w-c-ss-014 steel coating works specifications

7/30/2019 W-c-ss-014 Steel Coating Works Specifications

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0 02-02-2002 Approved Issuerev. date Description/issued for prepared authorised

client: ADWEAproject: STANDARD SPECIFICATIONS FOR WATER WORKStitle: SPECIFICATION FOR PAINTING & EXTERNAL COATING OF METAL PIPES &

STRUCTURES

tender: project: document: W-C-SS-014 rev: 0 sheet: 1 of: 23

SPECIFICATION FOR PAINTING &

EXTERNAL COATING OF METAL PIPES

& STRUCTURES


2/23

Client ADWEAProject: STANDARD SPECIFICATIONS FOR WATER WORKSTitle: SPECIFICATION FOR PAINTING & EXTERNAL COATING OF METAL PIPES &

STRUCTURES


TABLE OF CONTENTS PAGE

1. SCOPE...................................................................................................3

2. APPLICABLE STANDARDS AND CODES ..........................................3

3. SITE CONDITIONS................................................................................5

4. TECHNICAL REQUIREMENTS.............................................................54.1 Surface Preparation....................................................................54.2 Environmental Conditions/Safety.................................................84.3 Painting .......................................................................................94.4 Repair of Defects.......................................................................12

5. SAFETY REQUIREMENTS .................................................................12

6. INSPECTION AND TESTING..............................................................136.1 General......................................................................................136.2 Environment ..............................................................................136.3 Surface Preparation...................................................................136.4 Coating Film Thickness .............................................................136.5 Calibration .................................................................................146.6 Inspection Report ......................................................................146.7 Testing Instruments/Tools .........................................................14

7. MARKING, HANDLING AND STORAGE............................................15

8. APPROVALS.......................................................................................15

9. QUALITY ASSURANCE/QUALITY CONTROL...................................16

10. PERFORMANCE GUARANTEE..........................................................17

11. ANNEXURES.......................................................................................17


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1. SCOPE

This specification covers the minimum requirements for the surface preparation, and painting,

of the following:

1. : External Coating System for Carbon Steel Above Ground Piping.

2. : External Coating System for Stainless Steel Above Ground Piping.

3. : External Coating System for Galvanized Steel Above Ground Piping.

4. : Coating System for Structural Steel (Non Galvanised).

5. : Coating System for Galvanized Structural Steel Parts.

6. : Coating System for Stainless Steel Structural Parts

Coating system on submarine pipeline, wood, concrete structures and metal fittings are not

covered under this specification.

No deviations or exceptions from this specification shall be permitted without the written

approval of the ADWEA/ENGINEER.

Intended deviations shall be listed by the manufacturer on a separate sheet of paper as an

alternative at the time of bids and supported with reasons by the CONTRACTOR for

consideration by ADWEA/ENGINEER.

Compliance with this specification shall not relieve the CONTRACTOR of the responsibility of

furnishing specified material.

The CONTRACTOR shall co-ordinate, expedite and resolve any problems with the

manufacturer/ supplier. The CONTRACTOR shall be responsible for ensuring that all relevant

information and documentation is passed on to the manufacturer/ supplier, to complete the

work to the satisfaction of ADWEA/ENGINEER.

The final responsibility for the satisfactory completion of the work shall lie with the

CONTRACTOR.

2. APPLICABLE STANDARDS AND CODES

Swedish Standard SIS 05 59 00 Pictorial Surface Preparation Standards Steel

Surfaces for Painting

SSPC - SP1 Solvent cleaning

SSPC - SP2 Hand tool cleaning

SSPC - SP3 Power tool cleaning

SSPC - SP10 Near-white blast cleaning

SSPC - PA1 Shop, field and maintenance painting

SSPC - PA2 Measurement of dry film thickness with magnetic

gauges


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ASTM B117 Salt spray (fog) testing.

ASTM D4060 Abrasion resistance of organic coatings by the Taber Abraser.

ASTM D4541 Pull off strength of coatings using portable adhesion tester.

ASTM D 5162 Dissimilarity (Holiday) testing of non conductive protective coating

on metallic substrates.

RAL 840 HR Standard Colours.

ISO 2409 Paints and varnishes cross of test for adhesion.

ISO 2808 Paints and varnishes Determination of film thickness.

ISO 4624 Paints and varnishes Pull off test for adhesion.

ISO 4628 Paints and varnishes Evaluation of degradation of paint coatings

ISO 8501 Preparation of steel surfaces before application of paints and related

products.

