel or, if approved by the Buyer, polyvinylchloride (PVC) high impact plastic pipe sleeves, Schedule 40.

2.4 Joints

Bars shall be jointed, by laps, couplers or welding as per the requirements of ENV 13670, in accordance with EUROCODE 2 and conform to the requirements shown on the design drawings.

2.5 Steel Shapes and Plates

Materials for structural steelwork used in the fabrication of embedded parts shall conform to the requirements of EUROCODE 3, and shall be grade S355J2 conforming to EN 10025.

2.6 Anchor Bolts

Anchor bolts, nuts, washers, plates and sleeves shall be supplied as per the design drawings and specifications. Materials and dimensions for anchor bolts shall conform to the requirements of EN 4014 or EN 4016. Nuts for anchor bolts shall conform to EN 4032, and washers to ISO 7089, ISO 7090, or ISO 7091. Plates for anchor bolt embedment shall conform to the requirements of EN 10025. If required, anchor bolt sleeves shall be made out of mild steel conduit. Unless noted otherwise threads shall be according to EN 4014, Table 1 – Preferred Threads. Anchor bolts for potroom areas fabricated from reinforcing steel shall be grade 460B conforming to BS 4449 or equivalent.

2.7 Headed Studs

Nelson studs, with ferrules, or Buyer approved equivalent, shall be provided as required by the design drawings.

3.0 EXECUTION 3.1 Detailing 3.1.1 Reinforcing steel shall be detailed in accordance with EUROCODE 2 and EN ISO 4066,

unless noted otherwise on the design drawings. 3.1.1 Reinforcing steel detail drawings, placing drawings, and bills of reinforcing shall be

prepared in accordance with EN ISO 4066.



3.1.2 All detail and placing drawings for reinforcing steel shall be submitted to the Buyer for approval. Buyer approval shall be obtained prior to fabrication.

3.1.3 Shop drawings for embedded steel and anchor bolts shall be prepared and Buyer

approval of shop drawings obtained prior to fabrication. Shop drawings shall indicate, the quantities, locations, spacing, sizes, profiles, connections, attachments, and piece marks of elements. A bill of material, showing member piece marks, shape designations, number of pieces required, length, unit weight and total weight of each member, and total weight of steel, shall be provided on each drawing. All welds shall be shown using welding symbols in accordance with EN 22553. Field welded connections shall not be used, unless specifically approved by the Buyer.

3.2 Storage and Handling

3.2.1 Before and after fabrication, reinforcing steel shall be stored off the ground and protected from oil or other deleterious materials.

3.2.2 The Seller shall establish and maintain controls for handling and storing anchor bolts

and embedded parts during fabrication, and preparation for shipment, to prevent damage and deterioration.

3.3 Fabrication

3.3.1 Reinforcing steel tolerances for cutting and/or bending dimensions shall be in accordance with Table 1, and shall be taken into account when completing the schedule. The end anchorage or the dimension in parentheses in the shape codes of EN ISO 4066 shall be used to allow for any permissible deviations resulting from cutting and bending.

TABLE 1

TOLERANCES

Cutting and bending processes Tolerance (mm)

Cutting of straight lengths (including reinforcement for subsequent bending)

+25, -25

Bending: ≤ 1000 mm > 1000 mm to ≤ 2000 mm > 2000 mm

+5, -5 +5, -10 +5, -25

Length of wires in fabric ± 25 or 0.5% of the length (whichever is greater)



3.3.2 Bars shall be bent cold to the dimensions shown on the design drawings, and in accordance with EUROCODE 2 and EN ISO 4066

3.3.3 Welded wire fabric shall be furnished in flat sheets, unless prior approval is obtained

from the Buyer. 3.3.4 Embedded steel and anchor bolts shall be fabricated in accordance with EUROCODE

3. Seller shall substitute sections or modify design details only with the Buyer’s written approval prior to fabrication.

3.3.5 Size 5 mm nail holes shall be provided, as required, in embedded steel assemblies to

facilitate installation. 3.4 Marking

3.4.1 Each bundle of reinforcing steel bars shall be tagged after fabrication. The tag shall show the quantity, grade, size, piece mark, and suitable identification to allow checking, sorting, and placing.

3.4.2 Each bundle of flat sheets of welded wire fabric shall be tagged after fabrication. Tags

shall show the piece mark, quantity, style designation, width, and length. 3.4.3 Weatherproof tags that will remain legible for one year (minimum) when stored outside

shall be used. 3.4.4 Prior to shipment of anchor bolts and embedded parts, all pieces shall be marked with

paint indicating the piece number, building, area, and any other information required for identification. Marks shall be visible when material is stacked and be legible for one year (minimum) when stored outside.

3.5 Welding

3.5.1 Refer to Standard Potroom Drawings and Section 3.7, Special Provisions for Potroom Areas, for special provisions for potroom reinforcing steel and embedded parts.

3.5.2 Unless the uncoated reinforcing steel conforms to prEN 10080 or NS 3576, reinforcing

steel shall not be welded or tacked 3.5.3 Only reinforcing steel that conforms to prEN 10080 or NS 3576 shall be welded or

tacked, when shown on the design drawings. If welding or tacking is shown, the Seller shall obtain prior approval from the Buyer of welding procedures, procedure qualification



records, and inspection plan in accordance with international and national standards as per EUROCODE 2, DIN 4099 or other approved standard.

3.5.4 Materials used in the fabrication of anchor bolts and embedded parts shall be welded in

accordance with EUROCODE 2 and EN 288. Seller shall obtain prior Buyer approval of all welding procedures, welder qualification procedures, welding inspections procedures, and weld material control procedures.

3.5.5 Welders shall be qualified in accordance with the requirements of EN 287, or an

approved equivalent. Seller shall maintain welder qualification records at the location where the work is being performed and make them available for review when requested.

3.6 Shop Inspection and Testing

3.6.1 Seller shall provide inspectors to inspect material and workmanship in the fabricating shop.

3.6.2 Seller shall visually inspect all welding in accordance with EN 970. 3.7 Special Provisions for Potroom Areas 3.7.1 For concrete in potroom areas, the minimum concrete covering over all metal

items, including reinforcing steel and reinforcement tie wires, shall be as shown on the drawings, and shall in no case be less than that required by Eurocode 2.

3.7.2 No metallic chairs, bolsters, form ties, or reinforcing steel tie wires are permitted.

Only special nonconductive reinforcement supports and non-metallic tie wire for tying reinforcing steel shall be used.

3.7.3 Clearances shown on the drawings between anchor bolts and reinforcing steel,

between inserts and reinforcing steel, and between layers of reinforcing shall be strictly maintained.

3.7.4 Reinforcing steel shall be welded together, as shown on the drawings.



1.0 GENERAL

Subsequent sections in this Appendix list approved brand names and/or manufacturers for some of the generic materials listed in this Specification. The sections of this Appendix carry a designation of “open” or “closed”. Open shall mean that any material meeting the generic requirements of this Specification may be used. Products listed are known acceptable products which meet the generic specification. “Closed” shall mean that products listed are the only acceptable products, and no substitutions shall be made without prior approval. Note: If a manufacturer is approved to supply several products covered in this Appendix, the manufacturer’s address is listed only once.

2.0 MATERIALS 2.1 Cement and Aggregates: Open – ENV 197 or ASTM C 150 and EN 12620 2.2 Air-Entraining Admixtures: Open – EN 934 or ASTM C 260

2.3 Accelerating Admixtures: Open – ASTM C 494, Type E

2.4 Water Reducers: Open – EN 934 or ASTM C 494, Type A, B or D

2.5 High Range Water Reducers: Open – ASTM C 494, Type F 2.6 Fly Ash: Open – EN 450

2.7 Silica Fume: Open – prEN 13263 2.8 Reinforcing Steel: Open ENV 10080, NS 3576

2.9 Mechanical Splices (Reinforcement): Open – EN 13670 and EUROCODE 2

2.10 Water Stops: Open – Corps of Engineers CRD-C572 2.11 Joint Fillers: Cellulose-Bituminous Fillers: Open ASTM D 1751

Cork Joint Fillers: Open ASTM D 1752, Type II

APPENDIX A: CONCRETE MATERIALS



2.12 Joint Sealants: Hot Applied, PVC-Coal Tar: Open – ASTM D 3406

Cold Applied, Polyurethane: Closed – ASTM C 920

a) Gardox W.R. Meadows

2.13 Slicone Rubber Sealant: Open – ASTM C 920, Type S, Grade NS, Class 25, Use T

2.14 Vertical Joint Sealants: Open – ASTM C 920, Type S or M, Class 25, Use NT

2.15 Preformed Joint Sealant: Open – ASTM D 2628

2.16 Varpor Barrier: Open – ASTM D 4397 E1

2.17 Sheet Materials (Curing): Open – ASTM C 171

2.18 Liquid Curing Compounds: Open – ASTM C 309, Type 1, Class B

2.19 Liquid Floor Hardeners: Closed

a) Lapidolith Chemrex, Inc. Division of Degussa Sonneborn Building Products 889 Valley Park Drive Shakopee, MN 55379 (952) 496-6000

(800) 433-9517

2.20 Dry-Shake Hardeners: Closed a) Masterplate 200 Master Builders, Inc.

2.21 NonSlip Aggregates: Open

CONFIDENTIAL-Access Limited to Persons under Obligation of Confidentiality to Fjarðaál sf. or named Fjarðaál sf. Affiliates. To the extent that any information contained herein is used or usable in the general provision of engineering, procurement or construction management services or generally in construction of industrial facilities, such as project management and engineering procedures, systems, controls, contract documentation and management tools Access is Further Limited to Persons under Obligation of Confidentiality to the applicable Bechtel entity/entities in the Bechtel group of companies (“Bechtel Information”), as such information is the confidential proprietary information of such Bechtel entity/entities. It is herein recognized and acknowledged that Fjarðaál sf. has the right of Access to all such Bechtel Information under the specific terms of Agreements that it has previously entered into with the relevant Bechtel entities or their Affiliates. All rights reserved.”

Fjarðaál sf.

SPECIFICATION

FOR

N - Materials Engineering Technology

PROTECTIVE COATINGS

/ /

/ /

/ /

/ /

000 04/10/18 Issue for Construction SB GK GK/CL DV

Rev. Date Reason for Revision By CHECK EGS PEM

DOCUMENT N° 24956-000-3PS-NX00-00001 P. 1 of 39



Protective Coatings 24956-000-3PS-NX00-00001 Rev. 000

Bechtel Confidential © Bechtel Corporation 2004

24956-000-GFS-GEX-00001-000 Page 2 of 39

TABLE OF CONTENTS

1.0 GENERAL ...................................................................................................................... 4

1.1 ITEM INCLUDED .............................................................................................................. 4

1.2 SURFACES NOT TO BE PAINTED ....................................................................................... 4

1.3 EXPOSURES .................................................................................................................. 5

1.4 SAFETY AND ENVIRONMENTAL ........................................................................................ 5

1.5 QUALITY STANDARDS ..................................................................................................... 5

2.0 REFERENCES, APPLICABLE STANDARDS, CODES AND REGULATIONS ............. 6

2.1 REFERENCES ................................................................................................................ 6

2.2 APPLICABLE STANDARDS ................................................................................................ 6

2.3 DOCUMENTS CONFLICTS ................................................................................................ 8

2.4 COMPLIANCE WITH ICELANDIC REGULATIONS ................................................................... 8

3.0 SUBMITTALS ................................................................................................................. 9

3.1 DOCUMENTS TO BE SUBMITTED BY SELLER ...................................................................... 9

4.0 MATERIALS ................................................................................................................... 9

4.1 MATERIAL MANUFACTURERS .......................................................................................... 9

4.2 MACHINED-SURFACE COATINGS ..................................................................................... 9

4.3 ABRASIVE MATERIALS .................................................................................................... 9

4.4 THINNERS, SOLVENTS, AND CLEANERS .......................................................................... 10

4.5 TOUCH-UP MATERIALS ................................................................................................. 10

4.6 MATERIALS FOR USE OVER STAINLESS STEEL ............................................................... 10

5.0 MATERIALS SHIPPING, HANDLING, STORAGE & PROPER DISPOSAL ............... 10

5.1 DELIVERY AND STORAGE .............................................................................................. 10

5.2 DATE OF MATERIALS .................................................................................................... 10

5.3 HANDLING OF COATED ITEMS ........................................................................................ 11

6.0 EQUIPMENT ................................................................................................................ 11

7.0 SURFACE PREPARATION ......................................................................................... 11

7.1 GENERAL REQUIREMENTS ............................................................................................ 11

7.2 GALVANIZED STEEL ..................................................................................................... 12

8.0 MIXING AND APPLYING COATINGS ......................................................................... 13

9.0 INSPECTION AND TESTING ....................................................................................... 14

9.1 GENERAL REQUIREMENTS ............................................................................................ 14




24956-000-GFS-GEX-00001-000 Page 3 of 39

9.2 SURFACE PREPARATION INSPECTION ............................................................................ 14

9.3 COATING INSPECTION .................................................................................................. 15

9.4 DOCUMENTATION ......................................................................................................... 15

10.0 REMEDIAL WORK ....................................................................................................... 15

11.0 COATING SYSTEM SELECTION ................................................................................ 16

11.1 PAINTING OF "OFF THE SHELF" EQUIPMENT AND BULK ITEMS ............................................ 16

11.2 STRUCTURAL STEEL .................................................................................................... 16

11.3 PIPING AND VALVES ...................................................................................................... 17

11.4 COATING SYSTEM FOR UNDER INSULATION ..................................................................... 17

12.0 GALVANIZING ............................................................................................................. 17

12.1 ZINC COATING ............................................................................................................. 17

12.2 PROCESS AND PROCEDURES ........................................................................................ 17

12.3 POST GALVANIZING TREATMENT .................................................................................... 19

12.4 REMEDIAL ACTION ........................................................................................................ 19

12.5 IDENTIFICATION ........................................................................................................... 19

12.6 INSPECTION AND TESTING ............................................................................................. 19

Appendix A - Protective coating systems (Coating Schedule) 21

Table A1 Exposure and Paint System Code, Excerpts from 33.218.2 Table A2 Paint Systems, Excerpts from 33.218.2 Table A3 Added paint system for Fjarðaál Smelter Project

Appendix B - Color Scheme 36

Safety Colors Plant Color Scheme Appendix C - Standard Coating Data Sheet 37

Appendix D - Surface Preparation and Coating Inspection Form 38

Appendix E - List of Banned Substances 39




24956-000-GFS-GEX-00001-000 Page 4 of 39

1.0 GENERAL

This specification covers the minimum requirements for materials, surface preparation, application, and inspection of above ground, external protective coatings (paints and galvanizing). Internal tank linings, concrete secondary containment, pre-finished buildings, architectural coatings, and fireproofing coatings are not covered by this specification.

Appendix A contains guidelines for selecting the protective coating systems and Appendix B gives the color scheme.

Unless indicated otherwise in the material requisition (MR) or purchase order, all coats will be shop applied.

1.1 Item included

1.1.1 Preparation of the surfaces, furnishing and the application of protective coatings to all surfaces as defined in Appendix A.

1.1.2 Documentation of materials and procedures (including MSDS).

1.1.3 Inspections and tests

1.1.4 Protection of coated surfaces (including proper blocking, bracing, and padding to preclude damage during shipping and handling).

1.1.5 Environmental control equipment to provide the application and curing conditions required.

1.1.6 Erection marking - Marks for color-coding of bulk materials and erection marking shall be an inorganic coating (Buyer approved) fully compatible with the coating systems specified.

1.1.7 Touch-up and repair of defective or damaged coatings.

1.2 Surfaces not to be painted

1.2.1 Surfaces within 50-75 mm (two inches) of field welds, unless otherwise specified.

1.2.2 Name and instruction plates

1.2.3 Rubber or similar nonmetallic parts

1.2.4 Machined surfaces except as noted in section 4.2.

1.2.5 Structural Steel: All shop weld areas and shop bolted or riveted connections shall be blast cleaned to the same standard as adjacent steel.

1.2.6 Nonferrous metals.




24956-000-GFS-GEX-00001-000 Page 5 of 39

1.3 Exposures

The Fjarðaál Smelter site environment is classified as C4, per ISO12944 Paints & Varnishes – Corrosion Protection of Steel Structures by Protective Paint Systems. Average Relative humidity, temperature range and wind conditions are described in Document n° 24956-000-3DR-G01D-00001 Site Conditions.

Values for Fluorides, Sulfur Dioxides, Particulates, and Chlorides (coastal weather) averaged concentrations in the atmosphere surrounding the site and inside the plant, are estimated in Table 1.

Table 1 Indoor and outdoor contaminants

PARAMETER EXTERIOR

INTERIOR

Potroom Roof Cast House Pallet Storage

HF- 12 µg/ m3 Note 1 5 mg/ m3 5 mg/ m3 10 mg/ m3

SO2 7 µg/ m3 Note 1 3 mg/ m3 3 mg/ m3 3 mg/ m3

PMtot 1-5 µg/ m3 Note 1 - - -

Note 1 Values in the dispersion zones.

1.4 Safety and Environmental

1.4.1 All surface preparation, materials, and coatings work shall comply with all applicable environmental and safety provisions, laws, regulations, ordinances, etc., of the city, county, state, province, or nation pertaining to the work being performed and the coating materials being used.

1.4.2 Seller shall comply fully with OSHA Hazard Communication Standard 29 CFR 1910.1200 and 1926.59 or the applicable Icelandic code. Material Safety Data Sheets (MSDS) shall be available for review at the jobsite.

1.4.3 The volatile organic compound (VOC) content of all materials shall meet Federal, State, and Local Regulatory requirements. As a minimum, VOC compliance for the Fjarðaál Smelter Project is defined as less than 420 g/l (3.5 pounds/gallon).

1.4.4 Supplied materials shall meet Buyer's requirements in terms of banned substances. Seller will refer to Appendix F for the list of banned substances.

1.5 Quality Standards

1.5.1 Seller shall control the quality of items and services to meet the requirements of this specification, applicable codes and standards, and other procurement documents. Documentation shall be prepared and maintained to provide evidence of compliance with approved procedures and this specification. For shop-coated items, a copy of the




24956-000-GFS-GEX-00001-000 Page 6 of 39

Surface Preparation and Coatings Inspection Form (Appendix E, Documentation) shall be included with the shipping documentation.

1.5.2 Seller, including any lower-tier organizations engaged by him, shall be subject to surveillance inspection by Buyer’s inspector until completion or termination of the procurement. This surveillance inspection does not relieve Seller from the responsibility for conformance to the requirements of procurement documents and procedures.

1.5.3 Buyer’s inspection personnel shall be provided with a schedule and shall be notified of all required inspection points prior to the scheduled date for coating activities.

2.0 REFERENCES, APPLICABLE STANDARDS, CODES AND REGULATIONS

2.1 References

Document N° Title

24956-000-3DR-G01D-00001 Site Conditions 33.218.2 Alcoa Standard Practice for Painting – Paint Systems 18.21 Alcoa Standard Practice for Safety Color Code – Painting 35.2.7 Alcoa Specification for rust preventive coatings

2.2 Applicable standards

Standards and references provided herein, or in the item description, or in any reference document form a part of the requirements of this specification in the manner and to the extent specified. European Equivalents (EN) to standards listed below may be acceptable but are subject to Buyer's approval before commencement of work.

Unless otherwise specified, the latest edition or revision of these codes, standards, and specifications in force at the time of purchase shall apply.

