W-c-ss-014 Steel Coating Works Specifications

SPECIFICATION FOR PAINTING & EXTERNAL COATING OF METAL PIPES & STRUCTURES
0
rev.
02-02-2002 Approved Issue

date Description/issued for prepared authorised client: ADWEA project: STANDARD SPECIFICATIONS FOR WATER WORKS title: SPECIFICATION FOR PAINTING & EXTERNAL COATING OF METAL PIPES &
STRUCTURES
tender: project: document: W-C-SS-014 rev: 0 sheet: 1 of: 23
TABLE OF CONTENTS PAGE

1. 2. 3. 4. SCOPE...................................................................................................3 APPLICABLE STANDARDS AND CODES ..........................................3 SITE CONDITIONS................................................................................5 TECHNICAL REQUIREMENTS.............................................................5 4.1 Surface Preparation....................................................................5 4.2 Environmental Conditions/Safety.................................................8 4.3 Painting .......................................................................................9 4.4 Repair of Defects.......................................................................12 SAFETY REQUIREMENTS .................................................................12 INSPECTION AND TESTING ..............................................................13 6.1 General......................................................................................13 6.2 Environment ..............................................................................13 6.3 Surface Preparation...................................................................13 6.4 Coating Film Thickness .............................................................13 6.5 Calibration .................................................................................14 6.6 Inspection Report ......................................................................14 6.7 Testing Instruments/Tools .........................................................14 MARKING, HANDLING AND STORAGE............................................15 APPROVALS .......................................................................................15 QUALITY ASSURANCE/QUALITY CONTROL...................................16 PERFORMANCE GUARANTEE..........................................................17 ANNEXURES.......................................................................................17
5. 6.
7. 8. 9. 10. 11.
Client Project: Title:
ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR PAINTING & EXTERNAL COATING OF METAL PIPES & STRUCTURES
project: document: W-C-SS-014 rev: 0 sheet: 2 of: 23
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1.
SCOPE
This specification covers the minimum requirements for the surface preparation, and painting, of the following: 1. 2. 3. 4. 5. 6. : : : : : : External Coating System for Carbon Steel Above Ground Piping. External Coating System for Stainless Steel Above Ground Piping. External Coating System for Galvanized Steel Above Ground Piping. Coating System for Structural Steel (Non Galvanised). Coating System for Galvanized Structural Steel Parts. 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 Solvent cleaning Hand tool cleaning Power tool cleaning Near-white blast cleaning Shop, field and maintenance painting Measurement of dry film thickness with magnetic gauges
SSPC SSPC SSPC SSPC SSPC SSPC
SP1 SP2 SP3 SP10 PA1 PA2
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ASTM B117 ASTM D4060 ASTM D4541 ASTM D 5162
Salt spray (fog) testing. Abrasion resistance of organic coatings by the Taber Abraser. Pull off strength of coatings using portable adhesion tester. Dissimilarity (Holiday) testing of non conductive protective coating on metallic substrates. Standard Colours. Paints and varnishes cross of test for adhesion. Paints and varnishes Determination of film thickness. Paints and varnishes Pull off test for adhesion. Paints and varnishes Evaluation of degradation of paint coatings Preparation of steel surfaces before application of paints and related products. Quality Systems Model for Quality Assurance in Design, Development, Production, Installation and Servicing. Quality Systems - Model for Quality Assurance in Final Inspection and Test. Quality Management and Quality System Elements Guidelines. Specification for mineral solvents (white spirit hydrocarbon solvents) for paints and other purposes. Methods of test for paints. Methods of test for metallic and related coatings. Specification for bitumen based coatings for cold application excluding use in contact with potable water. Preparation of steel substrates before application of paints and related products. Specification for Coal tar based hot applied coating materials for protecting iron and steel, including a suitable primer. Fire tests on building materials and structures. and related
RAL 840 HR ISO 2409 ISO 2808 ISO 4624 ISO 4628 ISO 8501
ISO 9001
ISO 9003
ISO 9004 BS 245
BS 3900 BS 5411 BS 6949
BS 7079
BS 4164
BS 476
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BS 1070 BS 2523 BS 4800 BS 5252 BS 6150 BS 7664 BS 8202 BS EN ISO 12944
Specification for black paint (Tar based) Specification for Lead Based Priming Paints. Schedule of paint colours for building purposes. Framework for colour co-ordination for building purposes. Code of practice for painting for buildings. Specification for undercoat and finishing paints. Coating for fire protection of building elements. Code of practice for protective coating of iron and steel structures against corrosion. Water protective coating and lining for steel water pipelines enamel and tape hot applied.
AWWA C203
3.
SITE CONDITIONS
For site and climate conditions refer General Technical Requirements document
4. 4.1
TECHNICAL REQUIREMENTS 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 of welded, 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
4.1.3.1
Techniques and Restriction