ISO 9001 Quality Systems Model for Quality Assurance in Design,

Development, Production, Installation and Servicing.

ISO 9003 Quality Systems - Model for Quality Assurance in Final Inspection

and Test.

ISO 9004 Quality Management and Quality System Elements Guidelines.

BS 245 Specification for mineral solvents (white spirit and related

hydrocarbon solvents) for paints and other purposes.

BS 3900 Methods of test for paints.

BS 5411 Methods of test for metallic and related coatings.

BS 6949 Specification for bitumen based coatings for cold application

excluding use in contact with potable water.

BS 7079 Preparation of steel substrates before application of paints and

related products.

BS 4164 Specification for Coal tar based hot applied coating materials for

protecting iron and steel, including a suitable primer.

BS 476 Fire tests on building materials and structures.


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BS 1070 Specification for black paint (Tar based)

BS 2523 Specification for Lead Based Priming Paints.

BS 4800 Schedule of paint colours for building purposes.

BS 5252 Framework for colour co-ordination for building purposes.

BS 6150 Code of practice for painting for buildings.

BS 7664 Specification for undercoat and finishing paints.

BS 8202 Coating for fire protection of building elements.

BS EN ISO 12944 Code of practice for protective coating of iron and steel structures

against corrosion.

AWWA C203 Water protective coating and lining for steel water pipelines enamel

and tape hot applied.

3. SITE CONDITIONS

For site and climate conditions refer General Technical Requirements document

4. TECHNICAL REQUIREMENTS

4.1 Surface Preparation

Surface preparation and technical requirements are applicable for the pipes and structural

items are as under.

4.1.1 Pipes

Surface preparation shall be carried out by dry blast cleaning to a visual standard in

accordance with Swedish standard SIS 05 59 00, Sa 2.1/2 (equivalent to U.S. Standard

SSPC-SP10), unless other wise specified.

Sand shall be not used as a blast cleaning material.

The abrasive shall be dry and free from oil, grease, dust, salts, and other impurities, and shall

not contain any sand or silica component.

The average profiles height shall be in the range of 50 - 80 microns . Rough peaks are

acceptable up to a maximum of 100 microns.

Alternative surface preparation techniques shall only be applied when dry blast cleaning is

unsafe, not feasible or impractical.


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Carbon Steel Piping shall be thoroughly cleaned of all dirt, grease, rust and scale by means of

chipping, scraping wire brushing and/or solvent cleaning in accordance with SSPC-SP1.

Particular attention should be given to the cleaning of welded, brazed and soldered joints.

The surface shall be blast cleaned to near white metal finish in accordance with SSPC-SP10.

Apply one coat of metal primer immediately on the cleaned surfaces as approved by the

ADWEA/ENGINEER.

Galvanised piping for painting shall be thoroughly cleaned of dirt, grease, dusted and washed

down with fresh water and/or suitable solvent. Any minor areas of rust shall be removed by

wire brushing and spot primed with a zinc rich primer. For weld repair and minor damage,

clean the damage area per SSPC SP3. Touch up with a high zinc dust content cold

galvanising paint.

If the priming coat of pre-primed metal work has suffered damage in transit, or during erection

on site, the affected areas shall be cleaned off by wire brushing, abrading and dusting off, the

bared patches touched up with a primer of a similar type to that already applied.

Priming shall follow manual preparation as quickly as possible and not later than on the same

day with blast cleaned surfaces. Priming should follow with in 1 hour and under no

circumstance later than after 3 hours after blasting.

All surface finish requirements shall be met at the time of commencing painting/coating

operations.

4.1.2 For Structural Steel Items

Bare metal work shall be thoroughly cleaned of all dirt, grease, rust and scale by means of

chipping, scraping and wire brushing, particular attention should be given to the cleaning ofwelded, brazed and soldered joints. Wash down with white spirit and wipe dry with clean

rags. Apply one coat of metal primer immediately the cleaned surfaces have been approved

by the ADWEA/ENGINEER. Iron and steel surfaces shall receive two coats of primer of 50

microns thickness.

Galvanised metalwork scheduled for painting shall be thoroughly cleaned of dirt, grease,

dusted and washed down with white spirit and wiped dry with clean rag. Any minor areas of

rust shall be removed by wire brushing and spot primed with a zinc rich primer. Apply at least

one coat of a two pack high build epoxy undercoat, pigmented with zinc phosphate to all

surfaces subsequently to be painted.