2.2.1 Painting

Document N° Title

ASTM D 520 Standard Specification for Zinc Dust Pigment

ASTM D 4285 Indicating Oil or Water in Compressed Air

ASTM D 4417 Field Measurement of Surface Profile of Blast Cleaned Steel

ASTM E 337 Test for Relative Humidity by Wet-and-Dry-Bulb Psychrometer

ASTM D 1535 Standard Test Method for Specifying Color by the Munsell System

ASTM D 3359 Standard Test Method for Measuring Adhesion by Tape Test




24956-000-GFS-GEX-00001-000 Page 7 of 39

ISO 8501-1:1988 Preparation of Steel Substrates Before Application of Paints and Related Products – Visual Assessment of Surface Cleanliness

ISO 12944 Corrosion protection of steel structures by protective paint systems

OSHA 29CFR1910.144 Safety Color Code

OSHA 29CFR1910.1200 Hazard Communications Standard

OSHA 19CFR1926.59 Labeling of Hazardous Materials

SSPC AB 1 Abrasive Specification No. 1 Mineral and Slag Abrasives

SSPC AB 2 Cleanliness of recycled Ferrous Metallic Abrasives

SSPC AB 3 Newly Manufactured or Re-Manufactured Steel Abrasives

SSPC SP 1 Solvent Cleaning

SSPC SP 5 White Metal Blast Cleaning

SSPC SP 6 Commercial Blast Cleaning

SSPC SP 7 Brush-off Blast Cleaning

SSPC SP 10 Near White Blast Cleaning

SSPC SP 11 Power Tool Clean to Bare Metal

SSPC Vis 1-89 Visual Standards for Abrasive Blast Cleaned Steel

SSPC Vis 3 Visual Standard for Power and Hand Tool Cleaned Steel

SSPC PA 1 Shop, Field and Maintenance Painting

SSPC PA 2 Measurement of Dry Paint Thickness with Magnetic Gauges

SSPC Paint 20 Zinc-Rich Primers (Type I, “Inorganic,” and Type II, “Organic”)

SSPC Paint 36 Two-Component Weatherable Aliphatic Polyurethane Topcoat, Performance-Based.

2.2.2 Galvanizing

Document N° Title

AGA Recommended Details For Hot Dip Galvanized Structures-American Galvanizers Association

ASTM A 6 Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling.

ASTM A 53 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-coated, Welded and Seamless.

ASTM A 90 Standard Test Method for Weight (Mass) of Coating on Iron and Steel Articles with Zinc or Zinc-Alloy Coatings.




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ASTM A 123 Standard Specification for Zinc (Hot-Dipped Galvanized) Coatings on Iron and Steel Products.

ASTM A 143 Standard Practice for Safeguarding Against Embrittlement of Hot-Dipped Galvanized Structural Steel Products and Procedure for Detecting Embrittlement.

ASTM A 153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware.

ASTM A 384 Standard Practice for Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies.

ASTM A 385 Standard Practice for Providing High Quality Zinc Coatings (Hot-Dip).

ASTM A 563 Standard Specification for Carbon and Alloy Steel Nuts

ASTM A 653 Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM A 780 Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings.

ASTM B 6 Standard Specification for Zinc

ASTM B 695 Standard Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel.

ASTM E 376 Standard Practice for Measuring Coating Thickness by Magnetic Field or Eddy-Current (Electromagnetic) Test Methods.

NSF 61 Drinking Water System Components – Health Effects, National Sanitary Foundation.

2.3 Documents Conflicts

If conflicts occur between this specification, the paint manufacturer’s recommendations and the referenced standards, Buyer shall be contacted for clarification and approval.

2.4 Compliance with Icelandic Regulations

903/2002 Regulation on the use and banned use of certain chemicals in paint and wood preservative.




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3.0 SUBMITTALS

3.1 Documents to be submitted by Seller

3.1.1 When required by Purchase Order (Section 3), Seller shall provide a listing of the coating systems and material to be used on each item, component, or piece of equipment. The listing shall identify the specific products by manufacturer and catalog number. This information shall be submitted for Buyer's review and permission to proceed. The "Standard Coating Data Sheet" included in Appendix C shall be used for this purpose.

3.1.2 When required by Purchase Order (Section 3), Seller shall provide written procedures for storage, handling, surface preparation, environmental control, application, touch-up and repair, curing, and inspection for review and permission to proceed prior to use, for the specified coating systems. The Coating Manufacturer's latest published product data sheets and application instructions shall be attached to the procedure. Conflicts, if any, between the coating manufacturer's recommendations and this specification shall be noted in writing to Buyer for resolution.

3.1.3 Seller's proposed "Surface Preparation and Coatings Inspection Form" (Appendix D) shall be submitted for review if the format or content is different than Appendix E. A completed inspection form shall be submitted for items coated. When multiple components are coated during one shift, a single form may be submitted which covers all components.

4.0 MATERIALS

4.1 Material Manufacturers

Unless otherwise specified, all coating material shall be as specified by Buyer in Appendix "A". Materials from other manufacturers shall not be used without written acceptance from Buyer.

4.2 Machined-Surface Coatings

Machined surfaces not specified to be coated with a specific coating system shall be protected with a solvent cutback temporary preservative, in accordance with Alcoa Specification for Rust Preventative Coatings (N° 35.2.7). Product shall not contain banned chemicals listed in Appendix E.

4.3 Abrasive Materials

Abrasives for blast cleaning shall be clean, free of oil or contaminants, and dry. The particle size shall be capable of producing the specified surface profile. Mineral and slag abrasives shall meet the requirements of SSPC-AB 1. Steel abrasives shall meet the requirements of SSPC-AB 3.




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4.4 Thinners, Solvents, and Cleaners

Thinners, solvents, and cleaners shall be as manufactured or recommended in writing by the coating material manufacturer and shall be identified on the Standard Coating Data Sheet (Appendix C) by the product number or generic formulation.

4.5 Touch-Up Materials

Materials for touch-up of damaged areas shall be the same as those originally applied. Touch-up materials shall be in pre-measured units, and only complete kits shall be mixed.

4.6 Materials for Use Over Stainless Steel

The thinners, solvents, cleaning materials, and coatings, which are to be used in direct contact with austenitic stainless steels, shall meet the following requirements:

� The inorganic halogen content shall be less than 200 ppm by weight.

� The total halogen (inorganic and organic) content shall be less than 1 percent by weight. The sulfur content shall not exceed 1 percent by weight.

� Low melting point metals (lead, bismuth, zinc, mercury, antimony, cadmium, and tin) shall not be intentionally added to the coating material. This includes inorganic zinc and zinc rich epoxy coatings.

5.0 MATERIALS SHIPPING, HANDLING, STORAGE & PROPER DISPOSAL

5.1 Delivery and Storage

5.1.1 Coating materials shall be delivered to the place of application in the manufacturer's unopened, original containers bearing a legible product designation, batch number, and date of manufacture. Damaged containers shall not be used.

5.1.2 The coating material shall be handled and stored in accordance with the manufacturer's latest published instructions and shall be protected from damage, moisture, direct sunlight, and temperatures below 5°C (40°F) or above 32°C (90°F).

5.2 Date of Materials

� The coating materials shall be used within the manufacturer's published shelf life.

� Containers of coatings or components shall not be opened unless for immediate use.




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5.3 Handling of Coated Items

� Coated items shall be protected on non-abrasive supports during storage and shipment.

� Coated surfaces shall be protected from damage during lifting, handling, and shipment until accepted by Buyer at the designated destination.

6.0 EQUIPMENT

6.1.1 Seller shall provide equipment capable of regulating and controlling the specified environmental conditions within the work area, to perform the work according to the production schedule accepted by Buyer.

6.1.2 Application equipment shall be equivalent to the equipment recommended by the coating's manufacturer and shall be suitable to apply the coating as specified.

6.1.3 Equipment air supply lines shall be equipped with filters or traps to remove moisture and oil as close to the point of application as possible. These traps shall be in addition to the oil and water extractors mounted on the compressor.

7.0 SURFACE PREPARATION

7.1 General Requirements

7.1.1 Prior to the start of work, Seller shall examine all surfaces to be coated to determine their acceptability for the specified work. If the surfaces are found to be unacceptable, Seller shall either return the surface to an acceptable condition or immediately notify Buyer in writing if the repairs are outside his scope of work. Work shall not commence until corrective action has been taken. Commencement of work prior to the taking of corrective action shall preclude any subsequent claim by Seller. Buyer may require corrective action at Seller's expense.

7.1.2 All water shall be removed from the surface prior to beginning surface preparation. The steel surface temperature shall be at least 3° C (5° F) above the dew point, and, at all times, meet the paint manufacturer 's requirements.

7.1.3 Prior to blast cleaning, solvent cleaning in accordance with SSPC-SP 1 shall remove oil, grease, and heavy dirt.

7.1.4 Surfaces to be coated shall be initially abrasive blast cleaned in accordance with the surface preparation requirements specified in Appendix A. Where abrasive blasting is impractical, SSPC-SP 11 Power Tool Clean to Bare Metal may be substituted only in limited areas and only with Buyer's written approval.

7.1.5 The surface profile of the steel cleaned by blasting shall be as specified by the coating manufacturer.




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7.1.6 Blast cleaning shall not be performed in the immediate area where coating or curing of coated surfaces is in progress. All surfaces and equipment, which are not to be coated, shall be suitably protected from blast cleaning.

7.1.7 Burrs, slivers, scabs, laminations, cracks, deep pitting, and weld spatter which become visible after blasting shall be removed. Tight weld spatter will not be removed by blasting but must be removed before painting.

7.1.8 If visible rusting occurs or if the cleaned surfaces becomes wet or otherwise contaminated, these surfaces shall be re-cleaned to the degree specified. Blast cleaned surfaces shall be over coated within four hours of the start of cleaning, and the steel shall not be exposed outdoors during this period.

7.1.9 After blast cleaning and immediately before coating, dust shall be removed with compressed air, free of oil and moisture. Vacuuming shall be used if the surface cannot be made dust free using compressed air, as determined by Buyer's inspector.

7.1.10 Machined surfaces shall be wiped with clean solvent before the application of machined-surface coating (see 4.2) and shall be protected from damage due to cleaning and coating operations.

7.1.11 Machined portions of pipe flanges and other machined mating faces which will not be exposed after final fit-up shall be masked and covered with plywood or otherwise protected from surface preparation and coating activities. The remaining part of the flange face (including bolt holes) and exposed surface shall then be blasted and coated.

7.1.12 Equipment shall have all openings plugged, masked, and/or blinded sufficiently to protect internals before abrasive blasting. After the coating operation is complete, all internals shall be blown clean or vacuumed to remove any dust or abrasive blast media that may have entered the coated equipment.

7.1.13 The abrasive mixture and the compressed air shall be clean, dry, and oil-free.

7.2 Galvanized Steel

7.2.1 Where galvanized steel is to be coated with a Coating System, the surface shall be cleaned per the coating manufacturer’s written recommendation. As a minimum, the surface shall be cleaned per SSPC-SP 1, Solvent Cleaning, and allowed to dry.

7.2.2 Damaged hot-dip galvanized steel shall be repaired as follows - Clean the damaged area per SSPC-SP 3. Touch-up with a high zinc dust content coating in accordance with the paint manufacturer's instruction.




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8.0 MIXING AND APPLYING COATINGS

8.1 Mixing, applying, and curing of the coating material shall be in accordance with the manufacturer's latest published instruction, SSPC-PA 1, “Shop, Field and Maintenance Painting”, and the requirements specified herein. When multiple component units are mixed, each component shall be mixed separately prior to the mixing of the combined materials. Only complete kits shall be mixed; no partial kits will be allowed at any time.

8.2 Coating materials shall be thoroughly mixed until they are smooth and free from lumps, and then strained through a 30-mesh screen or finer. Material shall be agitated to keep the solids in suspension. Inorganic zinc coatings must be mechanically agitated at all times.

8.3 The cleaned surface shall be coated before any visible rust forms on the surface. Coating material shall not be applied when there is moisture on the surface, dust is present, which can contaminate the freshly coated surface, or when dirt or other detrimental material has re-contaminated the surface. Blast cleaned surfaces shall be over coated within four hours of the start of cleaning, and the steel shall not be exposed outdoors during this period.

No coating material shall be applied closer than 150 mm (6 inches) from adjacent non-cleaned surfaces.

8.4 The application of the coating shall be performed only when the steel surface is at least 3° C (5° F) above the dew point, and, at all times, shall meet the paint manufacturer 's requirements. Except for solvent-based ethyl silicate inorganic zinc, the relative humidity shall not exceed 85 percent, or any specific requirement from the paint manufacturer- during coating application and cure. For solvent-based inorganic zinc, the humidity shall not exceed 95 percent and shall meet the paint manufacturer's requirement. If the humidity falls below 50%, the cure of solvent based inorganic zinc primer will be inhibited. The cure time shall be extended, or the manufacturer's written procedure for cure shall be followed. Both ambient and surface temperature shall be in accordance with the manufacturer’s written requirements.

8.5 Over-coats/topcoats shall be applied within the manufacturer's minimum and maximum recoat times. Dry film thickness of each coating shall be in accordance with Appendix A. Each coat within a coating system shall be of contrasting color or shade to facilitate application.

8.6 Where possible, defects such as runs, sags, drips, and voids shall be corrected as detected during application of the coating. Loss of adhesion, blistering, peeling, mud cracking, inadequate cure, or rusting of the substrate shall be reworked.

8.7 Coating shall be applied using clean equipment. Surfaces which may become inaccessible shall be coated before assembly, tagging, fitting, or welding. Inaccessible surfaces may include lap joint flanges, nozzle necks, lap joint stub ends, lap rings, bolt holes, flanges for exchangers and vessels, and welded joints which may become inaccessible after assembly.




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9.0 INSPECTION AND TESTING

9.1 General Requirements

9.1.1 The following steps are subject to inspection by Buyer's representative:

� Following surface preparation and immediately prior to the coating application

� Following the application and curing of each coat

� Final inspection and sign-off, in accordance with the project requirements

9.1.2 Seller shall furnish the necessary testing and inspection instruments, properly calibrated and maintained. Such equipment shall be available for use by Buyer in conducting surveillance of the work.

9.1.3 Prior to using compressed air, the quality of the air downstream of the separator shall be tested in accordance with ASTM D 4285. The test shall be performed at the beginning of each shift and at approximately four-hour intervals. The test also shall be made after any interruption of the air compressor operation or as required by Buyer. The air shall be used only if the blotter test indicates no visible contamination, oil, or moisture. If contaminants are evident, the equipment deficiencies shall be corrected and the air stream shall be retested. Separators shall be bled continuously. All lines shall be tested individually prior to use. Surfaces which are determined to have been blasted, blown down, or applied using contaminated air shall be re-cleaned to remove oil, grease, and contaminants and new coatings applied using clean air.

9.1.4 Prior to surface preparation and coating application, dew point and relative humidity shall be determined using a sling Psychrometer or an accepted equivalent in accordance with ASTM E337. Readings are required approximately every four hours, or at other time intervals approved in writing by Buyer. Alternatively, continuous monitoring may be performed using systems established and/or accepted by Buyer. The work shall not proceed if the ambient temperature or relative humidity is outside the requirements of this specification or the paint manufacturer's data sheet.

9.2 Surface Preparation Inspection

9.2.1 Blast cleaned surfaces shall be compared with SSPC VIS 1-89, Visual Standards. Power tool cleaned surfaces shall be compared to SSPC VIS 3. The anchor pattern profile depth shall be verified in accordance with ASTM D4417.( Press-O-Film tape, Keane Tator Profile Comparator, Clemtec Anchor Profile Chips, or other Buyer approved methods).

9.2.2 Recirculated shot and grit used for abrasive cleaning shall meet the requirements of SSPC-AB 2, “Cleanliness of Recycled Ferrous Metallic Abrasives.” The test shall be performed at the beginning of each shift and at approximately four-hour intervals. If the test results are not satisfactory, all steel blasted since the last satisfactory test shall be re-blasted.




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9.3 Coating Inspection

9.3.1 Dry film thickness shall be verified in accordance with SSPC-PA 2. The Average Dry Film Thickness shall be in strict accordance with SSPC PA2, especially sections 5.2.1 and 5.2.2.

9.3.2 Coating shall be visually inspected for defects such as overspray, runs, sags, voids, blistering, peeling, rusting, mud cracking, inadequate cure, and lack of adhesion. Mud cracking must be removed by reblasting. Seller shall repair all defects according to Buyer approved touch-up and repair procedures. Areas where defective coatings have been repaired or replaced shall be re-inspected to the original requirements.

9.4 Documentation

Surface preparation and coating inspection shall be documented using the accepted Surface Preparation and Coating Inspection Form (Appendix D) or approved equivalent.

10.0 REMEDIAL WORK

10.1 Coated surfaces that are damaged during assembly, handling, or shipment shall be repaired in accordance with procedures approved by Buyer.

10.2 The surface profile shall be restored to meet the specified surface preparation requirements for cleanliness and profile. The periphery of a damaged area shall be feathered prior to coating application.

10.3 Precautions shall be taken to protect adjacent coated areas from damage caused by local abrasive blasting.

10.4 Power tool cleaning shall be done per the requirements of SSPC-SP 11.

10.5 For Tie-ins between existing and new equipment and existing coatings on connecting weld areas or flanges coatings shall be touched-up to the requirements of this specification.

10.6 Where shop coating has been damaged in transit, all damaged and loosely adhering coating shall be removed and the surface thoroughly cleaned. Edges of the breaks shall be feathered and the designated number of prime and finish coats applied. Applied coating (s) shall be as per original coating system, color and gloss.

10.7 Items shall be coated in accordance with Appendix A. Damaged coats shall be retouched before succeeding coats are applied. Finish colors shall be in accordance with Appendix B.

10.8 After assembly of parts, weld seams and other surfaces where primer to topcoats or both have been damaged or omitted shall be prepared and recoated in accordance with this specification.

10.9 Structural steel joints shall be painted with the specified materials to give the standard of protection achieved on adjacent steel. Stripe coats shall be used, particularly to seal all edges of steel and gaps between adjacent steel surfaces.




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11.0 COATING SYSTEM SELECTION

Responsible engineer, as indicated in the technical specification and/or Data sheet, and/or Material Requisition, is responsible for selecting the proper paint system. In case of conflicting requirements, Seller will confirm with the responsible engineer which coating is to be selected. As per 3.1 of this specification, Seller is to provide a listing of the coating systems and material to be used on each item, component, or piece of equipment for Buyer's review and permission to proceed.

Appendix A contains guidelines for coating system selection. Appendix A is, for the most part, extracted from Alcoa Standard 33.218.2 Standard Practice for Painting – Paint Systems. Detailed descriptions of paint systems are found in Appendix A as well as some precisions concerning coating selection.

11.1 Painting of "off the shelf" equipment and bulk items

"Off the shelf", or bulk items, are components and equipment which are normally mass-produced, inventoried, and supplied from stock. Included are valves, pumps, rotating equipment, filters, and electrical equipment to include indoor switchgear, control panels, motors, transformers and electrical enclosures. For the purpose of this specification, pipes are not considered bulk items.

Unless otherwise stated in the equipment data sheet or in the Material Requisition or Purchase Order, coating materials selected for use shall be “Manufacturer’s Standard” suitable for providing component corrosion protection in the plant environment, as defined in the project design documents, for at least five years, with no more than 0.3 percent failure (ASTM D 610 Rust Grade 7).

As a minimum, the coating system for valves shall consist of the required surface preparation and one coat of primer. Primer shall be compatible with epoxy finish coats. All other rotating equipment and electrical items shall be primed, coated with an intermediate coat and finish coated with a topcoat. When specified, finish coat color shall meet project requirements.

Seller is to provide details of its "Manufacturer's Standard" paint system for "off the shelf" and bulks items for review and approval by the Buyer during the bid stage.

Seller shall control the quality of items and services to meet the requirements of this specification.

11.2 Structural Steel

11.2.1 Concrete and cementitious fireproofing materials may be applied directly over galvanizing. If the steel is subjected to extremely wet conditions, it may be necessary to apply a single coat of epoxy over the zinc coating. Compatibility of proprietary epoxy




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and acrylic Intumescent fireproof coatings must be verified prior to use. Oil based coatings and alkyds should never be used in conjunction with cementitious fireproofing materials due to potential of saponification of the coating.

11.2.2 Galvanizing is not allowed on high strength steels to be used at temperatures over 246°C (475°F ).

11.2.3 Paint System to be adopted will be specified in the Material Requisition (Section 1), or as noted on engineering drawings. Paints systems are described in Appendix A, in relation to exposures.

11.3 Piping and valves

Refer to Appendix A.

11.4 Coating system for under insulation

Refer to Appendix A.

12.0 GALVANIZING

This section covers the minimum requirements for hot dip galvanizing of structural steel, fasteners, piping components, grating and miscellaneous hardware items, whenever required by technical specification or purchase order. Galvanized steel shall not be used inside process areas 300, 400, 500.