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., in good working condition and shall place them in an orderly manner to avoid any obstruction possible.
4.3
4.3.1
4.3.1.1
Painting
Materials
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 the manufacturer 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 of material. 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, or alternatively 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 zincrich 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 suitably impervious 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
4.3.3.1
Application Methods
Spray Application Application by spraying shall be the preferred process. Spraying equipment, guns, nozzle sizes and pressure ranges shall meet the paint MANUFACTURER/ 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. The CONTRACTOR shall ensure that the health and safety data sheets provided by the manufacturers of the product(s) are strictly observed.
6. 6.1
INSPECTION AND TESTING 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 surface temperature 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 finish and 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 profile 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 given type 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. information shall include steel grade, size and schedule as well as the date of coating. The
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-edged bearers 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 2 3 4 5 6 External Coating System for Carbon Steel Above Ground Piping. External Coating System for Stainless Steel Above Ground Piping External Coating System for Galvanised Steel Above Ground Piping Coating System for Structural Steel (Non Galvanised). Coating System for Galvanized Structural Steel Parts. 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.
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ANNEXURE - 2 EXTERNAL COATING SYSTEM FOR STAINLESS STEEL ABOVE GROUND PIPING 1. Scope External coating for atmospheric protection for above ground stainless steel piping. 2. Surface Preparation 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 Minimum total dry film thickness shall be 170 microns. Under any circumstances zinc containing paints shall not be used on stainless steel surfaces.
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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 Minimum total dry film thickness shall be 125 microns.
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ANNEXURE - 4 COATING SYSTEM FOR STRUCTURAL STEEL (non-galvanised) 1. Scope Coating for atmospheric protection of structural steelwork, (non-galvanised). 2. Surface Preparation 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: Minimum total dry film thickness shall be 325 microns.
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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 : Minimum total dry film thickness shall be 325 microns.
tender:
ANNEXURE - 6 COATING SYSTEM FOR STAINLESS STEEL STRUCTURAL PARTS 1. Scope Coating system for atmospheric protection of stainless steel structural parts. 2. Surface Preparation 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. Under any circumstances zinc-containing paints shall not be used on stainless steel surfaces.
Note:
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W-c-ss-014 Steel Coating Works Specifications

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SPECIFICATION FOR PAINTING & EXTERNAL COATING OF METAL PIPES & STRUCTURES

02-02-2002 Approved Issue

TABLE OF CONTENTS PAGE

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APPLICABLE STANDARDS AND CODES

SSPC SSPC SSPC SSPC SSPC SSPC

SP1 SP2 SP3 SP10 PA1 PA2

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ASTM B117 ASTM D4060 ASTM D4541 ASTM D 5162

ISO 9004 BS 245

BS 3900 BS 5411 BS 6949

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BS 1070 BS 2523 BS 4800 BS 5252 BS 6150 BS 7664 BS 8202 BS EN ISO 12944

TECHNICAL REQUIREMENTS Surface Preparation

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For Structural Steel Items

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Techniques and Restriction

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INSPECTION AND TESTING General

Coating Film Thickness

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MARKING, HANDLING AND STORAGE

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QUALITY ASSURANCE/QUALITY CONTROL

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