If the priming coat of pre-primed metal work has suffered damage in transit, or during erection

on site, the affected areas shall be cleaned off by wire brushing, abrading and dusting off, the

bared patches touched up with a primer of a similar type to that already applied.

Copper scheduled for painting shall be lightly abraded with emery cloth, washed with white

spirit and wiped dry with clean rag. When the cleaned surfaces have been approved apply.

One coat of etch primer of copper pigmented primer and one coat of alkyd gloss paint or other

approved coating system


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Aluminium scheduled for painting shall be lightly abraded with emery cloth, washed with white

spirit and wiped dry with clean rag. Apply a coat of each primer and zinc chromate primer

immediately the cleaned surfaces have been approved.

All surfaces finish requirements shall be met at the time of commencing painting/coating

operations.

4.1.3 Techniques and Restriction

4.1.3.1 Dry Blast Cleaning

Blast cleaning shall be done to a visual standard in accordance with Swedish standard SIS 05

59 00, Sa 2.1/2 (equivalent to U.S. Standard SSPC-SP10), unless other wise specified. Sand

shall be not used as a blast cleaning material. The abrasive shall be dry and free from oil,

grease, dust, salts, and other impurities, and not contain any sand or silica component. The

average profiles height shall be in the range of 50 - 80 microns . Rough peaks are acceptable

up to a maximum of 100 microns.

Blast cleaning shall only be conducted when the steel surface temperatures are minimum 3C

above dew point, and when the relative humidity is less than 85%, so as to avoid the risk of

condensation. Blast cleaning shall also not to be carried out during blowing winds or dust

storms .

Blast cleaning shall not be done where adjacent areas or equipment are insufficiently

protected from contamination by abrasive or debris.

Blast cleaning shall not be done in areas close to painting operations to prevent

contamination of wet paint films by dust and grit.

Factory coated equipment like pumps, compressors, motors, valves, electrical,

instrumentation and fire fighting items etc., shall be adequately protected prior to

commencing blasting operations.

All gasket surfaces, valve stems, name plates, pressure gauges, instrument cases, gauge

glasses, and all windows, previously coated or galvanized surfaces shall be adequately

protected prior to commencing any blasting operations (or these components shall be

carefully removed after proper marking and reinstalled at appropriate places after the blast

cleaning). All open piping, louvres, access fittings, nozzles, etc. shall be plugged or sealed to

prevent ingress of the abrasive material.

All welded areas shall be cleaned to remove weld slag and deposits in crevices. Welded

areas shall be freed from alkaline residues by rinsing with water. Weld splatter, slivers,

lamination and underlying mill scale, not removed during fabrication and exposed before and

during blast cleaning, shall be removed and the edges shall be ground flush.

Any blast cleaned areas not yet coated, which become rusty due to rain or condensation,

shall be reblasted to the specified grade of surface finish.


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4.1.3.2 Power Tool Cleaning

Power tool cleaning shall be to a visual standard in accordance with SIS 05 59 00 - St3

(equivalent to U.S. Standard SSPC-SP3). Power cleaning shall be done utilizing abrasive or

wire type power discs.

Where welds occur or when areas cannot accommodate a power disc, power impact tools

(needle guns, chisels) shall be applied followed up by wire brush cleaning.

4.1.3.3 Hand Tool Cleaning

Hand tool cleaning is the least effective of the surface preparation methods, but it may be

used for touch up/repair with certain surface tolerant coating systems. Handtool cleaning shall

be to a visual standard in accordance with SIS 05 59 00 -St2 (equivalent to U.S. Standard

SSPC-SP2). Cleaning shall be done with brushes, scrapers, sanders or other hand impact

tools.

4.1.3.4 Solvent Cleaning

Solvent cleaning shall be in accordance with U.S. Standard SSPC-SP1"Solvent Cleaning".

Before blast cleaning or power tool cleaning, and again before painting/coating, all surfaces

shall be examined for the presence of oil or grease. If present, it shall be removed by solvent

cleaning and the relevant areas shall be reblasted or power tool cleaned to the specified

standard.

All metal surfaces to be coated which do not require blast cleaning or power tool cleaning

shall be thoroughly cleaned to remove all mud, oil, grease or other foreign matter.

All bolt-holes shall be solvent cleaned before blast cleaning or power tool cleaning to remove

any oil/grease residues.

Note that solvent cleaning may incorporate the use of detergents or emulsifying agents. This

shall then be followed by fresh water washing.

No acid washes or other cleaning solutions or solvents shall be used on metal surface after

final surface preparation.