12.1 Zinc Coating

12.1.1 Zinc metal for hot dip galvanizing shall be in accordance with ASTM B 6, all grades.

12.1.2Pipe, pipe fittings, pipe handrails and fabricated pipe spools shall be hot dip galvanized in accordance with ASTM A 53 or A 123 whichever is applicable.

12.1.3 Structural shapes, plates, sheet, bars and fabricated assemblies shall be hot dip galvanized in accordance with ASTM A 123 or A 653, whichever is applicable.

12.1.4 Hardware, fasteners, threaded components and miscellaneous items shall be hot dip galvanized in accordance with ASTM A 153.

12.1.5 As an alternative to ASTM A 153, threaded components may be mechanically galvanized per ASTM B 695, Class 50 or higher.

12.2 Process and procedures

12.2.1 Prior to hot dip galvanizing, all items shall be inspected to ensure that no unvented, closed or blind sections exist in any assembly, that all vent and drain holes are free of burrs and projecting roughness, and that all welding residue is completely removed. Vent and drain holes should be a minimum of 10 mm (3/8") diameter and located at natural drainage




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points, such as at bottom of handrails, near ports, etc. Holes shall not be cut without prior approval.

12.2.2 Assemblies to be galvanized shall be properly fabricated, as recommended in the Standard Practice For Providing High Quality Zinc Coatings (Hot Dip) ASTM A 385 and the Standard Specification for Zinc (Hot Dip) Coating on Iron and Steel Products ASTM A123. Items that are improperly designed or fabricated shall be brought to the attention of the Buyer, in writing, for resolution.

12.2.3 In addition to required structural welding, all mating and/or faying surfaces shall be seal welded to prevent entrapment of the pickling fluid used in the cleaning process.

12.2.4 Punched or drilled boltholes shall be larger than the bolt by 2 mm (1/16 inch).

12.2.5 Hot dip galvanized nuts shall be tapped oversize in accordance with ASTM A 563 except that the maximum over tapping shall not exceed 25 percent of minimum over tapping. Mechanically galvanized nuts may be tapped oversize before galvanizing. Over tapping before mechanical galvanizing shall result in a diametrical increase by a minimum of 8t and a maximum of 10t, where t is the minimum zinc layer thickness specified. Hot dip or mechanically galvanized nuts shall be lubricated in accordance with ASTM A 563.

12.2.6Cold working, including cold forming and cold bending of steel before hot dip galvanizing, shall conform to the requirements of ASTM A143 to mitigate embrittlement. For materials with thicknesses 13 mm (1/2 inch) or greater, drilled and punched holes shall be enlarged by reaming to remove a minimum of 3 mm (1/8 inch) of metal all around. Paragraphs 5.1 and 5.2 of ASTM A123 contain additional guidelines.

12.2.7 Pre-surface preparation prior to pickling shall consist of removal of all oil, grease, paint, residue, scale, welding slag, foreign matter and heavy rust. Final cleaning prior to galvanizing shall be done by pickling. After pickling, surfaces shall be thoroughly rinsed with clean water. Blast cleaning may be substituted in lieu of pickling. In such cases, surfaces shall be blast cleaned to "Near White" condition, as per SSPC-SP 10.

12.2.8 The wet flux method shall not be used for hollow items, or surfaces which are difficult to flux inside and outside completely prior to hot dip galvanizing.

12.2.9 To prevent warpage and distortion, the provisions of ASTM A 384 shall govern.

12.2.10To prevent material embrittlement, the provisions of ASTM A 143 shall govern.

12.2.11Material specified to be galvanized shall be hot dip galvanized after fabrication on the same day the surface is sandblasted or pickled. Galvanizing shall occur before assembly by bolting.

12.2.12Hot dip galvanized items shall be stored in such a way as to provide air circulation to all surfaces. Flat surfaces shall be separated so that no condensation film forms and remains in the crevice between stored items.




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12.3 Post galvanizing treatment

12.3.1 Straightening: Structural sections and their major components warped during the galvanizing process shall be straightened to the tolerances of ASTM A6. Warped plates shall be pressed flat.

12.3.2 Re-drilling and re-tapping: All blind holes and threaded openings shall be drilled, re-tapped, or both, after hot dip galvanizing. Male threads may be recut after hot dip galvanizing, provided the minimum thread dimensions plus the specified zinc layer thickness can be maintained.

12.4 Remedial action

12.4.1 Damage to galvanized surfaces shall be repaired using one of the following two methods, as per ASTM A 780:

a) Abrasive blast clean damaged area to SSPC-SP 6, "Commercial Blast" (SSPC-SP 2 or SP 3 may be used for field repair). Sand or wire screen intact galvanized surfaces to a feather edge. Spray one coat of gray organic zinc, Ameron 68HS, Carboline 859, or Interzinc 52 to a minimum dry film thickness of 60 microns (2.5 mils).

b) Clean damaged area, solvent wipe (SSPC-SP 1), and repair, using low melt zinc alloy stick, in accordance with manufacturers' recommended procedure.

12.5 Identification

The identification mark number of each member shall be stamped in characters at least 13 mm (1/2 inch) high on a metal washer or tag wired to one end of the member with No. 9 annealed wire. This marking shall be legible after galvanizing. Alternate techniques require Buyer approval.

12.6 Inspection and testing

12.6.1 Buyer reserves the right to inspect any item at any stage of the hot dip galvanizing process.

12.6.2 Weight of the zinc coating shall be determined by ASTM A 90. Alternatively, the galvanized item may be inspected in accordance with ASTM E 376 to verify the thickness requirements of ASTM A 123. Items not meeting the required zinc weight, as specified in the appropriate ASTM standards, shall be rejected. Uniformity of the coating shall be determined and documented by visual inspection and magnetic thickness reading.

12.6.3 Warped and excessively distorted items which cannot be straightened shall be rejected. Materials that have been determined to be embrittled shall also be rejected.

12.6.4 All surface preparation, galvanizing, visual appearance, zinc layer thickness determinations, and other testing, shall be subject to inspection for conformance with applicable specification requirements. Zinc coatings shall have a visual appearance and finish which comply with ASTM A53, A123, A153, and B695, as appropriate.




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Exhibits, Appendix and Attachments

Appendix A - Protective coating systems (Coating Schedule)

Appendix B - Color Scheme

Appendix C - Standard Coating Data Sheet

Appendix D - Surface Preparation and Coating Inspection Form

Appendix E - List of Banned Substances




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APPENDIX A

PROTECTIVE COATING SYSTEMS (COATING SCHEDULE)

Table A1 lists Alcoa' Standard Paint Systems in relation to exposure as per Standard Practice for Painting – Paint Systems, n° 33.218.2.

Table A2 complements Table B1 and is extracted from same standard. It describes paint systems listed in Table B1 in terms of surface preparation, number of layers to be applied and minimum DFT. Seller shall ensure Manufacturer's Data Sheets do concur with listed instructions. If conflicts occur between this specification, the paint manufacturer’s recommendations and the referenced standards, Seller will contact Buyer for clarification and approval.

Table A3 are added Paint Systems to reflect special concerns on the Fjarðaál Smelter Project.

Table A1 Exposure and Paint System Code, Excerpts from 33.218.2

Exposures/ Type of equipment

Paint System Code Current Coating Materials VOC

(less than 3.5 lb/gal) Systems shown are not in

recommended order, just numerical order.

I. EXTERIOR EXPOSURES

A. Structural Steel & Exterior of Tank Shells

1) Weather Only – Exposure to sunlight and weather, non coastal mild industrial atmosphere.

V6 (E/E/U)

2) Humid Weather – Exposure to sunlight and weather in high humidity, non coastal, mild industrial atmosphere.

V6 (E/E/U)

3) Coastal Weather – Exposure to sunlight and weather for dock and port structures, salt water splash and salt laden air prevalent.

V6 (E/E/U)

4)

Caustic – Exposure to sunlight and weather where caustic splash or fumes are prevalent. Majority of refining plants, including alumina handling areas where aluminum accumulates or there is abrasion from alumina.

V6 (E/E/U)

5) Caustic, Protected – Areas protected from weather, subjected to heavy splash and caustic builds up on surfaces. Steel remains smooth and black when scraped (caustic pacification).

No Paint




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6) Potroom Fumes – Exposure to sunlight and weather where potroom fumes are prevalent, potroom monitors, conveyor galleries and storage tanks near potrooms.

V6 (E/E/U)

7) Chlorine and Chlorides – Exposure to sunlight and weather where chlorine gas, fumes, or aluminum and magnesium chlorides are prevalent.

V6 (E/E/U)

8) Coal and Coke – Exteriors of coal and coke hoppers, dumpers, etc., where sulfur containing coal and coke dust accumulate and can become moist, forming acids of sulfur.

V12 (CT/CT)

9) Hydrochloric/Sulfuric/Hydrofluoric Acid – Exposure to sunlight and weather where possibility of acid splash exists or severe exposure to acid fumes. Not for immersion service.

V6 (E/E/U)

10) Sheet Piling and Bearing Piles – Substrate exposure, on dock structures below high waterline and in splash zone.

V12 (CT/CT)

11) Soil – Subsurface exposure in non aggressive soils or where long-term corrosion is acceptable.

V13 (BU/BU)

12)

Soil – Subsurface exposure in aggressive soils or where long-term corrosion is unacceptable. (Bulk storage tanks on grade where cone bottom is formed inside steel shell, unless oil will be dry and non-aggressive)

V12 (CT/CT)

13) Underside of Flat-Bottom Field Welded Tank. No Paint

14) Flat-Bottom Insulated Tanks – Lower one foot of vertical shell and exposed portion of bottom plates. Insulated portions of tank may require primer.

V2 (Z) V3 (Z/E)

B. Cranes

1) Weather and Humid Weather – Normal exposure to sunlight and weather in high humidity, non coastal, industrial atmospheres. V6 (E/E/U)

2) Weather and Humid Weather, Aggressive – Exposure to sunlight and weather, high humidity, coastal or aggressive industrial atmospheres.

V6 (E/E/U)

C. Stacks, Ducts, Breechings

1)

Heat 200-500°F – Exposure to sunlight and weather, 200-500°F (90-260°C) surface temperature, industrial atmosphere. Interiors Exposed to Oil: Mechanical Engineering will determine if an oil resistant coating is necessary in interior spaces of equipment.

F3

2)

Heat 500-1000°F – Exposure to sunlight and weather, 500-1000°F (260-540°C) surface temperature, non aggressive to mild chlorine industrial atmosphere. Machinery Interiors Exposed to Oil: Mechanical Engineering will determine if an oil resistant coating is necessary in interior spaces of equipment.

F3




24956-000-GFS-GEX-00001-000 Page 23 of 39

D. Machinery

Small items (pumps, motors, etc.) are purchased with manufacturer’s standard paint. Field painting may, or may not, be performed depending on desired protection and aesthetics. For large items, or for very aggressive environments, it may be economical to specify, or bid option for, system consistent with exposures described above. Systems specified below assume manufacturer’s standard paint has been applied.

1) Non-aggressive V21 (A)

2) Aggressive – Exposure to acid, phosphate ester hydraulic fluid, caustic splash or to severe atmosphere. V19

E. Miscellaneous (Alcoa Red and Alcoa Blue) with sunlight

or industrial atmosphere V32

II. INTERIOR EXPOSURES

A. Structural Steel & Exterior of Tank Shells

1) Non-aggressive, Dry – Typical interior exposure in heated fabricating buildings, non-acid, non caustic atmosphere. V38 (EM)

2) Aggressive, Dry – Partially open buildings, normally dry due to process heat, possible periodic shutdown of process heat source (potrooms and carbon baking buildings)

V5 (E/E)

3) Non aggressive, Humid – Interior exposure in heated or unheated buildings where process produces very humid, nonacid, non-caustic atmosphere.

V5 (E/E)

4) Caustic, Humid – Interior exposure in heated or unheated buildings where process produces very humid, caustic laden atmosphere.

V5 (E/E)

5)

Severe Caustic, Steam – Interior exposure in buildings where excessive caustic laden steam released by process produces severely humid, caustic atmosphere condensing on a structural steel (filter press buildings, precipitator headhouses).

V31 (FLK-CT) (3 Coats)

6) Chlorine, Dry – Interior exposure to mild chlorine fumes in dry, heated buildings. Casting buildings where chlorine is used in fluxing.

V22 (A/AM)

7) Hydrochloric/Sulfuric/Hydrofluoric Acid – Interior exposure to severe acid fumes or possibility of acid splash exists. Not for immersion service.

V5 (E/E)

B. Cranes




24956-000-GFS-GEX-00001-000 Page 24 of 39

1) Non aggressive, Dry – Typical exposure in heated fabricating buildings.

V24 (A/E) (Yellow)

2) Aggressive, Dry – Partially open buildings, normally dry due to process heat with sulfur or fluoride atmosphere (potrooms and carbon baking buildings).

V5 (E/E) (Yellow)

3) Humid, Aggressive or Non aggressive – Exposure in buildings with aggressive or non aggressive atmospheres where process produces humid atmosphere.

V5 (E/E) (Yellow)

C. Furnaces, Ducts, Breechings

1)

Heat 200-500°F – Exposure to 200-500°F (90-260°C) surface temperature, non-aggressive atmosphere. Machinery Interiors Exposed to Oil: Mechanical Engineering will determine if an oil resistant coating is necessary in interior spaces of equipment.

V14 or 14 (HTI)1 1 Note: The allowable VOC Limit for high temperature coatings, may be higher than 3.5.

2)

Heat 200-800°F (90-430°C), 1000°F (540°C) peak surface temperature, non-aggressive atmosphere. Machinery Interiors Exposed to Oil: Mechanical Engineering will determine if an oil resistant coating is necessary in interior spaces of equipment.

Use system 17 (Sz/HT4)1 Use Note: 1

3)

Heat 500-1000F – Exposure to 500-1000 °F (260-650°C) surface temperature, non-aggressive atmosphere. Machinery Interiors Exposed to Oil: Mechanical Engineering will determine if an oil resistant coating is necessary in interior spaces of equipment.

Use system 15 (HT3)1 16 (wt3/wt3)1 17 (Sz/HT4)* * Continuous <800°F. 1 NOTE – The allowable VOC limit for high temperature coatings may be higher than 3.5.

D. Miscellaneous

1) Lubricating Oil – Exposure to petroleum based lubricating or hydraulic oil, not immersion. V2 (Z)

2) Phosphate Ester Hydraulic Fluid – Not immersion. V19

3) Damp Surfaces – Valve pits, Penstocks, etc. V42

4) Alcoa Red and Alcoa Blue V32

5) Traffic Marking V26

E. Machinery

Machinery – Small items (pumps, motor, etc.) are purchased with manufacturer’s standard paint. Field painting may or may not be performed depending on desired protection and aesthetics. For large items or for very aggressive environments, it may be economical to specify (option bid) a system consistent with exposures described above. Systems specified below assume manufacturer’s standard paint has been applied.




24956-000-GFS-GEX-00001-000 Page 25 of 39

1) Non aggressive V38(EM)

2) Aggressive – Exposure to acid or caustic splash or to severe atmosphere. V5 (E/E)

F. Tank Interiors (Immersion in Liquid)

1) Non potable water, Brackish Water Ambient Temperature. Not for salt water concentrations similar to or greater than sea water. V8 (E/E/E)

2) Brine, Concentrated Salt, Ambient Temperature V12 (CT/CT)

3) Potable Water V8 (E/E/E)

4) Transformer Oil Use 25

5) Make-Up Water, to 250°F (120°C) V10 (ME/ME)

6) Condensate or Deionized Water to 250°F (120°C) V10 (ME/ME)

7) Distilled, Fresh, Salt, or Sea Water to 200°F (93°C) V9 (PE/PE)

8) Crude Oil – Paint tank bottom and 1 ft. up tank wall. V8 (E/E/E) V12 (CT/CT)

9) Air Receivers See Note 6

10) Mineral Spirits V2 (Z)

III. NONFERROUS METALS

A. Aluminum

1) Interior or Exterior, Non aggressive – Exposure in nonacid, non caustic atmospheres. (For aluminum in contact with masonry or concrete see below)

No Paint

2) Interior, Aggressive – Exposure in acid or caustic atmospheres, or splash conditions. (Use yellow on cranes)

V33 (E/E/E)

3) Exterior, Aggressive – Exposure in acid or caustic atmospheres, or splash conditions. (Use yellow on cranes)

V11 (E/E/U)

B. Galvanized Steel

1) Interior V5 (E/E)

2) Exterior V6 (E/E/U)




24956-000-GFS-GEX-00001-000 Page 26 of 39

Notes for paint system selection

1. Insulated items operating above 250 °F (121°C) do not require coating except nozzles, clips, and flanges, which shall be coated as if un-insulated. Their surface preparation and coating should extend at least six inches onto the adjacent area.

2. Flange surfaces (except gasket surfaces) & bolt holes shall be cleaned and coated the same as the adjacent component.

3. Fireproofed areas are to be treated the same as structural steel.

4. Normal no flow (NNF) conditions for lines associated with relief conditions shall be coated per the highest normal operating condition, not the relief condition. NNF associated with venting to flare shall be coated with the coating system specified for the highest temperature the line will be exposed to during venting or the highest normal operating condition.

5. Refractory lined items such as heaters and stacks shall be coated in accordance with calculated cold face temperatures.

6. Aluminum in contact with concrete, masonry or plaster: The type of coating used on aluminum which is in contact with masonry will depend on how objectionable staining of the masonry will be to the overall appearance and protection of the surfaces. A bituminous paint can be used if staining is not objectionable. Staining may occur following the silicone waterproofing of a masonry surface because the solvent in the waterproofing material will dissolve any of the bituminous paint with which it comes in contact. When staining of a masonry, concrete or plaster is objectionable; any aluminum in contact with the masonry (sash, door frames, lath, etc.), should be coated with a clear methacrylate lacquer. The lacquer must be spray applied in multiple coats to a dry film thickness of at least 0.6 mil (15 micron). An acceptable lacquer is "Clear Lacquer No. 1234" (manufactured by Dupont). Aluminum embedded in concrete ordinarily need not be painted where used as conduit, anchor bolts, hatch frames and pipe posts.

7. Seller have to use a First coat compatible with Galvanizing.




24956-000-GFS-GEX-00001-000 Page 27 of 39

Table A2 Paint Systems, Excerpts from 33.218.2

SYSTEM CODE MANUFAC-

TURER

SURFACE PREPA-RATION

1st

COAT

DFT (mils)

2nd

COAT

DFT (mils)

3rd

COAT

DFT (mils) NOTES

V1

Sherwin Williams

SP-6

Zinc Clad III HS**

3.0 – 4.0

International Interzinc 52

3.0 – 4.0

Carboline Carboline 859

3.0 – 4.0

V2

Sherwin Williams

SP-10

Zinc Clad II HS*

3.0 – 4.0

International Interzinc 22 HS

3.0 – 4.0

Carboline CZ 11 HS

3.0 – 4.0

V3

Sherwin Williams

SP-10

Zinc Clad II HS

3.0 – 4.0

B58-600/B58V600

3.0 – 6.0


3.0 – 4.0

Interseal 670 HS

3.0 – 6.0

Carboline CZ 11 HS

3.0 – 4.0

890

3.0 – 6.0

V4

Sherwin Williams

SP-10

Zinc Clad II HS

3.0 – 4.0

Macropoxy 646

4.0 – 6.0

Acrolon 218 HS

1.5 – 2.5


3.0 – 4.0

Interseal 670 HS

3.0 – 6.0

Interthane 990 HS

1.5 – 2.5

Carboline CZ 11 HS

3.0 – 4.0

890

3.0 – 6.0

134 HG

1.5 – 2.5

V5

Sherwin Williams

SP-6

Epolon II Rust Inhibitor

2.0 – 3.0

Epolon II Multi-Mil

4.0 – 6.0

International Interseal 670

2.0 – 3.0

Interseal 670

4.0 – 6.0

International Intergard 345

2.0 – 3.0

Intergard 345

4.0 – 6.0




24956-000-GFS-GEX-00001-000 Page 28 of 39


TURER


1st

COAT

DFT (mils)

2nd

COAT

DFT (mils)

3rd

COAT

DFT (mils) NOTES

Carboline Carboguard 888

2.0 – 3.0

Carboguard 890

4.0 – 6.0

V6

Sherwin Williams

SP-6

Epolon II Rust Inhibitive

B62-800B62V800

4.0 – 6.0

Acrolon 218 HS

B65-600/B65V600

1.5 – 2.5

International Interseal 670 HS* Interseal 670 HS

4.0 – 6.0

Interthane 990

1.5 – 2.5

*Apply 4.0 – 6.0


2.0 – 3.0

Carboguard 890

4.0 – 6.0

Carboguard 134 HG

1.5 – 2.5

V7

Sherwin Williams

Clean/Dry

Macropoxy HS,

B58-400/B58-400/B58V400

2.0 – 4.0

Macropoxy HS, B58-400/B58-400/B58V400

2.0 – 4.0


2.0 – 4.0

Intergard 735

2.0 – 4.0

International Intergard 670 HS * Interseal 670 HS

2.0 – 4.0 *Apply 4.0 –

6.0


2.0 – 4.0

Carboguard 890

2.0 – 4.0

V8

Sherwin Williams

SP-5

Epolon II Rust Multi-mil

5.0 – 6.0

Epolin II Multi-mil

5.0 – 6.0

Epolin II Multi-mil

5.0 – 6.0

International Interline 850

5.0 – 6.0

Interline 850

5.0 – 6.0

Interline 850

5.0 – 6.0


5.0 – 6.0

Carboguard 890

5.0 – 6.0

Carboguard 890

5.0 – 6.0

V9

Sherwin Williams*

SP-5

Phenicon HS

5.0 – 6.0

Phenicon HS

5.0 – 6.0

*Low Temp. Harderner

Carboline 368 WG 368 WG

V10

Sherwin Williams

SP-5

Dura-Plate UHS

3 Coats 4-5 Ea.

Dura-Plate UHS

2 Coats 7-8 Ea.

Carboline 368 WG* 1205** *1-2 mils dft **3-5 mils dft




24956-000-GFS-GEX-00001-000 Page 29 of 39


TURER


1st

COAT

DFT (mils)

2nd

COAT

DFT (mils)

3rd

COAT

DFT (mils) NOTES

V11

Sherwin Williams

SP-7

DTM Wash Primer

2.0 – 3.0

Epolon II Multi-mil

2.0 – 4.0

Acrolon 218 HS

1.5 – 2.5

International Interseal 670 HS

2.0 – 3.0

Interseal 670 HS

2.0 – 3.0

Interthane 990 HS

1.5 – 2.5

Carboline Rustbond Sealer* Carboguard 890** Carboguard 134 HG

1.5 – 2.5

*1-2 mils dft **3-5 mils dft

V12

Sherwin Williams

SP10

Targuard

8.0 – 10.0

Targuard

8.0 – 10.0

International Intertuf 132

8.0 – 10.0 Intertuf 132

International Intertuf 708*

Can be applied in 1 coat @ 16-

20 mils

Carboline Bitumastic 300 M

8.0 – 10.0

Bitumastic 300 M

8.0 – 10.0

V13

Carboline SP6

Kop-Coat Super Service Black

14.0 – 16.0

Kop-Coat Super Service Black

14.0 – 16.0

V14

Sherwin Williams

----

Ken Hi Temp 850*

2 mils.

Dampney 260C

2 mils.

Carboline Thermaline 4900

2 mils.

NON-VOC

14

Sherwin Williams

SP10

Ken Hi Temp 850*

1.0

International Intertherm 50

1.0

Intertherm 50

1.0

Carboline High Temp 1248

1.0

High Temp 1248

1.0

V15

Carboline ---

Thermaline 4700*

1.0

Thermaline 4700 *

1.0

* See manufacturer's recommendation for surface and application




24956-000-GFS-GEX-00001-000 Page 30 of 39


TURER


1st

COAT

DFT (mils)

2nd

COAT

DFT (mils)

3rd

COAT

DFT (mils) NOTES

NON-VOC

15

Dampney

SP10

240

1.0 ----


1.0

Intertherm 50

1.0

Carboline 4631

1.0

4631

1.0

V16

Carboline

SP10

Thermaline 4763

2.0

Thermaline 4700 *

2.0


2.0

Intertherm 601

2.0

NON-VOC

16

International

SP10

Intertherm 50

1.0

Intertherm 50

1.0

Sherwin Williams

Silver-Brite Hi-Heat Silicone B59S8

1.0

Silver-Brite Hi-Heat Silicone B59S8

1.0

V17

Carboline ---

Thermaline 4763

2.0

Thermaline 4700 *

2.0

NON-VOC

17

Dampney SP10 245

1.0 – 1.5

230

1.5 – 2.0

V18

Carboline Clean/Dry

Carbocoat 818

1.0 – 1.5

Carbocoat 139

1.0 – 1.5

V19

Carboline SP6

SP5

1205

8.0

1205

8.0

Sherwin Williams

Dura-Plat UHS

8.0

Dura-Plat UHS

8.0

V20

Carboline

SP6

Carbocoat 818

1.5 – 2.0

Carbocoat 139

1.0 – 1.5

Carbocoat 139

1.0 – 1.5

Sherwin Williams

HS Alkyd Primer

1.5 – 2.0

Industrial Enamel

1.0 – 1.5

Industrial Enamel

1.0 – 1.5

V21

International Sand Existing

Coating

Interlac 820

1.5 – 2.0




24956-000-GFS-GEX-00001-000 Page 31 of 39


TURER


1st

COAT

DFT (mils)

2nd

COAT

DFT (mils)

3rd

COAT

DFT (mils) NOTES

PPG*

7.280

1.5 – 2.0

*If not primed, use

PPG MultiPrime

97-682 (red) and 97-684 (White)

Carboline Carbocoat 139

1.5 – 2.0

Sherwin Williams

Industrial Enamel

1.5 – 2.0

V22

Colonial Refinery

SP6

Coro-Kote

6.0

Kool Seal, Inc. Kwench-Kote 505

6.0

V23

Sherwin Williams

Sand Existing Coating

Kem Bond HS

1.0 – 2.0

Epolon II Multi-mil

3.0 – 6.0

Epolon II Multi-mil

3.0 – 6.0

International Interprime 298

1.0 – 2.0

Intergard 735

3.0 – 6.0

Intergard 735

3.0 – 6.0


1.0 – 2.0

Interseal 607 HS

3.0 – 6.0

Interseal 607 HS

3.0 – 6.0


1.0 – 2.0

Carboguard 890

3.0 – 6.0

Carboguard 890

3.0 – 6.0

V24

Sherwin Williams

P6 or Sand Existing Coating

Kem Bond HS

1.0 – 3.0

Epolon II Multi-mil

3.0 – 6.0


1.0 – 3.0

Interseal 670 HS

3.0 – 6.0


1.0 – 3.0

Interseal 735 HS

3.0 – 6.0


1.0 – 3.0

Carboguard 890

3.0 – 6.0

International (Alternate

Epoxy Primer)

Intergard 270

1.0 – 3.0

Intergard 735 WB

3.0 – 6.0

V25

Con-Lux ---

Custom Flex

102.89 & 101-89




24956-000-GFS-GEX-00001-000 Page 32 of 39


TURER


1st

COAT

DFT (mils)

2nd

COAT

DFT (mils)

3rd

COAT

DFT (mils) NOTES

NON-VOC

25

Glyptal, Inc. --- Glyptal 1202 Glyptal 1202

V26 Sherwin Williams *

SW–ALK 40 White TM5494, TM5494 White, TM5493 Yellow, A300 White, A301 Yellow, B54Z Yellow Enamel, B29W1 Fast Dry A300, B29Y2Fast Dry A301

* See Manufacturer's Data

Sheet

V28

Sherwin Williams

Clean/Dry

Heavy Block Filler B42W46

6.0 – 12.0

Elastomeric Coating A5 Series

5.0 – 15.0

Carboline Carbocrylic 650

6.0 – 12.0

Carbocrylic 600

5.0 – 15.0

V29

Sherwin Williams

P7

Elastomeric A5 Series

7.0 – 10.0

Elastomeric A5 Series

7.0 – 10.0


7.0 – 10.0

Carbocrylic 600

7.0 – 10.0

V30

Sherwin Williams

Clean Dry

Prep Rite

1.0 – 1.5

Pro Mar

1.0 – 1.5

Pro Mar

1.0 – 1.5

International Intercryl 520

1.0 – 1.5

Intercryl 520

1.0 – 1.5

Intercryl 520

1.0 – 1.5

V31

Ceilcote

SP10

Flakeprime

2.0 – 3.0

Flaketar

10.0

Flaketar

10.0


2.0 – 3.0

Interzone 1000

10.0

Interzone 1000

10.0

V32

(Alcoa Blue)

Carboline

SP6 Minimum

134 HG 3134

2.5 – 6.0

Alcoa Blue 3134

International

Interseal 670 HS

MSC 71599

2.5 – 6.0

670 HS MSC 71599

V33

Carboline SP7

Rustbond Sealer*

Carboguard 890**

Carboguard 890**

*1-2 mils dft

**3-5 mils dft




24956-000-GFS-GEX-00001-000 Page 33 of 39


TURER


1st

COAT

DFT (mils)

2nd

COAT

DFT (mils)

3rd

COAT

DFT (mils) NOTES


2.0 – 3.0

Intergard 735

4.0 – 6.0

Intergard 735

4.0 – 6.0

V34

Sherwin Williams Clean/Dry

A-100 Latex Primer

1.5 – 2.5

A-100 Latex Flat

1.5 – 2.5

V35

Sherwin Williams

SP6

DTM Acrylic B66W1

2.0 – 4.0

DTM Acrylic B66-100

2.0 – 4.0

2.0 – 4.0

DTM B66 Series

2.0 – 4.0


2.0 – 4.0

Intercryl 530

2.0 – 4.0

Intercryl 530

2.0 – 4.0


2.0 – 4.0

Carbocrylic 3358

2.0 – 4.0

Carbocrylic 335

2.0 – 4.0

V36

Sherwin Williams

Clean/Dry

Loxoh

2.0 – 3.0

A-100A8

2.0 – 3.0


2.0 – 3.0

Intercryl 530

2.0 – 3.0


2.0 – 3.0

Carbocrylic 3359

2.0 – 3.0

V37

Sherwin Williams

SP2

SP3

DTM B66W1

2.0 – 3.0

DTM B66-100

2.0 – 3.0


2.0 – 3.0

Intercryl 530

2.0 – 3.0


2.0 – 3.0

Carbocrylic 3359

2.0 – 3.0

V38

Sherwin Williams

SP6

Macropoxy 646

5.0 – 7.0

International Interseal 670 HS

5.0 – 7.0

Carboline Carboguard 890*

* 3-5 mils DFT

See Note 2 end of this

table

Hempel 45880** See Note 3 end of this

table




24956-000-GFS-GEX-00001-000 Page 34 of 39


TURER


1st

COAT

DFT (mils)

2nd

COAT

DFT (mils)

3rd

COAT

DFT (mils) NOTES

V39

Sherwin Williams

SP6

Macropoxy 646

5.0 – 7.0

Acrolon 218 HS

2.0 – 3.0


5.0 – 7.0

Interthane 990

2.0 – 3.0

Carboline Carboguard 890* Carbothane 134 HG*** *See Note 2 end of this

table

Hempel 45880** 5595U-19990

2.0 – 3.0

See Note 3 end of this

table

V40

Sherwin Williams

SP2 (Weathered Galvanize)

B54AZ600 Tower Guard

6.0 – 10.0

Keeler & Long 4400 Series

6.0 – 10.0

V41

Sherwin Williams SP6

Zinc Clad III HS 11

3.0 – 4.0

Macropoxy 646

4.0 – 6.0

International Interzinc 52

3.0 – 4.0

Intergard 670 HS

4.0 – 6.0

Carboline Carbozinc 859

3.0 – 4.0

Carboguard 890

4.0 – 6.0

V42 Sherwin Williams SP2-SP3

Dura-Plate 235

7.0

Dura-Plate 235

7.0

Note 1: The surface preparation requirements represent the minimum degree of cleaning desired. The application and DFT Information are provided for general guidance only. Consult with the manufacturer's Product Data Sheet for specific requirements.

Note 2: For caustic or severe acidic environments, do not use aluminum-pigmented mastic. In aggressive environments, use two coats. Overspray from this material will carry. Consider brush or roller application in areas subject to overspray. Brush or roller application may require two coats to achieve the same film build.

Note 3: Hempel 45880 – 1440 (Gray), 185F0 (Gray), 20250 (Yellow), 10000 (White).




24956-000-GFS-GEX-00001-000 Page 35 of 39

Table A3 Added paint systems for Fjarðaál Smelter Project

SYSTEM CODE

MANUFAC-TURER


1st

Coat

DFT (µm)

2nd

Coat

DFT (µm)

3rd

Coat

DFT (µm)

4th

Coat

DFT (µm)

F1

Carboline SP-6

Org. Zn

(45)

CZ-859

Epoxy HS

(150)

893

Epoxy HS

(150)

893

Polyurethane

(50)

134 HG

International SP-6

Org. Zn

(45)

Interzinc 52

Epoxy HS

(150)

Interseal 670 HS

Epoxy HS

(150)

Interseal 670 HS

Polyurethane

(50)

Interthane 990

F2

Ameron SP-10

Org. Zn

(75)

Amercoat 68

Polysiloxane

(125)

PSX 700

Carboline SP-10

Org. Zn

(75)

CZ-859

Polysiloxane

(125)

Carboxane 2000

International SP-10

Org. Zn

(45)

Interzinc 52

Polysiloxane

(125)

Interfine 979

F3

Outdoors

T° <230°C

International SP-10

Epoxy Phenolic

(125)

Intertherm 228

Epoxy Phenolic

(125)

Intertherm 228




24956-000-GFS-GEX-00001-000 Page 36 of 39

APPENDIX B

COLOR SCHEME

B1. Safety Colors

Safety Color Code is defined in Alcoa Standard 18.21 Standard Practice for Safety Color Code. Sections 1 to 4 of Alcoa Standard 18.21 are to be considered part of this specification (Section 5 applies to specification n° 24956-000-3PS-NXP0-00001 Physical Identification For Mechanical Process Equipment).

"18.21 Standard Practice for Safety Color Code Painting.pdf"

B2. Plant Color Scheme

Plant Color Scheme is defined in the "Color Scheme Matrix" Doc. N° 24956-000-30X-A10D-00001




24956-000-GFS-GEX-00001-000 Page 37 of 39

APPENDIX C

STANDARD COATING DATA SHEET

Seller proposes that the surface preparation and coating shall be as described below.

1. Equipment Description:

A. Tag Number B. Part(s) i.e. skirt, shell, channels, lugs, etc.* C. Design/Operating Temperatures, designate °F or °C / D. Does Equipment Receive Steamout (Yes/No), Temperature / E. Insulated/Uninsulated F. Fireproofing (Yes/No)

G. Carbon Steel (CS), Stainless Steel (SS), other

2. Seller

3. Surface Preparation: SSPC No./Profile /

4. Coating System Description:

A. Coating System Code (Appendix A)

First Coat Second Coat Third Coat

A. Type of Coating B. Coating Mfg./No C. Dry Film Thickness (Min/Max / / / D. Wet Film Thickness (Min/Max) / / / E. Curing Method F. Color G. Dry to Recoat H. Pot Life I. Thinner Type/ % / / /

5. Total Dry Film Thickness of System (Min/Max) /

6. Material Storage Temperature Requirements (Min/Max) /

7. Shelf Life

8. Application Environmental Limits:

A. Temperature (Min/Max) /

B. Humidity (Min/Max) /

9. Protection of surfaces that will be inaccessible after

equipment installation (such as underside of base

plates, interior of fans or vessels)

10. Rust Preventative for machined faces. (Mfg./No.) /

11. Additional information

*Use additional copies of this form for each part described in 1 above that requires a different coating system. A completed copy of this data sheet shall be submitted to Buyer with the initial vendor data submittal.




24956-000-GFS-GEX-00001-000 Page 38 of 39

APPENDIX D

SURFACE PREPARATION AND COATING INSPECTION FORM

REPORT NO.: DATE: SHIFT:

PROJECT NUMBER: 24956 COATING SPEC N°/REV.: Paint System N°.

SUBCONTRACTOR: EQUIPMENT/AREA:

INSPECTOR:

SUBSTRATE: STEEL CONCRETE OTHER

ENVIRONMENTAL CONDITIONS

COATING WORK ACTIVITY

TIME

DRY BULB TEMP. °F (°C)

WET BULB TEMP. °F (°C)

RELATIVE HUMIDITY, %

DEW POINT °F (°C)

SURFACE TEMP. °F (°C)

BLOTTER TEST

PRE-SURFACE PREPARATION

SOLVENT CLEANING (SP-1): MASKING/PROTECTION:

SURFACE DEFECTS:

SURFACE PREPARATION

METHOD: ABRASIVE TYPE/SIZE/STORAGE:

SPECIFIED CLEANLINESS: ACTUAL CLEANLINESS:

SPECIFIED PROFILE: ACTUAL PROFILE:

COATING MATERIALS & MIXING

PRODUCT (S): BATCH NO. (S):

SELF LIFE EXPIRATION: INDUCTION TIME:

QUANITY MIXED: MIXING RATIOS:

THINNER TYPE: THINNER QUANITY per GALLON:

POT LIFE: MATERIAL TEMPERATURE:

COATING APPLICATION

APPLICATION EQUIPMENT: TYPE ACTIVITY: INITIAL REPAIR/TOUCHUP

COAT: PRIMER INTERMEDIATE TOPCOAT

START TIME: FINISH TIME:

RECOAT TIME/TEMPERATURE: CURE TIME/TEMPERATURE:

FINAL INSPECTION OF APPLIED COATING*

VISUAL-Free of over spray, runs, sags, voids, blistering, peeling, rusting, mud cracking? Yes No

DRY FILM THICKNESS (Average): Specified: Actual:. HOLIDAY (If Required):

FINAL CURE: Yes No CORRECTIVE ACTION:

* Comments and actual dry film thickness readings – Use reverse side.

Inspector Signature: .




24956-000-GFS-GEX-00001-000 Page 39 of 39

APPENDIX E

LIST OF BANNED SUBSTANCES

List A

1. Benzene (limit benzene content to 0.1% or less in all solvents, hydrocarbons, etc.) 2. Lead and chromate in paints, lubricants 3. Cadmium and antimony in paints, solders, metals, etc. 4. Oils (petroleum hydrocarbons) which are not severely hydrotreated and solvent refined 5. Methyl and ethyl cellosolve and their acetates 6. Methylene chloride 7. Chloroform 8. Asbestos 9. Formaldehyde containing products or formaldehyde generating products 10. Methyl chloroform 11. Trichloroethylene 12. Mercury 13. Ortho toluidine 14. Perchloroethylene 15. Trichloroethylene 16. Nitrosamines and precursors compounds capable of forming nitrosamines 17. Polychlorinated Biphenyls (PCBs)

List B

1. Antimony in paints, solders, metals, etc. 2. Aromatic amines in plastic resins, etc. 3. Asbestos (insulations, pump packings, brake shoes, press clutch plates, gaskets, etc.) 4. Benzene (i.e. hydrocarbons containing greater than 0.1% benzene except for gasoline) 5. Beryllium 6. Cadmium in paints, solders, metals, etc. 7. Chlorinated hydrocarbons, including methylene chloride, chloroform, Perchloroethylene and

Trichloroethylene 8. Chromium (hexavalent) 9. Ethylene glycol ethers (i.e. more toxic forms such as 2-methozyethyl acetate) 10. Formaldehyde, including materials generating formaldehyde (e.g. biocides) 11. Lead in paints and lubricants 12. Mercury 13. Oils/petroleum hydrocarbons not severely hydrotreated or solvent refined 14. Refractory ceramic fibers 15. Sensitizers (i.e. potent sensitizers such as toluene diisocyanate and acrylates).

A1

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ALCOA FJARDAAL

DRAWING NUMBER SCALE

PAPER SIZEFJA NUMBER:

ASSET NUMBER

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MAPPROVED BY FJARDAAL FOR GENERAL / DATE

APPROVER / DATE

FJA ERPEP ENGINEER:

CHECKER / DATE

DRAWN / DESIGNED / DATE

STATUS

ARRANGEMENTS AND OVERALL DIMENSIONS ONLY.THIS DOES NOT CONSTITUTE DESIGN APPROVAL.