4.1.3.5 Surface Cleaning

Immediately after blasting stops, all grit, dirt and dust shall be removed from the area to be

coated by blowing -off with clean and dry compressed air or vacuum cleaning.

4.2 Environmental Conditions/Safety

Storage, handling, mixing, and application of the paints and materials shall be done strictly in

accordance with the manufacturer/supplier recommended procedures and hardware for

assurance of personal safety. Safety precautions shall be clearly written on the containers.


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Facilities shall be available for effective removal of spillage, collection and disposal of paints,

brushes, scaffolding, equipment, waste, etc., upon completion of painting activities.

All necessary precautions shall be taken to safeguard the environment.

The CONTRACTOR shall maintain all the blasting and painting equipment, airlines, etc., ingood working condition and shall place them in an orderly manner to avoid any obstruction

possible.

4.3 Painting

4.3.1 Materials

4.3.1.1 Preparatory Materials

Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping,

knotting, fillers and other commodities shall be of the types recommended by themanufacturer of the coating to be applied.

White spirit shall comply with BS 245.

Knotting shall comply with BS 1336.

4.3.1.2 Primers, Paints and Coatings

All brands of primers, paints and coating shall be approved and shall comply with the relevant

BS where one exists.

Undercoats on metal surfaces shall be of the drying-oil/resin binder type pigmented with

titanium dioxide and/or coloured pigments providing a matt or low-sheen finish suitable for

subsequent application of a drying-oil finish.

Water thinned priming paints and undercoats shall only be used with the specific approval of

the ADWEA/ENGINEER and compliance with BS 5082 will need to be demonstrated in order

to obtain such approval.

Finish coats on metal surfaces shall be of the drying-oil/alkyd resin binder type pigmented

with titanium dioxide and/or light fast, coloured pigments, marine environment type paint or

any other coating system approved by the ADWEA/ENGINEER.

4.3.2 Workmanship

Before painting commences all floors shall be washed over and every possible precaution

taken to keep down dust. No paint shall be applied to surfaces structurally or superficially

damp and all surfaces damp and all surfaces must be ascertained to be free from

condensation, efflorescence, etc., before the application of each coat.

No primed or undercoated metalwork shall be left in an exposed or unsuitable situation for

any undue period before completion of the painting process. No exterior or exposed painting

shall be carried out under adverse weather conditions, such as rain, extreme humidity, etc.


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All items not required to be painted (e.g. ironmongery) shall first be fitted and then removed

before any painting preparation commences. The fittings shall be refixed in position when all

painting is completed.

Brushes, pails, kettles, etc., used in carrying out the work shall be clean and free from foreign

matter. They shall be thoroughly cleaned before being used for different types or classes ofmaterial.

All materials shall be used strictly in accordance with the manufacturer's printed instructions

and paints of different brands shall not be mixed or used in the same coating system. No

dilution of painting material shall be allowed except strictly as detailed by the manufacturers

and as approved by the ADWEA/ENGINEER.

The specified surface finish shall exist at the time of applying the first coat. If required,

surfaces shall be re-prepared to the specified finish. Refer the Annexures 1 to 6 for the

applicable coating system.

All surfaces shall be rendered dust free and dry before painting.

Surfaces shall be cleaned by high pressure water to remove any dust, grease etc.; after the

first coat. The surfaces shall be rendered dry before applying the subsequent coats.

Storage, mixing to an even consistency, thinning and application of paints and coating

materials and the type of application equipment shall meet the instructions and

recommendations of the paint MANUFACTURER/SUPPLIER. Mixing by high speed shakers

or rotary mixers with flat blade and speed control, shall be done in a well ventilated and dust

free area.

Paint MANUFACTURER/SUPPLIER instructions and recommendations regarding pot life,

drying/curing intervals between successive coats and final curing periods shall be followed.

Such instructions and recommendations shall be mentioned on paint

MANUFACTURER/SUPPLIER data sheets and be appropriate for prevailing environmental

conditions.

The type, brand name, number of coats, colour and coating thickness shall be strictly in

accordance with this specifications and to the ADWEA/ENGINEER.

Paints shall not used beyond the date of expiry, where indicated on the container, oralternatively as stated by the MANUFACTURER/SUPPLIER for given batches. All paint shall

be used in order of its successive manufacture and/or delivery.

Paint shall not be applied within 50 mm of edges prepared for field welds, except when a zinc-

rich epoxy or equivalent is used.