COORDINATION DESIGNER / DATE

CHK.DES. ERPEPAPP.

VENDOR REFRENCE NUMBER

VENDOR PROJECT NUMBER

VENDOR

DESCRIPTION

DRAWING NUMBER

REVISION DATE

ORIGINAL DRAWING

DATE

REVISION HISTORY

REV.

Hönnunarstjóri

00

0124956-300-CE-312-00002-000-000

FJA-D-038157-001

FJA-0312 RECTIFIERSC_CIVILMODELC20-CONCRETE STRUCTURES,WALLS,CULVERTS

00

01

00

H001-03-Alcoa Fjardaal RF 16 Project

H001-03-312-115-C-EN00-436-001

FOR BID

Ágúst N. JónssonSvavar Páll Pálsson

Scale:3D - Model1

2012-01-12 1 FOR BID SPP EVV

b

a0,000±

0,000±

200

12

10

y

x

x

yStands for elevation 0,000 m on sections

Indicates thickness of wall or slab 200 mm

Stands for elevation 0,000 m on plans

Detail no. 12

Indicates locationof section

Shown on sheet no. 10

REINFORCEMENT BAR REINFORCEMENT BAR

AN INSULATING SPACER SHALL PREVENT ELECTRICAL CURRENTS FROMDEVELOPING WITHIN REINFORCEMENT. THE SPACER IS PLACED IN-BETWEENREINFORCEMENT BARS WHERE CROSSING CAN OCCOUR AND SECURED WITH APLASTIC FASTENING STRAP. THE SPACER SHALL BE MADE OF NON-DEGRADABLEINSULATING MATERIAL SUCH AS PLASTIC.

THIS MEANS, THAT NO CLOSED LOOPS OF REBAR SHALL BE WITHIN THIS ZONE

PVC sleevePVC sleeve

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ALCOA FJARDAAL



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APPROVER / DATE

FJA ERPEP ENGINEER:

CHECKER / DATE


STATUS



CHK.DES. ERPEPAPP.



VENDOR

DESCRIPTION

DRAWING NUMBER

REVISION DATE

ORIGINAL DRAWING

DATE

REVISION HISTORY

REV.

Hönnunarstjóri

00

As indicated 0124956-300-CE-312-00003-000-000

FJA-D-038158-001

FJA-0312 RECTIFIERSC_CIVILGENERAL NOTESC20-CONCRETE STRUCTURES,WALLS,CULVERTS

01

02

00


H001-03-312-115-C-EN00-436-001

FOR BID


CONCRETE NOTES:

1.0 GENERAL

1.1 ALL DIMENSIONS ARE IN MILLIMETERS - DO NOT SCALE DRAWINGS.

1.2 ALL ELEVATIONS ARE IN METERS.

1.3 ALL MATERIALS AND WORKMANSHIP SHALL BE IN ACCORDANCE WITHTHE RELEVANT CURRENT EURO STANDARDS, UNO.

1.4 DURING CONSTRUCTION THE CONTRACTOR SHALL BE RESPONSIBLEFOR MAINTAINING THE STRUCTURE IN A SAFE AND STABLE CONDITIONAND ENSURING THAT NO PART IS OVERSTRESSED AS A RESULT OFCONSTRUCTION ACTIVITIES.

2.0 CONCRETE

2.1 ALL CONCRETE WORK SHALL BE IN ACCORDANCE WITH ÍST EN 206, ÍST EN 1992 ANDTHE STANDARD PROJECT SPECIFICATIONS:

24956-000-3PS-DB00-00000 CONCRETE WORK24956-000-3PS-DB01-00001 FURNISHING AND DELIVERING READY-MIX CONCRETE

2.2 PRIOR TO EXCAVATION AND PLACING CONCRETE,VERIFY REQUIREMENTS FOR ALL RELEVANT SERVICESREGARDING THE DETAIL AND LOCATION OF ALL EMBEDDEDSLEEVES, BOLTS, CONDUITS, GROUNDING, HOLES etc.

3.0 CONCRETE SUPPLY & TESTING

3.1 UNLESS NOTED OTHERWISE THE FOLLOWING CONCRETE CLASSES (SEE IST EN206-1) SHALL BE USED.

(A) GENERAL.......................................................................................................PRECAST MEMBERS....................................................................................

3.2 UNLESS NOTED OTHERWISE CONCRETE SHALL BE THE FOLLOWING TYPE:

STRUCTURAL ELEMENTSCOLUMNS, SLAB-ON-GRADE AND EXPOSED CAST-IN-SITU....................MAIN FOUNDATIONS.....................................................................................ELEVATED SLABS AND BEAMS....................................................................CONCR. ON HOLLOW CORE SLABS AND HOLLOW CORE SLABS CONNECTIONS

THE CONCRETE TYPE SHALL BE DESIGNATED AS Caa/bb:XEi-D-Ax, WHERE Caa/bb INDICATESTHE COMPRESSIVE STRENGTH CLASS OF CONCRETE, XEi THE EXPOSURE CLASS, AND D THE UPPERSIEVE SIZE OF THE AGGREGATE IN mm, AND Ax IF AIR ENTRAINMENT IS REQUIRED (Ae) OR NOT (Ao).SIEVE SIZE SHOULD BE CONSIDERED AS A RECOMMENDED VALUE, NOT A REQUIREMENT.

4.0 REINFORCEMENT

4.1 ALL REINFORCING STEEL SHALL COMPLY WITH PROJECT SPECIFICATION 24956-000-3PS-DG00-00001

4.2 REINFORCEMENT SHALL BE TO THE FOLLOWING GRADE:

- B500NC CONFORMING TO ÍST 16:2006- DESIGNATED AS TYPE "S"

REINFORCEMENT NOTATION

ABBREVIATIONS: (T) TOP(B) BOTTOM(EW) EACH WAY

INDICATES THICKNESS OF CONSTRUCTION ELEMENT AND MAJOR BAR DIRECTION.

4.4 IF LESS THAN 30% OF TENSION BARS IN A SECTION ARE LAPPED AND a>10ø AND b>5øTHEN TENSION LAP LENGTH IS SUFFICIENT

4.5 IF MORE THAN 30% OF TENSION BARS IN A SECTION ARE LAPPED OR EITHER a<10øOR b<5ø THEN TENSION LAP x 2,0 IS REQUIRED

4.6 IF NEITHER 4.4 NOR 4.5 APPLY, TENSION LAP x 1.4 IS REQUIRED

4.7 BOND CONDITION ARE GOOD FOR:a) ALL BARS WITH AN INCLINATION OF 45-90° TO THE HORIZONTAL DURING CONCRETINGb) MEMBER DEPTH IN DIRECTION OF CONCRETING IS LESS THAN 250mmc) IN LOWER HALF OF MEMBER WITH A DEPTH GREATER THAT 250mm OR AT LEAST 300mm FROM TOP IF MEMBER DEPTH GREATER THAN 600mm

4.8 IF BOND CONDITIONS ARE NOT GOOD, LENGTHS IN THE TABLE HAVE TO BE MULTIPLIED BY 1.4

4.9 ALL BENDS SHALL BE STANDARD IN ACCORDANCE WITH EN 1992 ANDÍST EN ISO 4066 UNLESS NOTED OTHERWISE ON DRAWINGS.

4.10 ALL REINFORCEMENT SHALL BE SUPPORTED SUCH THAT IT IS NOTDISPLACED DURING CONCRETING. RECOMMENDED MAXIMUM CLEAR SPACING OFSUPPORTS IS 800mm

5.1 ALL EMBEDDED ITEMS SHALL CONFORM TO PROJECTSPECIFICATION:24956-000-3PS-DG-00-00001

5.0 EMBEDDED ITEMS

6.1 ALL CONCRETE WORKS SHALL BE FOUNDED AT 1.2m BELOWFINISHED GRADE (FROST DEPTH) OR A DEPTH NOT LESS THANTHAT SHOWN ON THE DRAWINGS AND ON FIRM MATERIAL, AS SPECIFIED ON THE DESIGN DRAWINGS.

6.0 SUB GRADE PREPARATION

7.0 CONCRETE CONSTRUCTION

Lap length, mm

Diameter Compression bars

Tension bars 1.4*Comp 2.0*Comp

8 290 400 58010 360 500 72012 435 600 87016 580 810 116018 650 910 145020 725 1010 145025 900 1260 1800

S20c300 OR 5-S20-2000 BAR SPACING IN mm BAR LENGTH

BAR DIA. IN mm No. OF BARS BAR DIA. IN mm BAR TYPE - "S" BAR TYPE "S" - GENERAL REINFORCEMENT - GRADE B500C.

REINFORCEMENT AROUND OPENINGS(if not shown otherwise)

REINFORCEMENT STIRRUPS

NOTE: THE VALUES SHOWN REPRESENT NOMINAL COVER AND SHOULD BEUSED AS A REFERENCE IN BENDING REBAR. MINIMUM ACCEPTABLEVALUES ARE 10mm LESS FOR SLABS & WALLS AND 15 mm LESS FORALL OTHER ITEMS.

Columns

Slab and beams

Walls

Foundations

45

45

45 45

40

40 45

45

4040

45

75 cast against fill55 cast against levelling grout

45 45

Place extra bars close toopening. On each side half of theinterrupted reinforcement area.

Anchorage length, I, is equal to the lap length forcompression bars, see table below.

Corner bar (place inside of facereinforcement). Same size asextra bars.

Additional corner barif slab or wall is morethan 250mm thick.

C openingL

C

open

ing

L

W/2 + 1,4* ld

H/2 + 1,4* ld

H/2

W/2

1,4* ld

D=3 d or diameter of enclosed bar

DD

D D

db

7d b

NOTE:1. UNLESS OTHERWISE INDICATED ON THE DRAWING, ALL BARS ARE TENSIONBARS.

7.2 CONSTRUCTION JOINTS SHALL BE ROUGHENED IN ACCORDANCE WITHTHE PROJECT SPECIFICATION.

7.3 PROVIDE A 20x20mm CHAMFER TO ALL CORNERS INCLUDING RE-ENTRANTCORNERS AND EDGES OF ALL EXPOSED CONCRETE, ALL PEDESTALSPLINTHS & WALLS.

7.4 BAR SUPPORTS, INCLUDING CHAIRS, BOLSTERS, SPACERS AND TIE WIRESHALL BE STANDARD PRODUCTS FROM A RECOGNIZED MANUFACTURER.

7.5 REFER TO PROJECT SPECIFICATION 24956-000-3PS-DB00-00001 FOR DETAILSOF CONCRETE FINISHES AND FORMWORK.

bC30/37C50/60

C30/37: XF1-25-AeC30/37:XF3-25-AeC30/37: XF1-25-AeC30/37: XF3 16mm

7.1 THE CONCRETE COVER TO REINFORCEMENT SHALL BE AS SHOWNBELOW UNLESS NOTED OTHERWISE ON THE DESIGN DRAWINGS ANDSHALL BE AS PER CLAUSE IN ÍST EN 1992-1-1 BUT NOTLESS THAN THE FOLLOWING:

400

OR

OR

REINFORCEMENT OF CORNERS

REINFORCEMENT OF A T-JOINTREINFORCEMENT OF WALL ENDS

S12 every seccond horizontal bar2S12

3S12

Stirrups with the samediameter and centers asthe wall reinforcement

Stirrup with the samediameter and center asthe wall reinforcement

2S12

9.0 IRON FREE ZONES

200

4.3 LAP LENGTHS FOR REINFORCEMENT SHALL BE INDICATED ON THE DESIGN DRAWINGS.DEFAULT LAP LENGTHS ARE INDICATED BELOW FOR ALL CLASSES UP TO C30/37CONCRETE AND GOOD BOND CONDITIONS:

INDICATES A CONSTRUCTION JOINT.WATER BAR ON OUTSIDE OF CONSTRUCTION JOINT50x50mm

8.0 STEEL WORK

2.1 ALL STEEL WORK SHALL BE IN ACCORDANCE WITH ÍST EN 1993 ANDTHE STANDARD PROJECT SPECIFICATIONS:

24956-000-3PS-SS00-00001 SPECIFICATION FOR STRUCTURAL STEELWORK. SUPPLY ANDFABRICATION24956-000-3PS-SS00-00002 SPECIFICATION FOR STRUCTURAL STEELWORK. ERECTION

60 x d

40 x

d

60 x

d

60 x d

40 x d

60 x

d


106

207

206

750

300

1500

5531

600

1143

600

2057

600

1143

600

2626

2000

030

0

400

350

300

350

1700

010

50

1870

0

300 0300 400 13150 3650 300 7634 300 6166 750 400 1500

6300 1300 10705 300 2230 300 6165 300 1050 300 4400 900 300 4400

400

2700

1400

300

2531

600

1143

600

2057

600

1143

600

526

1800

300

2000

750

300

1500

400

2300

300

750

400

1800

2650

1426

300

600

300

2000

16.54 m

16.30 m

FD

14.80 m

16.50 m

16.05 m

16.05 m

108

208

308

308

Sim

208

Sim

408

408

Sim

508

508

Sim

508

Sim

508

Sim

508

Sim

608

608

Sim

608

Sim

608

Sim

708

808

908

Sim908

408

Sim

Sim908

34550

1800

2057

Rebar:#S16c200

350

EXISTING WALL

306

7040

950

750

300

300

400

308

Sim

308

Sim

1900

307

400

5217

300

9600

300

2883

300

8150

1217

31003001900

809

15.75 m

16.05 m

508

Sim

Sim908

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ALCOA FJARDAAL



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FJA ERPEP ENGINEER:

CHECKER / DATE


STATUS



CHK.DES. ERPEPAPP.



VENDOR

DESCRIPTION

DRAWING NUMBER

REVISION DATE

ORIGINAL DRAWING

DATE

REVISION HISTORY

REV.

Hönnunarstjóri

00

1 : 50 0124956-300-CE-312-00004-000-000

FJA-D-038159-001

FJA-0312 RECTIFIERSC_CIVILFOUNDATIONC20-CONCRETE STRUCTURES,WALLS,CULVERTS

02

03

01


H001-03-312-115-C-EN00-436-001

FOR BID


Scale: 1 : 5006Foundation1


106

FD

FD

DrainagePit

207

FD

FD

206

Sim908

Gravel Fill Gravel Fill

Gravel Fill

Gravel Fill

1008

1108

Sim908

FD

109

17.60 m

17.60 m

209

309

Sim908

409

509

3°

3°

3° 3° 3°

609

300

7031

600

1143

600

2057

600

1143

600

4626

300

1800

30026750300

2057

1426

300

2326

1426

900

300

2000

1143

2057

1143

300

400

200

1200

200

780

1421

300

2531

2831

1743

2657

1743

2626

30010503006165300223030011705300

900

2000

40031003001900300

400

2700

200

1200

200

917

300

9600

300

2883

11278 283 2248 283 1609 200 1450 200 2200 200 1250 200 500 4850

1160

0

2531

900

580

200

4252

110

17.60 m

L:17.55

L:17.55 L:17.55

17.60 m

17.60 m

17.60 m

EXISTING WALL

306

400

200

1980

200

1721

300 1200 200 6450 200 7750 200 1200

200

1150

300

8150

300

1800

300

2000

1900

Gravel Fill

307

809

Gravel Fill

Sim908

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ALCOA FJARDAAL



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FJA ERPEP ENGINEER:

CHECKER / DATE


STATUS



CHK.DES. ERPEPAPP.



VENDOR

DESCRIPTION

DRAWING NUMBER

REVISION DATE

ORIGINAL DRAWING

DATE

REVISION HISTORY

REV.

Hönnunarstjóri

00

1 : 50 0124956-300-CE-312-00005-000-000

FJA-D-038160-001

FJA-0312 RECTIFIERSC_CIVILOIL PIT PLANC20-CONCRETE STRUCTURES,WALLS,CULVERTS

03

04

02


H001-03-312-115-C-EN00-436-001

FOR BID


Scale: 1 : 50Oil Pit Plan1

NOTE: COMPACTIVE OF GRAVEL FILL DURING CONSTRUCTION SHALL BE APPROVED BYTHE ENGINEER. IT WILL NOT BE ALLOVED UNTIL OIL PIT WALLS ARE CAST


Alcoa Fjarðaál RF16 Project SCOPE OF WORK

Concrete Work in Bay, Duct Banks and Tunnel

Extension

PROJECT NO. H001-03

DOCUMENT NO: H001-03-312-117-C-EN00-303-001

HRV NUMBER: 24956-300-3PS-312-00011

PAGE NO: [1 of 14]

01 2012-01-12 Issue for use SPP EVV ÁKS 00 2011-10-04 Issue for use SPP EVV ÁKS

REV ISSUE DATE (YYYY-MM-DD)

DESCRIPTION PREP. BY APPROVED FUNCT. MGR

APPROVED PROJ. MGR

APPROVED CLIENT

ALCOA FJARÐAÁL RF16 PROJECT Scope of Work

Doc.no: H001-03-312-117-C-EN00-303-001

REVISION NO. 01

ISSUE DATE. 2012-01-18 PAGE NO. 2 OF 14

HRV ENGINEERING | ICELAND | TEL. +354 575 4700 | www.hrv.is | [email protected]

Copyright © 2011. HRV Engineering. All rights reserved. Printed documents are uncontrolled and if printed they may become outdated.

1 Scope of Included Work ...................................................................................................... 3

2 Work Not Included ............................................................................................................. 14

3 Battery limits ...................................................................................................................... 14


Doc.no: H001-03-312-117-C-EN00-303-001

REVISION NO. 01




1 Scope of Included Work Item QTY Unit DESCRIPTION

NOTE: At the end of 2010 existing versions of structural Eurocodes were withdrawn and new versions adopted. When older versions are referenced in the specifications those are to be replaced by the new versions with accompanying National Annexes. When there is a conflict between old and new version of standards this shall be brought to the attention on the Engineer. In particular attention is drawn to the following is to be used.

• IST EN 13670-1:2000 Execution of concrete structures • ÍST 16: 2006 Bendistál og bendinet

GENERAL Unless noted otherwise all items shall include all work and materials to complete the items as shown on the drawings. Quanities listed are indicative only and the Contractor is solely responsible for all material take off for his bid.

1 Lump sum

Electricity and Lighting The Owner will provide basic lighting for the RF16 bay. Other lights, including spot lights required during construction are to be provided by the Contractor. The contractor will get access to 3 Phase, 63A socket in RF11 bay.

2 Lump sum Water protection The contractor shall remove ground and surface water from the construction area into the stormwater system.

3 Lump sum

Concrete cutting Various openings are to be cut in the existing bus bar basement wall at different levels, as shown on the drawings. The cut is to be painted, the whole width of the cut. Approved manufacturers directions is to be followed, e.g Málning, concrete paint system, Option – C with two coatings of Kópal Steintex or equivalent.

Color “Concrete gray”

Included disposal of cut concrete. Note: it is not allowed to cut the wall until the bus bar extension is water tight

Estimated quantities: 54m

4 Lump sum

Grounding wire Installation of grounding conductor as shown on drawings. Included is connection to existing grounding grid and removal of old grounding conductor. All grounding connections that need to be changed due to installation of the new rectifier bay shall be repaired and


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REVISION NO. 01




Item QTY Unit DESCRIPTION reinstalled with all modifications necessary. Grounding wire will be supplied by owner, contractor supplies connections.

5 Lump sum

Gravel fill, reused material The contractor shall place fill against the walls along the rectifier area.

Excavated material from the RF16 bay is allowed, provided that maximum grain size is 100 mm on area 300 mm next to concrete elements.

Special care shall be taken on compaction of material next to concrete walls.

Compaction method, layer thickness and compaction equipment shall be accepted by client representative.

Estimated quantities 270 m3

6 Lump sum

Gravel fill inside of bay, reused material The contractor shall place a fill inside of bay, surrounding the oil pit according to drawings.

Excavated material from the RF16 bay is allowed, provided that maximum grain size is 100 mm on area 300 mm next to concrete elements.

Special care shall be taken on compaction of material next to concrete walls.

Compaction method, layer thickness and compaction equipment shall be accepted by client representative.


7 Lump sum

Gravel fill, alluvial material The contractor shall place fill under the construction as shown on the drawings.

The material used shall be Alluvial material, full filling material and grading requirements for “neðra burðarlag” from Alverk ’95.

The compaction of the fill shall meet the requirements for the plate loading test.

Excavated material from the rectifier area will not be accepted


8 Lump sum

Plate loading test The contractor shall perform plate loading tests for the fill under the transformer area bay and/or the fill against the walls as directed by the Client representative.

The test shall be performed by an approved body accepted by the by the Client representative.

The requirement for the plate loading test are:


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REVISION NO. 01




Item QTY Unit DESCRIPTION

E2>=100MPa

E2/E1<2,2

All tests shall meet the requirements for “neðra burðarlag” from Alverk ’95.

Number of tests 4.

9 Lump sum

Rock excavation Excavation work for new drainage pipes.

Rock excavation for drainage pipes.

Estimated quantity,2 m3.

10 Lump sum Drainage pipes, pipes in bay Drainage pipes from floor drains to existing drainage system as shown on drawing 24956-300-P0-312-00007.

11 Lump sum

Drainage pipes, pipes in ground Drainage pipes from floor drains to existing drainage system as shown on drawing 24956-300-P0-312-00007.

Included sanding e.t.c according to specifications.

Battery limits to existing system are 9,0 m along RF11 bay.

The telescopic extension spindle and valve is to be included in this item.

12 Lump sum

Drainage pipe, connection Connecting drainage pipe with the old system.

Connection of the new drainage system to the existing system in front of the RF 11 bay

13 Lump sum

Formwork, walls and wall supports. Unless approved by the Client representative all forms are to be as specified in 3.1.2 a, in 24956-000-3PS-DB00-00001, Concrete work, i.e. exposed to public eye.

Estimated quantity 3010m2

14 Lump sum

Blockout in wall In north gable wall blockouts are to be placed.

In the blockout reinforcement couplers are to be placed, LENTON standard Coupler or equivalent for the wall reinforcement.

Coupler details, development lengths e.t.c are to be according to manufacturers specification

The blockouts are to be closed approximately in April 2012. Size of blockouts approx 2x3 m each.

Included in this item are to be couplers, threading, starter bars

Approx. quantities: 3 pc of block out 2x3 m each.


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15 Lump sum

Formwork, slabs. Unless approved by the Client representative all forms are to be as specified in 3.1.2 a, in 24956-000-3PS-DB00-00001, Concrete work, i.e. exposed to public eye.

Estimated quantity 220 m2 (Bottom surface).

16 Lump sum

Formwork, beams. Unless approved by the Client representative all forms are to be as specified in 3.1.2 a, in 24956-000-3PS-DB00-00001, Concrete work, i.e. exposed to public eye.

Estimated quantity 37 m2

17 Lump sum

Reinforcement, S10 All reinforcement shall be grade B500NC according to ÍST 16:2006

Estimated quantity 970 kg

18 Lump sum


Estimated quantity 10430kg

19 Lump sum



20 Lump sum



21 Lump sum



22 Lump sum

Concrete, C30/37 All concrete shall be C30/37 as noted on general notes drawing.

In all construction joint in new concrete the contractor shall place waterstop, 100mm flat dumbbell eyeleted waterstop of approved type.

Formwork ties for concrete walls in busbar basement, below grade shall be watertight and approved by the Client representative.

Included in this items are the waterstops.


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Estimated quantity, concrete 1180 m3

23 Lump sum

Concrete for joints

The concrete for joints in-between hollow core slabs shall be air-entrained of a quality suitable for this use.

The concrete mix shall be approved by the Client representative.

It is pointed out that smaller upper sive size will ease placing of the concrete mix.


24 Lump sum

Slab elements On top of the busbar basement, prefabricated concrete slab, HP320 are to be placed.

The slab elements shall be designed for: • Superimposed dead load, 2,0N/m2 (concrete topping), • Snow load Sk1,7kN/m2 • Live load 3,0kN/m2.

Prior to fabrication, the contractor shall submit type approval or other documentations showing the slab element proposed meet the requirements of the Icelandic building regulation (Byggingarreglugerð 441/1998)

Upon request the contractor shall provide design briefs for the design of the slab elements by a registered professional engineer.

Estimated quantity, prefabricated slab 200 m2

25 Lump sum

Water membrane on roof Roof shall be covered with two layer Bitumen membrane.

Icopal Base 400 + Icopal Top 500 or equivalent.

Fixing of membrane to wall and roof edges according to details.

Included is material for any preparation of concrete surface according to manufacturer instruction

Estimated quantity, double layer membrane 220 m2

26 Lump sum

Topping Concrete topping on prefabricated slab, as shown on the drawings. The surface finish of the topping shall be suitable for applying the membrane


27 Lump sum

Construction joints In all construction joint against old concrete the contractor shall put a double barrier water sealing system, SCHOMBURG AQUAFIN CJ4 and AQUAFIN CJ2 or equivalent

Approximately 2 months, or as directed by the client representative, after concreting the AQUAFIN CJ2 system shall


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REVISION NO. 01




Item QTY Unit DESCRIPTION be injected and cleaned for future use. For this work the contractor shall submit and follow manufacturer instructions.

Included is material for injection and flushing of the first injection according to manufacturers instruction

Approximate quantities: 45m.

28 Lump sum

Waterproof foundation sheet On the outside of the basement on the east and north wall knobbed polypropylene waterproof sheet (“sökkuldúkur”) shall be installed between gravel and foundation.

Icopal Fonda or equivalent.

The foundation sheet shall be terminated approx. 10 cm below final grading level.

Overlap at joint shall be according to manufacturer instructions.

Approximate quantities: 130m2.(excluding overlaps)

29 Lump sum

Foundation sheet flashing At the upper edge, where the foundation sheet terminates a flashing shall be installed as indicated on the drawings.


30 Lump sum

Conduit block, type 1 The contractor shall cast conduit block from the rectifier bay to the GIS building as shown on drawing 24956-300-CE-312-00015-000-000.

Excavation work for conduit block shall mainly be done by hand/small vehicle (bobcat). Compaction method, layer thickness and compaction equipment shall be accepted by client representative and meet the materials for the plate loading test.

In the conduit block there shall be 4 D160 PEH pipes.

Quantity pr. Meter.

Formwork:1,1m/m

PEH pipes:4,0 m/m

Reinforcement: 17 kg/m

Concrete: 0,66 m3/m

Estimated quantities: 61 m

The conduit block will not be fully connected to the GIS building until casted block has settled on soil. First cast of the Conduit block shall end approx. 3 m from the GIS basement wall. At the end of the Conduit block the rebar shall extend the concrete, so in further construction, contractor will be able to continue casting. The PEH pipes shall connect through GIS basement wall by core drilling in location and arrangement approved by client representative. Connecting rebar for conduit block to GIS building


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Item QTY Unit DESCRIPTION shall be placed and await completion of casting.

Closed reinforcement loops in conduit ducts are not permitted.

31 Lump sum

Conduit block, type 2 The contractor shall cast conduit block from the rectifier bay to the Control room as shown on drawing 24956-300-CE-312-00015-000-000



Quantity pr. Meter.

Formwork:0,95m/m

PEH pipes:6,0 m/m


Concrete: 0,53 m3/m


The conduit block will not be fully connected to the Control room building until casted block has settled on soil. First cast of Conduit block shall end approx. 1,5m from the GIS basement wall. At the end of the Conduit block the rebar shall extend the concrete, so in further construction, contractor will be able to continue casting. The PEH pipes shall connect to Control room building by arrangement and in location approved by client representative. Connecting rebar for conduit block to Control room buildings foundation shall be placed and await completion of casting.


32 Lump sum

Conduit block, type 3 The contractor shall cast conduit block from the rectifier bay in the direction to the harmonic filter as shown on drawing 24956-300-CE-312-00015-000-000.



Quantity pr. Meter.

Formwork:1,9m/m


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PEH pipes:15,0 m/m


Concrete: 1,3 m3/m


At the end of the Conduit block the PEH pipes and rebar shall extend the concrete block and closed off for soil, so in further construction, contractor will be able to connect to PEH pipes and continue casting. Arrangement to be approved by client representative.


33 Lump sum

Conduit block, type 6 The contractor shall cast conduit block from the rectifier bay to the GIS building as shown on drawing 24956-300-CE-312-00015-000-000.



Quantity pr. Meter.

Formwork:1,1m/m

PEH pipes:6,0 m/m


Concrete: 0,55 m3/m


The conduit block will not be fully connected to the GIS building until casted block has settled on soil. First cast of the Conduit block shall end approx. 2m from the GIS basement wall. At the end of the Conduit block the rebar shall extend the concrete, so in further construction, contractor will be able to continue casting. The PEH pipes shall connect through GIS basement wall by core drilling in location and arrangement approved by client representative. Connecting rebar for conduit block to GIS building shall be placed and await completion of casting.


34 Lump sum

Conduit block, type 6 A The contractor shall cast conduit block from the rectifier bay in the direction to the harmonic filter as shown on drawing 24956-300-CE-312-00015-000-000.

Excavation work for conduit block shall mainly be done by


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REVISION NO. 01




Item QTY Unit DESCRIPTION hand/small vehicle (bobcat). Compaction method, layer thickness and compaction equipment shall be accepted by client representative and meet the materials for the plate loading test.


Quantity pr. Meter.

Formwork:1,1m/m

PEH pipes:6,0 m/m


Concrete: 0,55 m3/m


At the end of the Conduit block the PEH pipes and rebar shall extend the concrete block and closed off for soil, so in further construction, contractor will be able to connect to PEH pipes and continue casting. Arrangement to be approved by client representative.


35 Lump sum

Grating Hot dip galvanized steel grating for upper and lower level of oil pit as shown on the drawings. Lower part in elevation 17,53 and upper in same elevation as concrete slab. Also grating for the drainage pit The steel grating shall be designed for superimposed dead load, 6,0kN/m2, snow load Sk1,7kN/m2 and a live load 3,0kN/m2. Sizes of grating shall be determined assuming 2,5 mm gap on each side. All grating shall be provided with a binding bar. Fastenings shall be an approved part of the grating system. Approximate quantities: 468m2.

36 Lump sum

Steel angle L65x60x6 supports under the grating for oil and drainage pit The angles shall be galvanized. Steel grade shall be S355JR or equivalent. Approximate quantities: 540m

37 Lump sum

Gravel Gravel on top of the grating of lower level of oil pit shall be washed, uniformly sized approximately 3,8 cm í diameter.

Layer thickness approximately 30 cm.

The gravel shall be approved by the Client representative prior to placement.


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38 Lump sum

Crane rails Crane rail profile shall be A100 according to DIN 536.

Crane rail material shall conform to EN 13674-1:2003, Grade R260.

Included in this item is also cast in threaded bars, supporting steel plate for the rail and non-shrink mortar under the rail and steel plates

Included is also steel angle welded on one side of the rail.

The rails shall be welded together end to end.

NOTE: The elevation of the rail and between rails is to be +/- 1 mm.

Estimated quantity of rails is 132 m

39 Lump sum Pulling lugs Pulling lugs as shown on the drawings.

Estimated quantities: 4 pc

40 Lump sum

Connection rebar The contractor shall drill connection rebar (starter bars) into existing concrete where new concrete meets old concrete as shown on the drawings.

Estimated quantities: 1270 pc

41 Lump sum

Aluminium covers and supporting grates incl. supports. The contractor shall install, aluminium covers to trench as shown on the drawings. The aluminium covers shall have Quintet texture on top.

Supporting the aluminium covers, supporting grates will be placed, seated on L65x60x6 steel angles bolted inside of the cable trench walls as shown on drawings.

The steel grating shall be designed for snow load Sk1,7kN/m2 and a live load 5,0kN/m2. Aluminium cover and the supporting grates shall be fastended togather by fasteners provided by contractor.The size of the covers shall be determined assuming 2,5 mm gap at the sides.

The aluminium covers shall have slotted holes, for inserting lifting devices, one at each end. Steel angles and grates shall be painted according to 24956-0003PS-NX00-00001 Protective coatings. Paint system V5. Color according to color Matrix All grating shall be provided with a binding bar.

Estimated quantities of covers and grates: 32 m2.

Estimated quantity of supporting angles: 53m


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42 Lump sum

Floor drains Floor drains shall have stainless steel cover/grillage and be flush with the concrete surface.

Floor drains shall be approved by the Client representative prior to installation.

Estimated quantity: 6 pc.

43 Lump sum

Stair relocation Existing FRP Staircase moved to a new location as shown on drawing 24956-300-A0-310-0004-002.

It is to be assumed the stair is taken down but put up at a later date. FRP material fasteners will be provided by owner.

44 Lump sum

Stair fundament Rectangular fundaments supporting stairs and stair platform at the north wall as indicated on drawing 24956-300-A0-310-0004-004. Fundament size: 1,8x0,50x0,3m Reinforced by S12 c150 net in bottom face. At top face, contractor shall cast in hot dip galvanized S12 loop for hoisting the fundament. S12 loop shall be connected to the reinforcement in the bottom of the block.

Approximate quantities: 2 pc.

45

Lump sum

Fire hydrant The Contractor shall reinstall a fire hydrant and pipe along the RF-16 bay as shown on drawing.

Included is also on additional flange to the pipe.

Included is also testing of the fire hydrant after installation.

46 Lump sum

FRP rebar The contractor shall install FRP rebar as shown on the drawings, Aslan 100 or equivalent

Estimated quantity 56 pc

47 Lump sum

Steel beams The contractor shall install steel beams, supporting cooling fans (by others).

Included is also end plates and bolts for installing the beams Steel shall be painted according to 24956-0003PS-NX00-00001 Protective coatings. Paint system V5. Color according to color Matrix Steel grade shall be S355JR or equivalent. Estimated quantity, 3620kg

48 Lump sum Plastic conduits


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REVISION NO. 01





The contractor shall place plastic pipes in ducts in bay according to drawings

D110 PEH pipes estimated quantity: 82m

D160 PEH pipes estimated quantity: 50m.

Closed reinforcement loops in concrete ducts in bay are not permitted.

49 Lump sum

Wall flashing On top of concrete walls, and along roof edge at busbar building flashing shall be placed as indicated at drawings.


2 Work Not Included

3 Battery limits The Vendor shall submit full and complete drawings and documents for approval by the Client representative. Supply of all documents shall be in accordance, Contract or Purchase Order.

Alcoa Fjarðaál RF16 Project

Worksite Conditions for Contractors

Concrete Work in Bay, Duct Banks and Tunnel

Extension

PROJECT NO: H001-03

DOCUMENT NO: H001-03-312-117-C-HS00-126-001

PAGE NO: [1 of 16]

00 2011-09-26 Issued for Use JD EV ÁKS SJ



APPROVED PROJ. MGR

APPROVED CLIENT

FJARÐAÁL RECTIFIER PROJECT Worksite Conditions for Contractors

Doc.no: H001-03-312-117-C-HS00-126-001

REVISION NO. 00

ISSUE DATE. 2011-09-26

PAGE NO. 2 OF 16

HRV ENGINEERING | ICELAND | TEL. +354 575 4700 | www.hrv.is | [email protected] Copyright © 2009. HRV Engineering. All rights reserved. Printed documents are uncontrolled and if printed they may become outdated.

1 PURPOSE........................................................................................................................... 3

2 COMMITMENT ................................................................................................................... 3

3 COMPLIANCE WITH REGULATIONS ................................................................................ 3

4 PRE-QUALIFICATION ........................................................................................................ 3

5 PRE-BID MEETING ............................................................................................................ 4

6 INDUCTION TRAINING ...................................................................................................... 4

7 ENVIRONMENTAL EXPECTATIONS ................................................................................. 4

8 HEALTH AND SAFETY EXPECTATIONS........................................................................... 5 8.1 Conduct of Contractor Employees ................................................................................ 5 8.2 Substance Abuse ......................................................................................................... 6 8.3 Housekeeping .............................................................................................................. 7 8.4 Work Permits................................................................................................................ 7 8.5 Hazardous Material Handling ....................................................................................... 8 8.6 Mobile Equipment ........................................................................................................ 8 8.7 Ladders/Scaffolding...................................................................................................... 9 8.8 Electrical Hazards ....................................................................................................... 9 8.9 Work Requiring Special Skills ..................................................................................... 10

9 LOCATION SPECIFIC ISSUES ......................................................................................... 10 9.1 Securitas .................................................................................................................... 10

9.1.1 Property Control .................................................................................................. 10 9.1.2 Entrance Identification ......................................................................................... 10

9.2 Driving and Parking .................................................................................................... 11 9.3 Emergency Plan ......................................................................................................... 11 9.4 First Aid and Emergency Treatment and Response Plan ........................................... 11 9.5 Personal Protective Equipment (PPE) ........................................................................ 11 9.6 Fire Protection ............................................................................................................ 12 9.7 Utilities ....................................................................................................................... 13

10 REFERENCES .................................................................................................................. 13

11 INJURY/ILLNESS/INJURYFREE EVENT - NOTIFICATION, INVESTIGATION AND REPORTING ............................................................................................................................ 15

12 ADMINISTRATION REQUIREMENTS .............................................................................. 15


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1 PURPOSE Work Site Conditions is a required document, mandated by Alcoa EHS Standard 33.051 EHS Process for Contractors, Subcontractors and Contracted Services Working on Engineering Projects that describes the Environment, Health and Safety (EHS) responsibilities of Contractors, Subcontractors, and Contracted Services when performing work for HRV and Alcoa. This document will be attached to the pre-bid package and will be considered the abiding standard. Contractors, Subcontractors, Contracted Services and Vendors who are working under direct supervision of Alcoa or the Engineering, Construction and Procurement Management (ECPM) are subject to this standard on or off the plant premises. Subcontractors may not be used without specific written consent from the ECPM and the Alcoa Responsible Person. Approved Subcontractors must meet all the pre-job requirements including Prequalification, Orientation, Training, and Identifications.

2 COMMITMENT All Contractors, Subcontractors and Vendors are expected to understand and comply with the following EHS Value and its related Policy.

EHS VALUE: We will work safely in a manner that promotes the health and well being of the individual and the environment. EHS POLICY: It is Alcoa’s policy to operate worldwide in a safe, responsible manner which respects the environment and the health of our employees, our customers and the communities where we operate. We will not compromise environmental, health or safety values for profit or production.

The Contractor's Management is accountable for the safety and health of the Contractor's employees. The Contractor is also accountable for the impact that the actions of his employees and subcontractors may have on the safety and health of others.

3 COMPLIANCE WITH REGULATIONS The Contractor and Subcontractors shall comply with all applicable EU, state and local EHS laws, regulations, rules, and codes and other documents referenced in the contract specifications. Also, the Contractor and its Subcontractors shall comply with Alcoa Standards and other additional provisions as specified by Alcoa representatives. All construction activity shall be performed in such a manner to minimize interference with normal Alcoa operations. Contractor’s employees shall remain in their assigned work areas unless the nature of their business requires they travel elsewhere. Any violation or deviation from the above conditions by the Contractor may result in the dismissal of the Contractor or Contractor’s employee from the property and cancellation of contracts with Alcoa.

4 PRE-QUALIFICATION The Contracted Services Safety Annual Prequalification Questionnaire (33.055.1) is intended for use in evaluating the safety performance of construction, maintenance, service related contractors and any other contractor who will perform work involving the

http://esd-standards.intranet.alcoa.com/ESD_WEB/asp_files/logpdf.asp?Filename=/esd_web/Site_Facilities/33_051_2010_April.pdf&DocNum=33.051&theFile=33_051_2010_April.pdf



http://esd-standards.intranet.alcoa.com/ESD_WEB/asp_files/logpdf.asp?Filename=/esd_web/Site_Facilities/33_055_1_2010_January.pdf&DocNum=33.055.1&theFile=33_055_1_2010_January.pdf


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use of tools and equipment. This process provides information necessary to make judgments as to the contractors' potential to meet Alcoa EHS expectations once on site and should be used for screening bidders. The use of this information for evaluating consultants, engineering and other professional services is optional, with the following exception; if we have any contracted service where the provider or providers will be involved with contractors covered by the standard they, too shall have the standard applied.