No coating shall be applied when steel surface temperatures are less than 3C above dew

point, and when the relative humidity is more than 85% so as to avoid the risk of

condensation during painting.


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No coating shall be applied to surfaces which have a surface temperature above 45C at the

time of coating.

Precautions shall be taken to prevent the coating from being applied to name plates,

couplings, shafts, valve stems, bearings, linkages, vent openings, gauge glasses, pressure

gauges, instruments, windows, louvres, etc. Masking tape, plastic film, or some other suitablyimpervious material shall be used, and all materials shall be removed after the painting has

been completed and accepted.

All coating surfaces shall be kept clean and dry until the coating has reached a hard set.

All coatings shall be applied under favourable conditions by highly skilled applicators. Coating

shall not be applied to wet or damp surfaces.

Over spray and drip shall kept to an absolute minimum, consistent with good painting

workmanship practices. All unavoidable over spray and drip shall be removed or covered by

an additional finish coat.

Special attention shall be given to painter safety, ventilation, the use of non-explosive lights

and other safety equipment.

4.3.3 Application Methods

4.3.3.1 Spray Application

Application by spraying shall be the preferred process.

Spraying equipment, guns, nozzle sizes and pressure ranges shall meet the paintMANUFACTURER/ SUPPLIER recommendations for the material to be applied.

The equipment used shall be provided with adequate air and oil vapour traps, regulators and

gauges to achieve proper paint application. Traps or separators shall be periodically drained.

The air caps, nozzles and needles shall be those recommended by the Manufacturer of the

equipment for the material being sprayed.

The air pressure shall be adjusted to obtain optimum effectiveness that will cause no

excessive fogging of coating, excessive evaporation of solvent, or loss by over spray.

Ingredients shall be kept properly in agitation by mechanical means to maintain consistency in

the material. The spray equipment shall be kept sufficiently clean of dirt, any paint and other

foreign materials.

Each coat shall be applied uniformly and completely over the entire surface free from runs

and sags.

4.3.3.2 Brush Application

Brush application shall be done on areas which cannot be properly sprayed, and for touch-up

where spray application is not practical.


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Brushes shall be of a type and size which permits proper application of paint. Round or oval

brushes are most suitable for irregular surfaces, i.e. bolts holes, welds, pitted steel. Wide flat

brushes shall be used for large flat areas. The brushing shall be done such that a uniform

coat, with no deep or detrimental brush marks, is obtained. Paint shall be worked into all

corners and crevices. Runs and sags shall be avoided.

Surfaces not accessible to brushes shall be painted by spray or sheep skin roller.

4.4 Repair of Defects

When coating has been damaged in handling or due to any reason, all of damaged and

loosely adhering coating shall be removed and the surface shall be thoroughly cleaned. One

of the following methods shall be adopted with the approval of ADWEA/ENGINEER.

- Dry blast cleaning to standard Sa 2.1/2

- Power tool cleaning to standard St 3.

- Hand tool cleaning to standard St 2 (only in exceptional cases and only for minor touch

up/repair work).

Surfaces to be coated which become contaminated with oil, grease, salts, etc. shall be

cleaned with solvents and/or with detergent/fresh water solutions, followed by washing with

clean fresh water.

The type of coating materials used for repair shall be identical to, or in any case compatible

with the original materials. The designated coats of prime & finish coats shall be applied to the

satisfaction of ADWEA/ENGINEER.

All defects detected by spark testing (holiday detection) and any damaged coating areas

(resulting from mechanical damage or destructive testing shall be marked and repaired to the

satisfaction of ADWEA/ENGINEER.

The defective areas shall be cleaned down to bare metal and the surrounding coating edge

shall be bevelled. Repairs shall be then be effected by means of priming and coating.

The repaired coating shall meet the thickness requirements of the final coating and the

repaired sections shall be visually examined and re-inspected by spark testing.

5. SAFETY REQUIREMENTS

All necessary precautions shall be taken to ensure the safety of personnel and property. The

CONTRACTOR shall comply with applicable National, State or local codes and regulations

and safety orders and practices of the ADWEA covering working conditions, scaffolding,

clothing, fire and explosion hazards, safety equipment, solvents, lighting, venting and

grounding of tanks.

Rags and other waste material soiled with paints, thinners or solvents shall be kept in tightly

closed metal containers while on the job or not in use.


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Extreme precautions shall be used when working with paint materials, cleaning fluids, etc.

especially in close proximity to oxygen piping or oxygen equipment. Heavy concentrations of

volatile or toxic fumes shall be avoided. When working in confirmed areas, blowers or

exhaust fans shall be used.