5 PRE-BID MEETING Prior to starting work, the ECPM shall meet with Alcoa’s representatives, including the Project Manager and Alcoa Responsible Person(s), for a pre-bid meeting in order to ensure a correct understanding of the required EHS, security, fire protection, accident reporting, permits, scheduling, and operating requirements. The Contractor shall supply the Alcoa representative(s) with copies of the Contractor's Safety Manual, training documentation, and any other related materials. The meeting will consist of a review of the job scope and a site visit. A Hazard Identification & Risk Assessment will be developed so that all safety and health aspects of the work will be identified and the contractor can be well informed of all the requirements as they prepare their bid. The meeting will also address materials and equipment required to perform the job. The Hazard Identification & Risk Assessment shall be reviewed with the crew prior to starting work.

6 INDUCTION TRAINING “Level III” induction training in accordance with Alcoa Fjardaal Contractor Safety Program is required for all contractor entities that perform work for Alcoa. Induction training shall be presented by the Alcoa Responsible Person(s) or other designated trainer who has written authorization from Alcoa. The training will be site-specific and may be in the form of overheads, videos, or other prepared material. Information on EHS aspects of the job or task, Site Conditions, emergency procedures, permit requirements, traffic patterns, adjacent operating production equipment, and waste disposal shall be included in the training. The training program should conclude with a test for comprehension. The training shall be documented and a Photo ID, or other appropriate means of employee identification, shall be presented to employees who have successfully completed the Contractor training. Records shall be maintained by the ECPM that provide training information that include, but is not limited to the topic, instructor, date, length of training and location.

7 ENVIRONMENTAL EXPECTATIONS The Contractor is expected to operate in a manner, which protects the environment and the health of his employees and the citizens of the surrounding community. Releases to the environment, including spills, gas releases, explosions, etc., are considered a serious matter. A release constitutes potential for ground water contamination, surface water contamination or releases of hazardous materials into the atmosphere, even if the material released is not generally considered hazardous. Releases that could be encountered at the location include, but are not limited to the following:

1) Oil/Petroleum Spills (diesel, gasoline, etc.) 2) Hazardous Waste Spills 3) Hazardous Substance Spills/Releases (solvents, acid, paint, etc.) 4) Fires or Explosions related to any of the above.


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Contractor shall provide impermeable secondary containment in storage areas where flowable materials are subject to spilling. Contractor shall maintain a spill kit with adequate materials to protect against the specific substances that can potentially be spilled or released. If a release occurs, the Contractor shall take the following steps:

1) Attempt to contain the release without risking bodily harm. If there is immediate danger, evacuate the area. 2) Immediately contact the Location Emergency Response Team and provide them with the details of the release, even if the material involved is not considered hazardous. The EPCM shall also be contacted as soon as the appropriate containment and notification activities have been completed.

When notifying the Alcoa Location Emergency Response Team (Securitas – 843 7600), provide the following information:

1) Exact location of the release. 2) Type and description of released material. 3) Estimated amount of material released or size of the fire. 4) Extent of injury or property damage occurring. 5) Extent of actual or potential environmental damage, if known. 6) What actions, if any, have been taken to control the release?

The Alcoa's Location Emergency Response Team will take appropriate action according to the Location Release Prevention, Control and Countermeasure Plan. The Contractor is required to comply with the Emergency Planning and Community Right-to-Know Law and all applicable State Right-to-Know Laws. The EPCM along with Alcoa will ensure the Contractor is aware of any location specific environmental concerns. Disposal of Contractor generated batteries, engine oil, transmission fluids, hydraulic fluids, filters, radiator fluids, tires and fluorescent light bulbs shall be in accordance with Alcoa’s Environmental Waste Disposal Plan. The ECPM in collaboration with the Alcoa Representative will direct the disposal of any non-hazardous waste from the job sites. The ECPM in collaboration with the Alcoa Representative shall direct the disposal of any hazardous waste from the job sites. Advanced notice must be given to Alcoa’s Environmental Representative so that appropriate sampling, labeling and notifications can be made.

8 HEALTH AND SAFETY EXPECTATIONS

8.1 Conduct of Contractor Employees While on Alcoa Property, the Contractor's employees shall not engage in any dangerous, illegal or outrageous conduct, including but not limited to the following:

1) Violating safety rules or common safety practices, or causing a safety threat to a co-worker. 2) Creating or contributing to any unsafe or unsanitary condition. 3) Unnecessarily distracting the attention of any employee who is working, or participating in a non-work related activity that interferes with job. 4) Using abusive language. 5) Threatening, intimidating, harassing, coercing or interfering with fellow employees.


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6) Discriminating by talk or action against groups or individuals on the basis of race, color, sex, age, religion, disability, veteran’s status, pregnancy, or national origin. 7) Immoral conduct or indecency, sexual harassment, or possessing or displaying offensive verbal, visual or physical material or objects of any kind. 8) Fighting or instigating a fight. 9) Theft, abuse or deliberate destruction of property, tools or equipment of employees or the Company. 10) Gambling of any type. 11) Possessing or consuming any intoxicating beverage or illegal substance on the premises. 12) Reporting for work in an unfit condition, including being under the influence of intoxicants or controlled substances, or misuse of any prescription drug. 13) Refusing to submit to drug and/or alcohol testing when properly directed by supervisor. Test results showing the presence of alcohol or illegal drugs in any amount. 14) Possessing firearms or other weapons on Company premises. 15) Making false or malicious statements concerning an employee, the Company, or its products. 16) Falsifying records, including time cards, or making untrue statements that may result in the falsification of records, or abuse of Company credit cards, phone cards, or expense accounts. 17) Misusing or removing from premises, without permission, employee lists, blueprints, records, or confidential information of any nature, in any form. 18) Soliciting, collecting contributions, or distributing written or printed matter without permission of management. 19) Posting or removing notices, signs or writing in any form on bulletin boards or Company property without specific permission of management. 20) Possessing or using televisions, radios, DVD’s, or cameras for personal use on Company premises without permission. 21) Horseplay or throwing materials on Company premises, or not giving attention to job during working hours. 22) Failure to obey supervisor or other forms of insubordination. 23) Leaving job or work area during working hours without permission. 24) Performing personal work on Company time or excessive use of telephones for personal use. 25) Any action or behavior illegal under local, state or federal law. 26) Smoking outside of designated smoking areas.

8.2 Substance Abuse Possessing or consuming any intoxicating beverage or illegal substance is forbidden. It is the responsibility of the contractor to monitor their employees prior to their entry to Alcoa property and also in the course of their work. Those found to be under the influence of alcohol or drugs will be removed from the premises and will be denied future admittance. Contractor and Subcontractor employees may be required to submit to drug and/or alcohol testing in compliance with Alcoa policy and EU regulations. Test results showing the presence of alcohol or illegal drugs in any amount will be grounds for dismissal.


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8.3 Housekeeping Good housekeeping is indicative of a proactive safety attitude and can eliminate the root cause of many accidents. Good housekeeping practices increase productivity and improve the quality of goods produced and services rendered. Housekeeping is the responsibility of each Contractor or Subcontractor who shall:

1) Have a daily clean-up plan. 2) Stack materials to maintain safe clearances and prevent toppling. 3) Remove loose overhead materials. 4) Immediately remove or bend over any nails protruding from lumber. 5) Not allow refuse to accumulate. 6) Locate containers throughout the Contractor's work area for collection of his employee's trash and empty on a regular basis. 7) Maintain unobstructed passageways for pedestrian and vehicle traffic. 8) Obtain approval for material storage locations from the Owner's Engineer. 9) Maintain roofs free of combustibles, trash and debris. 10) Secure all loose materials so they cannot become airborne. 11) Maintain hoses and cords such that they will not become tripping hazards. 12) DO NOT store material or equipment under or near high voltage lines or equipment. 13) Compressed air used for cleaning shall be fitted with a bypass on the nozzle to prevent air from being injected through the skin. Compressed air shall not be used for personal cleaning.

The specific locations for the disposal of varies waste (clean excavated material, common construction trash, solvents, flammable liquids, etc.) shall be in accordance with Alcoa instructions.

8.4 Work Permits A work permit is a written document requiring authorized sign-off by Alcoa/Designee and the Contractor to perform designated activities. The work permit is the final check-off document that ensures that all aspects of the job have been evaluated and safe work procedures developed to prevent incidents. Work permits include, but are not limited to:

1) Hot Work Permit for welding, burning or grinding. 2) Digging Permit for excavation, trenching or other ground surface permeation. 3) Fall Control Plan for working at unprotected heights over 3 meters. 4) Roof work plan for working on low-sloped roofs at heights over 1.6 meters. 5) Confined Space Permit for entering any confined space 5) High Voltage Clearance for working on or near high voltage. 6) Working with or removing hazardous materials

The Alcoa Responsible Person(s) will provide the Contractor with details regarding other work permits that may be required to perform work in other high hazard areas such as high fire risk or explosion areas, and high potential chemical exposure areas.


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8.5 Hazardous Material Handling The Contractor must comply with the Hazard Communication Standard, all applicable Right-to-Know laws and shall use document 33.052.4 Hazardous Chemical Communication for Contractors, Subcontractors and Contracted Services Working on Engineering to assist with compliance. Alcoa will make the Contractor aware of specific industrial Hygiene concerns. In accordance with document 33.052.4, Hazardous Chemical Communication for Contractors, Subcontractors and Contracted Services Working on Engineering the Contractor will:

1) Provide Alcoa with a list of all hazardous materials that the Contractor brings into the workplace. 2) Provide Alcoa with MSDS describing in details the hazards of each hazardous material. 3) Label all containers of materials brought onto the workplace. 4) Provide its employees with information and training on the hazardous chemicals in their workplace

In accordance with document 33.052.4, Alcoa will: 1) Provide Contractors with a list of the hazardous materials to which the contractor or subcontractor may be exposed in the workplace. 2) Make available to the contractor or subcontractor and their employees Alcoa’s MSDS for each substance in Alcoa’s material inventory. 3) Notify the contractor of appropriate emergency procedures for the workplace.

8.6 Mobile Equipment Contractors may not operate any equipment belonging to Alcoa unless authorized by the Alcoa Responsible Person(s). Contractors who use equipment belonging to Alcoa shall sign a “Equipment Hold Harmless Agreement” prior to use. Contractor shall ensure that employees assigned to operate mobile equipment have had the required medical clearance, training and licensing and have demonstrated the necessary skills to operate the equipment. Contractors shall also ensure and attest that the equipment has been successfully tested and checked for compliance with applicable European Union requirements. Each operator prior to operating the equipment shall complete a written “Pre-Operational Inspection”. The inspection remains on the vehicle for a shift and is reviewed and filed by the Contractor. Immediate action shall be taken on items noted that pose serious safety concerns. Personal vehicles that are operated on the plantsite shall be inspected once a week with a minimum of 7 days between inspections. All motor vehicles and mobile equipment shall be maintained in a safe operating condition, free of oil, hydraulics, and other fluids leaks, and with the necessary guarding of moving parts in compliance with Alcoa’s requirements. Motor vehicles and mobile equipment shall be equipped with a flashing light, fire extinguisher, first aid kit and back-up alarm in accordance with Alcoa’s requirements. All vehicles shall be inspected by Securitas and approved prior to initial entry onto the plantsite. Vehicles shall have a identification sticker affixed in the lower corner of the driver´s side windshield that indicates the vehicle has been inspected and is authorized on the plantsite for the current time period. Contractor's equipment shall have occupant restraints and roll over protection (if so equipped) and used as required by Alcoa location policy. When mobile equipment is not in use, it must be positioned where it will not obstruct roadways, walkways, electrical lines or temporary passageways. All equipment not in use must be secured to prevent movement or operation.

http://esd-standards.intranet.alcoa.com/ESD_WEB/asp_files/logpdf.asp?Filename=/esd_web/Site_Facilities/33_052_4_2010_April.pdf&DocNum=33.052.4&theFile=33_052_4_2010_April.pdf

http://esd-standards.intranet.alcoa.com/ESD_WEB/asp_files/logpdf.asp?Filename=/esd_web/Site_Facilities/33_052_4_2010_April.pdf&DocNum=33.052.4&theFile=33_052_4_2010_April.pdf


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Mobile cranes shall not be parked with the boom suspended over walkways, employee passageways, roadways, electrical or mechanical equipment or buildings. Mobile cranes shall not be parked in location that may obstruct building crane or bridge crane travel. When mobile equipment is in use, clearances shall be maintained to prevent anyone from being caught between the equipment and structures. The Contractor shall barricade the work area or provide a safety watch person for the protection of persons passing by. Proper distance from electrical lines shall be observed per the requirements of document 32.60 titled High Voltage Electrical.

8.7 Ladders/Scaffolding Ladders and scaffolding shall be in good condition and comply with Alcoa requirements. Ladders shall be unpainted and constructed from non-conductive materials. Ladders shall be inspected prior to each use and routinely inspected and tagged once every 6 months. Scaffolding shall be erected by a competent scaffold person and shall be inspected each day prior to use.

8.8 Electrical Hazards All Contractor employees must be aware of the electrical hazards that exist at this location and follow the safe work procedures described below that are required to address them. These hazards are broken down into the categories of High Voltage (over 1000 volts) and Low Voltage (under 1000 volts).

7.9.1 High Voltage 1) Unless specially trained and authorized, DO NOT work on or around any high voltage power lines or electrical equipment. Special training shall be required as defined in document standard 32.60 and certified by the Alcoa Responsible Person(s). 2) DO Assume all power lines and electrical equipment are energized. 3) DO NOT work within 3 meters of uninsulated power lines or equipment. 4) DO NOT have materials, tools, or other objects within 3 meters of un-insulated power lines or equipment. 5) DO NOT operate mobile equipment within 3 meters of un-insulated power lines or equipment. 6) DO NOT place buildings, store materials, park vehicles, etc. under power lines or within a 3 meter right of way of power lines. 7) DO NOT block access to substations or other electrical equipment. 8) DO NOT work outside during thunderstorms or when lightning is present. 9) DO NOT leave a vehicle or other mobile equipment if it becomes energized due to contact with a high voltage power line. 10) DO notify the appropriate authority in the event of an electrical malfunction. 7.9.2 Low Voltage 1) DO NOT work on or around any electrical equipment unless you have been specially trained and certified. 2) DO NOT store materials, park vehicles, or leave equipment within 1 meter of breaker panels, transformers, or other electrical equipment. 3) DO NOT touch cables, breaker panels, transformers, or other electrical equipment. 4) DO NOT use faulty electrical tools, cords, or other equipment.

http://esd-standards.intranet.alcoa.com/ESD_WEB/asp_files/logpdf.asp?Filename=/esd_web/Engineering_Control_EHS/32_60_2011_February.pdf&DocNum=32.60&theFile=32_60_2011_February.pdf

http://esd-standards.intranet.alcoa.com/ESD_WEB/asp_files/logpdf.asp?Filename=/esd_web/Engineering_Control_EHS/32_60_2011_February.pdf&DocNum=32.60&theFile=32_60_2011_February.pdf


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5) DO use grounded or “Double Insulated” tools, cords, and other electrical equipment. 6) DO use “Ground Fault” outlets and/or cords for all construction activities. 7) DO use electrical cords and power tools that have an inspection tag showing the current inspection period. 8) DO NOT use metal or other conductive ladders. 9) DO NOT remove “Ground” wires from poles, towers, fences, transformers, motors, panels, or other electrical equipment.

8.9 Work Requiring Special Skills All Contractor employees who work in jobs that require special skills shall be qualified. If they do not have the appropriate qualifications, the Contractor shall provide EHS Specific Training. This training shall be specific to the hazards involved and provide the necessary knowledge and skill to safely perform the work. The Alcoa Responsible Person(s) will evaluate this training to assure that it meets Alcoa’s requirements. All training shall be documented and readily available to designated Alcoa and Contractor personnel.

9 LOCATION SPECIFIC ISSUES

9.1 Securitas

9.1.1 Property Control Contractor or Contractor's employees shall not remove Alcoa property from the plant location without approval of the Alcoa Responsible Person(s). This includes equipment, materials and waste. In the interest of security and plant protection, Contractor's employees are discouraged from bringing packages other than essentials, such as lunches, toolboxes and work clothes into the plant. All such items, as well as personal vehicles, are subject to inspection by Alcoa's security personnel both upon entering and leaving the plant site. Failure to submit to inspection will be sufficient grounds for restricting the individual from further entry to the property. Entrance to all contracted work by Contractor’s employees, visitors and deliveries shall be through the gate designated by the Alcoa Responsible Person(s). Contractor’s personal property removed from the construction site must be accompanied by a Gate Pass approved by Alcoa Responsible Person(s).and presented at Securitas.

9.1.2 Entrance Identification All employees of the contractors who are on site must have a Photo ID Site Entry Badge. Alcoa will provide the Site Entry Badge after employees have successfully completed the required Level 3 EHS Orientation and Training. The Site Entry Badge must be worn in view while working, or in the employee’s possession. The Site Entry Badge will be presented to Securitas whenever the Contractor Employee enters or departs the plant, and any other time it may be required. The Site Entry Badge or equivalent is good for one calendar year, after which, refresher orientation and training may be required, and the Site Entry Badge will be renewed.


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9.2 Driving and Parking Contractors must attend the Fjardaal Driver Training course and be approved to drive on the plant site by the Alcoa Responsible Person prior to driving on the plant site. Contractor's employees shall park their personal vehicles in those areas designated by the Alcoa Responsible Person(s). Alcoa is not liable for these vehicles. Contractor personnel shall remain in the area where their work is to be done. If access to and from the work area requires personnel to walk through a production area, pedestrian walkways shall be used wherever provided. Contractor’s personnel driving any mobile equipment shall obey all plant speed limits and warning signs. Failure to obey plant mobile equipment rules and speed limits will result in suspension of the contractor´s plant driving privilege.

9.3 Emergency Plan Before beginning work on a contract, the Contractor will be provided with Alcoa’s location specific Emergency Plan which will address the appropriate responses and expectations of the contractor at the location at the time of an emergency. The Contractor shall comply fully with this plan, communicate it to his/her employees and include any necessary training to ensure compliance. Report all emergencies to Securitas at 843-7600. Notify your Alcoa Responsible Person or Project Leader as soon as possible.

9.4 First Aid and Emergency Treatment and Response Plan Information will be provided to the Contractor regarding the use of Alcoa’s Emergency Medical and Rescue Response services. The emergency number for Alcoa Fjarðaál is 843-7600. The Contractor will be required to sign a “Medical Hold Harmless Agreement” governing the use of these facilities and the billing of the services. Many diseases are transported through the blood and bodily fluids. Anyone who may be exposed to blood and other bodily fluids must be trained and know the proper measures of control on prevention of exposure. If the Contractor has an employee with occupational exposure to blood-borne pathogens, they shall establish a written exposure control plan designed to eliminate or minimize the employee’s exposure.

9.5 Personal Protective Equipment (PPE) Personal Protective Equipment shall be kept clean and in good working condition. At minimum, Contractor's personnel shall wear the following personal protective equipment at all times on the plantsite unless in office buildings, lunchrooms, break rooms or any designated PPE free zone.

1) Long sleeve shirts that reach to the wrists. 2) Ankle length trousers. 3) Marlin V pants, shirts, jackets and coveralls are required in all production areas including the Potrooms, Rodding, the Casthouse, Maintenance and the Substation. 4) Contractors in construction areas may wear substantial clothing and foul weather clothing provided it is approved by the Alcoa Responsible Person. 5) Hi-Visibility vests or jackets shall be worn in construction areas that have been previously identified as a requirement for mobile equipment/pedestrian safety 3) Approved ANSI Z89.1 or equivalent non electricity conductive hard hat. 4) Steel toed safety boots with metatarsal guards.


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5) Approved ANSI Z87.1 or equivalent plastic safety glasses with permanent rigid side shields. Wire frame glasses are permitted if covered by approved safety glasses that encompass the wire frame glasses. 6) Working in certain exposures or operating areas of the plant may require additional PPE such as chemical resistant suits, arc flash protective equipment, fire retardant clothing, respirators, face shields or fall control equipment. 7) Approved hearing protection in all areas with noise level over 85 dBA or where posted signs indicate.8)

9.6 Fire Protection Temporary Buildings The type of construction, i.e., combustible or non-combustible, and location of temporary buildings shall be approved by the Alcoa Responsible Person(s) and the Plant Building Inspector. Temporary buildings located within another building or structure shall be of either a non-combustible construction or of a construction having a fire resistance of at least 1 hour. Temporary buildings, located outside and not used for the storage or handling of flammable or combustible liquids, flammable gases, explosives, blasting agents or similar hazardous occupancies, shall be located at least 3 meters from another building or structure. Buildings shall meet all applicable Alcoa and Icelandic building codes including proper number of fire extinguishers, adequate exit signs, proper door handles, etc. Open Fires are prohibited. Storage and Dispensing of Flammable Liquids

1) Do not store flammable liquids inside buildings unless approved by the Alcoa Responsible Person(s).