Application of tar based paints may pose a risk to health under conditions. TheCONTRACTOR shall ensure that the health and safety data sheets provided by the

manufacturers of the product(s) are strictly observed.

6. INSPECTION AND TESTING

6.1 General

Visual inspection (by ADWEA/ENGINEER) of materials, equipment for surface preparation

and for coating application, hoses, scaffolding, protective clothing shall be carried out to

ensure conformance with the relevant technical and safety requirements of this Specification

and with manufacturer/supplier recommended practices.

6.2 Environment

Before commencing work on surface preparation and coating the atmospheric temperature

and the relative humidity shall be measured in order to determine the dew point.

Readings may have to be repeated depending on changes in prevailing weather conditions.

For measurements a temperature gauge and a hygrometer shall be used.

Following determination of the dew point, the steel surface temperatures shall be measured

by means of a magnetic steel thermometer, at regular intervals. The steel surfacetemperature shall be at a safe margin of 3C or more above the dew point and relative

humidity less than 85%, thus avoiding the risk of condensation during surface preparation as

well as during coating. During coating operations the steel surface temperature shall not

exceed 45C.

Coating application shall be discontinued when the steel surface temperature becomes higher

than 45C.

6.3 Surface Preparation

Cleaned surfaces shall be visually checked for conformance with the specified surface finishand for absence of contaminants before coating application.

On dry blast cleaned surfaces the profile height shall be spot-checked by means of a surface

profile gauge or with replica tape and a calibrated micrometer. (Keane Tator surface profile or

similar device may be used). The profi le height shall be within the range of 50 to 100 microns.

6.4 Coating Film Thickness

The wet film thickness shall be spot checked as an initial indication of the excepted dry film

thickness, using wet film thickness gauges of a relevant scale.


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The dry film thickness of individual coats and of the total coating system shall be checked at

random over areas representative of the work in hand by magnetic coating thickness gauge.

The number of selected areas needs to be assessed for each work. There shall be at least

one area each for horizontal, vertical and curved surfaces. The number of readings taken in

an area shall be decided by ADWEA/ENGINEER. However, a minimum of 5 readings shall be

taken in each area.

Additional readings shall be taken if there is any change in prevailing weather, personnel,

application equipment, spray nozzle size, thinning of the paint, etc.

The specified minimum dry film thickness shall not be exceeded by more than 50% with the

exception of areas such as welds, crevices, etc., where such a requirement is not practical.

Maximum 10% of the readings may be below the specified film thickness, but no single

reading shall be less than 90% of the specified film thickness.

Dry film thickness shall be measured with a coating thickness gauge, suitable for the giventype of coating, thickness range and substrate material (magnetic or non-magnetic).

6.5 Calibration

Profile height and film thickness gauges shall be calibrated before use, every day.

6.6 Inspection Report

A report shall be provided on completion giving details of the visual inspection carried out

together with the readings noted at the different stages when measurements were made.

Upon completion of each of the activities, listed below in each part of the work, the work shall

be suspended for the purpose of inspection and ADWEA/ENGINEER's witness.

- Preliminary cleaning.

- Fettling of welds, edges and defects in the steel.

- Surface preparation.

- Application of each coat.

-Drying of coatings.

- Cleaning between coats.

6.7 Testing Instruments/Tools

CONTRACTOR shall provide necessary testing instruments/tools at site.


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7. MARKING, HANDLING AND STORAGE

All materials for coating shall, until usage, remain in the Supplier's containers, marked with

supplier's name, brand, batch number and expiry date.

Storage conditions shall comply with supplier's data sheet recommendations.

All coated pipe joints shall be clearly marked internally near one bevelled end. The

information shall include steel grade, size and schedule as well as the date of coating.

The coated pipe joints shall at all times be handled and stacked in such a manner as to

prevent damage to the coating, due to abrasion or impact. Particular care shall be taken to

avoid damage while the coating is above ambient temperature and still soft.

No stacking or loading shall be undertaken until the coating has cooled sufficiently.

The coated pipe shall be stored free from the ground on suitable bearers. Sharp-edgedbearers shall not be used.

Temporary storage stacking shall meet the limitations as given in the relevant code of

practice.

Steel wire rope slings or end clamps shall not be used.

Non-metallic soft slings of nylon or polypropylene may be used. Specially designed lifting

hooks shall be used to avoid pipe-end and bevel damage.

Damaged/rejected pipe joints shall be marked as such and be kept separate from accepted

pipe joints during interim storage.

Colour coding and marking of coated piping shall be carried out in accordance with ADWEA

specification which shall be advised at the time of application.

Identification marks and direction of flow shall be marked on the pipe lines to the satisfaction

of ADWEA/ENGINEER.

8. APPROVALS

Before commencement of work, the CONTRACTOR shall provide complete specification of

the coatings along with certificates of approvals. The following physical and chemical

properties of the paint shall be provided with all other necessary data :

- Pigmentation.

- Thinners.

- Cleaner.

- Pot life after mixing.


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- Nominal solid contents by volume (%).

- Theoretical spread at Nominal Dry Film thickness.

- Drying time at 25C.

- Colour available.

- Storage conditions and standard container size.

- Product weight per litre.

Approval of each of the following shall be obtained from ADWEA/ENGINEER, before

proceeding with any of the subsequent phase.

(a) Location of work.

(b) Equipment.

(c) Preparation of each batch of paint mix.

(d) Surface preparation.

(e) First Coat.

(f) Each subsequent coat.

9. QUALITY ASSURANCE/QUALITY CONTROL

CONTRACTOR's proposed quality system shall fully satisfy all the elements of ISO 9001,

9002 and 9004. The quality system shall provide for the planned and systematic control of all

quality-related activities performed during design, development, production, installation, or

servicing (as appropriate to the given system). Implementation of the system shall be in

accordance with the CONTRACTOR's Quality Manual and Project Quality Plan, which shall

both together with all related/referenced procedures, be submitted to ADWEA/ENGINEER for

review, comments and approval as required by purchase/contract documents.

The CONTRACTOR's shall submit certified reports of production tests as soon as the tests

are satisfactorily completed.

The ADWEA/ENGINEER reserves the right to inspect materials and workmanship at all

stages of manufacture and to witness any or all tests. The CONTRACTOR, 30 days after

award but prior to the pre-inspection meeting, shall provide the ADWEA/ENGINEER with a

copy of its application and inspection plan for review and inclusion of any mandatory

ADWEA/ENGINEER witness points.


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10. PERFORMANCE GUARANTEE

The CONTRACTOR shall provide a Joint Performance Guarantee (manufacturer and

CONTRACTOR) for the quality of paint and his workmanship for a period of 5 (five) years

according to level Re 3 on the European scale of Rusting Grades from the date of Provisional

Acceptance.

11. ANNEXURES

1 - External Coating System for Carbon Steel Above Ground Piping.

2 - External Coating System for Stainless Steel Above Ground Piping

3 - External Coating System for Galvanised Steel Above Ground Piping

4 - Coating System for Structural Steel (Non Galvanised).

5 - Coating System for Galvanized Structural Steel Parts.

6 - Coating System for Stainless Steel Structural Parts


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ANNEXURE - 1

EXTERNAL COATING SYSTEMS FOR

CARBON STEEL ABOVE GROUND PIPING

1. Scope

External coating for atmospheric protection of carbon steel above ground piping systems

(other than galvanized).

2. Surface Preparation

- Surface shall be cleaned with fresh water and / or suitable solvent water to remove

oil, grease, loose rust, loose paint etc. to SP-1.

- Dry blast cleaning to a visual standard of Sa 2.1/2 near-white metal finish SP-10

(SIS 05 59 00).

- For local touch up/repair work power tool cleaning to a visual standard of St 3 (SIS

05 59 00).

- Hand tool cleaning to a minimum visual standard of St 2 (SIS 05 59 00) only for

specific applications.

3. Coating Systems

- Primer Coat:

Inorganic zinc primer to a d.f.t. of 75 microns.

- Intermediate:

Polyamide epoxy to a d.f.t of 125 microns.

- Finish Coat:

Polyurethane high gloss finish to a d.f.t. of 75 microns.

- Total Dry film thickness:

Minimum total dry film thickness shall be 275 microns.


19/23


STRUCTURES


ANNEXURE - 2

EXTERNAL COATING SYSTEM FOR STAINLESS STEEL

ABOVE GROUND PIPING

1. Scope

External coating for atmospheric protection for above ground stainless steel piping.


- Removal of any grease and oil by solvent cleaning (Chloride free) to SP 1.

- Wash with fresh water to remove salts contamination.

- Removal of rust stains by light blast cleaning with aluminium-oxide or inert

aluminium-silicate grit, or by means of stainless steel wire brushing. Normal steel

wire brushes shall not be used.