2) Outside temporary/portable storage tanks of 1000-gallon maximum size shall be placed a minimum of 25 meters from buildings, construction equipment, parking lots, etc., to minimize their exposure to a fire involving the tank. Provide spill containment equivalent to the capacity of the storage tank. These tanks shall be equipped with self-closing dispensing nozzles. Containers of flammable liquid with flash points below 60 degrees C (vapor pressure not exceeding 70 millibar absolute at 38 degrees C) shall be provided with atmospheric and emergency relief vents equipped with flame arrestors. Tanks or drums from which such flammable liquids (by definition above) are dispensed shall be electrically grounded and shall be equipped with bonding wires to complete the grounding with the vessel into which the liquid is dispensed.

3) Identify tanks with the contents stenciled (4" letters) neatly on all viewable sides of the tank.

4) No smoking or open flames are allowed in flammable liquid storage areas. Post conspicuous and legible signs prohibiting smoking.

5) Provide portable dry-chemical fire extinguishers for fuel storage tanks, the size of which is consistent with NFPA Standards.

Refueling of Vehicles Refuel vehicles only in pre-designated outdoor areas. As a minimum, observe the following procedures for refueling:

1) Shut off the vehicle engine. 2) Do not smoke. 3) Do not over-fill fuel tanks.


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4) When the fuel is liquid propane gas, ground the nozzle of the fuel hose to the vehicle filler pipe with a ground wire.

Transporting Flammable Liquids Use containers approved by Underwriters' Laboratories for transporting flammable liquids and clearly label them to identify the contents. Portable Fire Extinguishers (To be furnished by the Contractor)

1) Provide and regularly inspect portable fire extinguishers suitable for the potential hazard for equipment, office, building and work activities as per instructions issued by the supervisor of plant fire protection.

2) Install portable fire extinguishers on all lubrication trucks and all other mobile equipment such as trucks, mobile cranes, service vehicles, etc.

Burning and Welding Perform burning and welding only in areas approved by the Alcoa Responsible Person(s) and with an approved welding or burning (Hot Work) permit. Generally, Securitas is responsible for issuing Welding & Burning Permits. Gas Cylinder Precautions Observe the following precautions when using or storing oxygen, acetylene and other flammable gas cylinders:

a) Oxygen storage areas shall be separated by at least 8 meters from combustible liquids, flammable materials or heat sources such as fire, molten metal or electric lines. If impossible to comply with this 8 meter distance, then isolate the oxygen storage area by a non-combustible fire barrier with a 1/2-hour fire-resistant rating.

b) Do not transport gas cylinders by overhead building cranes or truck cranes except in approved holder or carrier designed for this purpose.

c) Properly vent oxygen storage areas. d) Gas cylinders shall be stored, used and transported vertically and adequately

secured; keep valve caps in place when cylinders are not in use. e) Gas cylinders shall be stored in designated areas. If used in construction zones

or buildings, they shall be stored near the exit doors. e) Maintain regulators and gauges for oxygen and fuel in proper working order while

in use. Keep oil and grease away from oxygen cylinders, fittings and hoses.

9.7 Utilities When water, steam, compressed air, electric power or other utilities supplied by the Owner are used by the Contractor, the points of connection, method of connection and connected load shall be approved by the Owner's Representative.

10 REFERENCES 9.2 Alcoa EHS Controlled References - The following are EHS Controlled

Documents that have frequent application in contracted work and shall be considered where applicable to Contractor or Contracted Service work being performed.

Trusted Contractors, suppliers, consultants, etc will be granted access to Alcoa’s online documents. To reach Alcoa’s EHS Standards home page, click this link:

Alcoa’s EHS Controlled Documents Home Page

http://ehs-standards.intranet.alcoa.com/ehs_web/displayoverview.asp?cat=1&subcat=2&link=14


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15.1 Material Handling Slings 16.4.1 Excess Air Flow Safety Valves 17.10.1 Low-Velocity Powder-Actuated Tools 18.1 Entering and Working in Confined Spaces 18.1.1 Respiratory Protection 18.2 Fall Control 18.3 Tagout / Lockout / Verification Procedures 18.4.2 Prevention of Explosions of Aluminum Fines and Dust 18.6.1 Safe Handling of Compressed Gases 18.14 Welding and Cutting Containers 18.17 Project Environment, Health and Safety Review 18.17.1 Project Environment, Health and Safety Review Hazards Checklist 18.17.2 Project Environment, Health and Safety Review Process Checklist 18.17.3 Project Environment, Health and Safety Review Hazard

Questionnaire 18.18 Asbestos Operations 18.18.1 Asbestos Management 18.18.2 Asbestos Identification 18.18.3 Contractors Specification For Asbestos Work(1/22/96 revision of

form No. 1059A) 18.19 Excavation Trenching and Shoring 18.20.2 Specifications for Lead Hazard Control 18.20.3 Lead Hazard Control Checklist 30.3.1 Noise Control Specifications 30.3.2 Sound Level Requirements for Purchased Leased or Rented

Vehicles 30.31.1 Free Moving Mobile Equipment Safety 32.60 High Voltage Electrical 32.60.1 Electrical High Voltage Maintenance and Design Safety

Practices 32.60.1.1 High Voltage Electrical Assessment. 32.69 Low Voltage Electrical 33.013 Design Construction and Installation of Fixed Platforms

Walkways Stairways Ladders and Floor Openings 33.051.1 Government Regulatory Agency Project Inspection Guidelines 33.052 Contractor and Contracted Services Environment, Health and

Safety Process 33.052.1 Safety and Health Evaluation of Outside Contractors and

Subcontractors 33.052.4 Application of OSHA Hazard Communication Standard for

Outside Contractors 33.052.5 Application of OSHA Process Safety Management of Highly

Hazardous Chemicals Specification for Outside Contractors 33.053 Safety in Painting 33.054 Safety in Explosive Blasting 33.055 Foreword to Contracted Services Prequalification Questionnaire 33.055.1 Contracted Services Safety Prequalification Questionnaire


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11 INJURY/ILLNESS/INJURYFREE EVENT - NOTIFICATION, INVESTIGATION AND REPORTING

Contractor shall notify the Alcoa Responsible Person(s) immediately of ALL injuries, industrial illnesses, injury free events and property damage incidences. The Contractor shall investigate all incidents including first aid visits, recordable injuries, high potential injury-free and property damage events. The severity of the injury or severity potential of the injury free event will determine the degree of Alcoa’s participation in the investigation. Alcoa's Injury/Illness/Injury Free Event will be used for accident/incident reporting. Contractor shall submit a written report to Alcoa Responsible Person(s) of recordable and suspect recordable injuries, and major injury free events within 24 hours.

12 ADMINISTRATION REQUIREMENTS The Contractor will be provided with the appropriate documentation before beginning any work. The Alcoa representative will work with the contractor to ensure they understand the documents and how they should be utilized. The Contractor is responsible to consult with Alcoa if there are any questions regarding these documents. Prior to bidding a new job, the Contractor attend a Pre-Bid Meeting at which time the administrative requirements will be explained and a site visit conducted for the purpose of evaluating the job including health and safety requirements. All hazards and abatement processes will be identified through the utilization of a Hazard Identification & Risk Assessment also known as an EHS Risk Assessment. This will give the Contractor an opportunity to factor in the health and safety aspects in their bid. When a bid is awarded and the work is ready to commence, the Contractor will conduct an additional EHS Risk Assessment for each specific job. When the risk assessment is complete, a Work Permit checklist will be issued by the Alcoa Responsible Person or Project Leader that will ensure that the Risk Assessment and all related permits are completed, as well as other safety and health controls such as housekeeping plans, material storage, MSDS, etc. Some work will require that a Work Permit is issued each day due to the complexity of the job. Prior to starting work each shift, all Contractor employees shall attend a Pre-shift Safety Toolbox Meeting using a Daily Tool Box Meeting Card. This meeting will ensure that all employees understand the scope of the work, and EHS expectations for the work to be performed. Construction Contractors supervision shall review the applicable parts of the EHS Risk Assessment with the employees at the beginning of the shift and shall document this meeting on the Daily Tool Box Meeting Card that is signed by all participants. Any employee who joins the work later must review the card with the Contractor supervisor. All Contractors shall complete a “Contracted Services Weekly Incident Report”. The summary shall be given to the Alcoa Responsible Person(s) no later 10:00 am on Tuesday of the following week. This report includes man-hours worked for all areas of the plant and accident information. All Contractor employees prior to starting work shall attend the plant Safety Orientation and complete a test for comprehension. The Alcoa Responsible Person(s) or their designee will conduct an additional Contractor Safety Orientation that will provide specific EHS requirements for the specific work they will be doing. The orientation in addition to specific training for the work will be required for Contractors to access the site through a Level 3 permit. All orientations will be documented and a Site Entry Badge will be issued to each contractor employee. The contractor employee is expected to wear this badge in a visible location on the shirt or around the neck with a “break-away cord while on the plantsite. If there are additional PPE requirements for the job that will require additional primary clothing to be worn, the badge may be tucked under this clothing.


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In summary, Alcoa considers the safety of Contracted Services workers as their top priority, just as any person who enters the Alcoa Fjarðaál Site. Contractors are expected to manage their work in compliance with all Alcoa EHS requirements and not compromise the health and safety of their employees for production or profit. Alcoa Fjarðaál welcomes the opportunity to assist in any way to ensure that Contractors work is performed safely so each employee can leave work in the same condition in which they arrived.

Alcoa Fjarðaál RF16 Project

Pre-Bid Risk Assessment Concrete Work in Bay, Duct

Banks and Tunnel Extension

PROJECT NO: H001-03

DOCUMENT NO: H001-03-312-117-C-HS00-553-001

PAGE NO: [1 of 7]

00 2011-09-26 Issued for Use JD EV ÁKS SJ



APPROVED PROJ. MGR

APPROVED CLIENT

FJARÐAÁL RECTIFIER PROJECT Pre-Bid Risk Assessment

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1 Scope ........................................................................................................................................ 3

2 Contractor EHS Expectations .................................................................................................... 3

Alcoa and Fjarðaál Rectifer Project General Rules ........................................................................ 3

Personal Protective Equipment (PPE) ........................................................................................... 3

3 Contractor EHS Processes ........................................................................................................ 4

Contractor Job-Specific Requirements. ......................................................................................... 4

4 Risk Assessment ....................................................................................................................... 5

Assessor ....................................................................................................................................... 5

Definitions ..................................................................................................................................... 5

Methodology ................................................................................................................................. 5

5 Model ......................................................................................................................................... 6

6 Risk Assessment ....................................................................................................................... 7


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1 SCOPE This document provides an overview of contractor EHS expectations and required conditions for work on the Fjarðaál Rectifier Project. An EHS risk assessment of potential hazards is also included along with the countermeaures that are recommended to ensure identified hazards are controlled or eliminated.

This information is intended to give the bidder the opportunity to consider the EHS implications of the project prior to submission of the bid. When the bid is awarded, this document will be considered as part of the contractual requirements of the job.

2 CONTRACTOR EHS EXPECTATIONS

Alcoa and Fjarðaál Rectifer Project General Rules

• Cameras are forbidden without the authorization of the Alcoa project leader. In the rectifier yard, a flash from a camera could be interpreted by sensors as an arc and will trip the rectifier effectively shutting down the plant.

• Never perform work unless authorized and all pre-job safety documents have been completed and approved.

• Respect all barricaded areas. • Do not approach operating vehicles unless the operator has eye contact with you and

signals the OK to advance. • Smoking is permitted only in designated smoking areas. • Good housekeeping is required throughout the jobsite. • Remain clear of all work activity unless the nature of your job requires that you

participate in the task. • Use 3 point contact when climbing into and out of vehicles and when using stairs and

ladders. • In the event of an emergency, depart the area and go to the assembly point near the

project laydown yard north of the Casthouse or to the assembly point north of the Hot Metal Road at the ¼ North A Potline door.

Personal Protective Equipment (PPE)

• Hardhat • Safety glasses • Authorized safety boots with metatarsal guards • High visibility FR vest or FR jacket • Substantial gloves • Hearing protection when operating equipment and machinery where noise levels exceed

85 dB • Natural fiber, or approved FR long sleeved shirt and pants • Additional PPE may be designated due to the nature of the work, proximity to

construction activities and environmental conditions.


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3 CONTRACTOR EHS PROCESSES Contractors, sub-contractors and other entities will first be cleared to work on the plantsite in accordance with the Alcoa Fjardaal Contractor Safety Program. This includes prior approval by the plant Contractor Safety Single Point Accountable person (SPA) or the plant EHS or Safety Manager.

• Prior to entry into any work site, the contractor will attend the appropriate level of site-specific training provided by the HRV safety representative.

• Contractors may not operate any equipment belonging to Alcoa unless authorized by the Alcoa Responsible Person.

• Contractors shall ensure that employees assigned to operate mobile equipment have had the required medical clearance, training and certification and have demonstrated the necessary skills to operate the equipment.

• All industrial mobile equipment, including mobile cranes, shall be inspected prior to the work shift. All pickups, vans and cars shall be inspected each week (every 7 days). These inspections shall be documented and readily available.

• All pertinent engineering and EHS construction standards shall be provided to the Contractor with the expectation of full compliance with these requirements. If any part is not understood, seek assistance from the HRV representative.

Contractor Job-Specific Requirements.

• Initiate the Pre-Job EHS Risk Assessment prior to starting any job or job task. o Revised when the scope of the work changes or new hazards are identified. o Signed by all work participants.

• Conduct a daily toolbox safety meeting of at least 10 minutes duration to discuss the EHS aspects of the day´s work. Initiate a Daily Tool Box Meeting (Day) Card prior to each day of work. The Day Card must be signed by all participants. Note - The Day Card is not necessary on the initial day of work when the EHS Risk Assessment has already been completed.

• Initiate all applicable construction permits (Excavation, Fall Control, Hot Work,etc). Permits must be pre-approved prior to starting the work and reviewed by all personnel who are under the protection of the permit.

• Identify the High Risk Task of the Day and write it in the appropriate block on the Day Card.

• Initiate a Work Permit at the start of each day. Both copies of the Work Permit must be signed by the Contractor Lead Person and a designated representative of HRV or Alcoa. Turn in and sign the completed form at the end of the work day.

• Update the information on the construction sign at the entrance to the work area. • Keep all EHS documents at the job site and ensure they are readily available for review

and inspection. • Conduct a minimum of 2 job inspections per week (or every two days for jobs of shorter

duration). • All paperwork shall be turned in to the HRV EHS Manager at the completion of the job. • Contractor hours charged to work both on and off the site must be reported to the HRV

EHS Manager by Tuesday of each week.


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4 RISK ASSESSMENT

Assessor

Jack Dayley EHS Manager, Alcoa Rectifier Project HRV Engineering IS: + 354 843 7901 US: +1 509 979 6788

Definitions

• Safety: The quality or condition of being free from the risk of injury, illness or incident. • Hazard: A condition or practice with the potential for accidental loss. • Risk: The chance or probability that a person will be harmed or experience an adverse

health effect if exposed to a hazard. • Countermeasure: An action, process, device, or system that can prevent, or mitigate the

effects of risk.

Methodology

This risk assessment follows a standard method utilized by reputable firms throughout Europe and endorsed by HRV and Alcoa Fjardaal. Risk is expressed through the combination of severity and probability of loss. A risk rating will be assigned to each identified hazard with consideration to normal access and egress along with potential work activities. Entrants are assumed to be wearing the appropriate PPE. Countermeasures will be considered and added that are intended to eliminate or control the risk. The countermeasure may or may not render the risk acceptable. There are two risk ratings – one is performed prior to identification of the countermeasure and the second rating is applied after the countermeasure to determine if the risk has been controlled. Injury agents will be identified as follows: • Struck by: A person is contacted abruptly and forcefully by some object in motion. • Struck against: A person abruptly and forcefully contacts some object in the work area. • Contacted by: Being touched by an object or substance causes an injury. • Contacted with: Coming in contact with the object or substance causes an injury. • Caught between: Also known as a pinch point. A person or body part is injured when it is

caught between converging objects or substances. • Caught on: A person (or some part of their clothing) becomes caught on some protruding

object. • Overexertion: A person is injured as a result of putting excessive strain on some part of the

body. • Trapped in: Trapped in some kind of enclosure, such as a confined space or an excavation

site. • Different level fall: A person falls below the level on which they were standing or walking, in

other words, falling below foot level. • Same level fall: A person falls to the same level being stood on or walked upon. • Exposure: Exposure to harmful conditions such as toxic fumes, vapors, gases or airborne

particles; temperature extremes; oxygen deficiency; radioactivity; or intense light.


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5 MODEL Probability Rating Value Example (System life cycle = 25 years)

Frequent 5 Likely to occur repeatedly in the system life cycle Probable 4 Likely to occur several times in the system life cycle

Occasional 3 Likely to occur sometime in the system life cycle Remote 2 Not likely to occur in the system life cycle, but possible

Impossible 1 Physically impossible to occur Severity Rating

Catastrophic 5 Fatal Critical 4 Permanent or irreversible injury or illness. Serious 3 Serious injury causing hospitalization, lost time from work,

Considerable 2 Medical attention, restricted work without lost time Minor 1 Physically impossible to occur

Frequency

Severity Frequent Probable Occasional Remote Impossible

Catastrophic Very High 25 Very High 24 Very High

22 High 19 High 15

Critical Very High 23 Very High 21 High 18 High 14 Medium 10

Serious Very High 20 High 17 High 13 Medium

9 Low 6

Considerable High 16 Medium 12 Medium 8 Low 5 Low 3

Minor Medium 11 Medium 7 Low 4 Low 2 Low 1


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6 RISK ASSESSMENT

Sequence of Job Activities Potential Hazard

Risk Level

Before Countermeasures

Risk Level After

1 Transportation of equipment and material to and from the site.

1.1 Injuries from being struck by mobile equipment.

22

1.1.1 All vehicles entering the Alcoa Fjardaal site must first be approved by Securitas.

5

1.1.2 Pre-operational inspection required prior to operating vehicle. 6

1.1.3 Pedestrians maintain at least 1.5 meters distance from operating vehicles. Escorts are required for all vehicles where the operation does not provide the operator with a clear view of the direction of travel (backing up, etc.) 6 1.1.4 All personnel who are not seated in vehicles will wear a high visibity vest or outerwear.

1.2 Molten metal hazard from Hot Metal Haul trucks

1.2.1 All vehicles will be parked with a minimum of 2 meters clearance from the edge of the Hot Metal Road.

2 Unload equipment

2.1 Strain/sprain from manual lifting. 13

2.1.1 Use forklift, crane or other mechanical means to remove equipment from trailer or truck. 3

2.2 Fall from truck bed. 22

2.2.1 Personnel are forbidden to walk on the bed of a truck higher than 1.2m without fall prevention/protection.

3 Erect forms and shoring

3.1 Strain/sprain from manual lifting and transport of shoring

13 3.1.2 Get assistance for any lifting more than 20k.

3

3.2 Fall from shoring and/or scaffolding

22

3.2.1 All shoring shall be approved by the HRV package manager.

3.2.2 All scaffold shall be erected by a competetent scaffold erector and inspected by a competent scaffold inspector.

3.3 Injuries from collapsing excavations or shoring.

3.3.1 Shoring and sloping shall meet or exceed Alcoa EHS Standards.

4. Install rebar 4.1 Puncture wounds from begin caught on or stepping on protruding rebar.

13

4.1.1 All exposed rebar that has the potential to cause a puncture must be capped.

5. Pouring concrete

4.1 Injuries from being struck by mobile equipment.

22

4.1.1 All vehicles entering the Alcoa Fjardaal site must first be approved by Securitas.

2 4.1.2 Pre-operational inspection required prior to operating vehicle. Concrete pump truck must be inspected prior to operation.