3. Coating System

- First Coat

High build epoxy of marine environment type to a d.f.t. of 120 microns (minimum).

- Finished Coat

Polyurethane high gloss finish to a d.f.t. 50 microns.

- Total Dry film thickness


Note: Under any circumstances zinc containing paints shall not be used on stainless steel

surfaces.


20/23


STRUCTURES


ANNEXURE - 3

EXTERNAL COATING SYSTEM FOR GALVANIZED STEEL

ABOVE GROUND PIPING

1. Scope

External coating for atmospheric protection of above ground galvanized steel piping

system.

2. Surface preparation

- Surfaces shall be cleaned with fresh water and/or suitable solvent wash to remove

zinc salts, oil, grease, loose rust, loose paint etc. to SP 1.

- Dry light blast cleaning with suitable abrasive such as aluminium oxide/eqvt.

- If blast cleaning is absolutely impossible then solvent cleaning with an alkaline

detergent agent may be used as a second choice surface preparation.

3. Coating system

- Primer Coat

Polyvinyl butyral wash a d.f.t of 10 microns minimum.

- Intermediate

Polyamide MIO epoxy to a d.f.t of 40 microns minimum.

- Finish Coat

Polyurethane high gloss finish to a d.f.t of 75 microns.

- Total dry film thickness



21/23


STRUCTURES


ANNEXURE - 4

COATING SYSTEM FOR STRUCTURAL STEEL

(non-galvanised)

1. Scope

Coating for atmospheric protection of structural steelwork, (non-galvanised).


- Dry blast cleaning to a visual standard of Sa 2.1/2 near-white metal finish (SIS 05

59 00).

- For local touch up/repair work power tool cleaning to a visual standard of St 3 (SIS

05 59 00).

- Hand tool cleaning to a minimum visual standard of St 2 (SIS 05 59 00) only for

specific applications.

3. Coating System

- Prime Coat :

Inorganic zinc silicate to a d.f.t. of 75 microns minimum.

(Minimum pure Zinc content in d.f.t shall be 85%)

- Second Coat :

Polyamide cured tie coat of d.f.t 40 microns minimum.

- Third Coat :

Amine or Polyamide cured high-build epoxy of marine environment type to a d.f.t. of

125-175 microns.

- Fourth Coat :

Polyurethane high gloss finish to a d.f.t. of 50-75 microns, with finishing colour to

match the existing.

- Total dry film thickness:



22/23


STRUCTURES


ANNEXURE - 5

COATING SYSTEM FOR GALVANIZED STRUCTURAL

STEEL PARTS

1. Scope

Coating for atmospheric protection of galvanised steel structural parts.

2. Surface preparation

- Surfaces shall be cleaned with fresh water and/or suitable solvent wash to remove

zinc salts and/or oil, grease etc.

- Dry light blast cleaning with suitable abrasive such as aluminium oxide.

- If blast cleaning is absolutely impossible then solvent cleaning with an alkaline

detergent agent may be used as a second choice surface preparation.

3. Coating system

- Prime Coat :

Inorganic zinc silicate to a d.f.t of 75 microns minimum. (Minimum pure zinc content

in d.f.t shall be 85%).

- Second Coat :

Polyamide cured tie coat to a d.f.t of 40 microns minimum.

- Third Coat :

Amine or polyamide cured high build epoxy of marine environment type to a d.f.t of

125-175 microns minimum.

- Fourth Coat :

Polyurethane high gloss finish to a d.f.t of 50-75 microns minimum.

- Total dry film thickness :



23/23


ANNEXURE - 6

COATING SYSTEM FOR STAINLESS STEEL

STRUCTURAL PARTS

1. Scope

Coating system for atmospheric protection of stainless steel structural parts.


- Removal of any grease and oil by solvent cleaning.

- Wash with fresh water to remove salts contamination.

- Removal of rush stains by light blast cleaning with aluminium-oxide or inert

aluminium-silicate grit, or by means of stainless steel wire brushing. Normal steel

wire brushes shall not be used.

3. Coating System

- First coat:

High build epoxy of marine environment type to a d.f.t. of 120 microns (minimum).

- Top coat:

Polyurethane high gloss finish to a d.f.t. 50 microns.

- Total dry film thickness

Minimum total dry film thickness shall be 170 microns minimum.

Note: Under any circumstances zinc-containing paints shall not be used on stainless steel

surfaces.

w-c-ss-014 steel coating works specifications

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