Protective Coatings ES-14-102-12 23/04/2013Version No. 13.0 Page 1 of 49 Document last modified: 11 October 2012. PDF created: 23 April 2013. This is a Controlled Document that complies with Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards. Please check that this is the latest available version before use. Title: PROTECTIVE COATINGS Number: ES-14-102-12 Version Number: 13.0 Date Revised: 11 October 2012 Owner: Ryan Woodall Authoriser: Manoj Thakur Reasons for Creating or Amending Document New Owner New Authoriser Full Review of Document Actual Change Details: Section 1 A more detailed scope written Section 3.1 Minor change to definition of contractor vendor. Section 4 Updated the Australian Standard section. Section 5 Added aditional safety requirements. Sections 6.2, 6.3, 6.5 and 6.6 Minor changes made. Section 7 Added paragraph for new projects and major maintenance jobs. Section 8.2 Added additional section on Breathing Apparatus. Sections 8.3, 8.4, 8.5 Minor changes made Section 9.1.1 Added the following Note: Carbon or alloy steel components which will be heated above 425°C during fabrication or service shall not be contaminated by non-ferrous metals or sulphur compounds. Paint, labels, or tools used for identification or fabrication in such processes shall not contain lead, copper, zinc or tin in excess of 250 parts per million. Iron oxide, titanium or aluminium based paints are satisfactory for material marking. Sections 9.1.2, 9.1.3, 9.2, 9.3, 9.3.2, 9.4, 9.4.1, 9.4.2 Minor changes made Section 9.5 Thermal Spray Aluminium is an addition to the document. Section 9.6 Addition requirements for repairs to defects added. Section 10 A number of additional requirements for inspection and testing added. Sections 11, 12 and 13 Minor changes made. Appendex 4 Suppliers and products updated
Transcript
Protective Coatings
ES-14-102-12
23/04/2013Version No. 13.0 Page 1 of 49
Document last modified: 11 October 2012. PDF created: 23 April 2013.
This is a Controlled Document that complies with Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards.
Please check that this is the latest available version before use.
Title: PROTECTIVE COATINGS
Number: ES-14-102-12
Version Number: 13.0
Date Revised: 11 October 2012
Owner: Ryan Woodall
Authoriser: Manoj Thakur
Reasons for Creating or Amending Document
New Owner New Authoriser Full Review of Document
Actual Change Details: Section 1 A more detailed scope written
Section 3.1 Minor change to definition of contractor vendor.
Section 4 Updated the Australian Standard section.
Section 5 Added aditional safety requirements.
Sections 6.2, 6.3, 6.5 and 6.6 Minor changes made.
Section 7 Added paragraph for new projects and major maintenance jobs. Section 8.2 Added additional section on Breathing Apparatus. Sections 8.3, 8.4, 8.5 Minor changes made Section 9.1.1 Added the following Note: Carbon or alloy steel components which will be heated above 425°C during fabrication or service shall not be contaminated by non-ferrous metals or sulphur compounds. Paint, labels, or tools used for identification or fabrication in such processes shall not contain lead, copper, zinc or tin in excess of 250 parts per million. Iron oxide, titanium or aluminium based paints are satisfactory for material marking. Sections 9.1.2, 9.1.3, 9.2, 9.3, 9.3.2, 9.4, 9.4.1, 9.4.2 Minor changes made Section 9.5 Thermal Spray Aluminium is an addition to the document. Section 9.6 Addition requirements for repairs to defects added. Section 10 A number of additional requirements for inspection and testing added. Sections 11, 12 and 13 Minor changes made. Appendex 4 Suppliers and products updated
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5.7 PERSONAL PROTECTIVE EQUIPMENT (PPE) ............................................................... 8
5.8 ABRASIVE BLASTING AND SPRAY PAINTING ........................................................... 8
5.9 HIGH PRESSURE WATER BLASTING ............................................................................. 9
6. GENERAL ................................................................................................................................. 9
6.1 STANDARD OF WORKMANSHIP .................................................................................... 9 6.2 MATERIALS AND SURFACES NOT TO BE COATED ................................................... 9
APPENDIX 3 - SELECTION OF PROTECTIVE COATING SYSTEM S ................................... 44
APPENDIX 4 - APPROVED PRODUCTS FOR COATING SYSTEMS ..................................... 48
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1. SCOPE
This Standard defines the minimum requirements for organic/inorganic and thermal spray coating systems used to protect steel and other surfaces on facilities owned by CSBP. It covers the requirements for new construction and maintenance work as well as ferrous and non-ferrous materials. It covers facilities such as storage bins, chemical plants, jetties, tankage and loading facilities.
This standard defines the minimum acceptable requirement for surface preparation, industrial coating application, quality control and supervision. All coating systems used shall meet the minimum requirement of this document and specification
For structural and other steelwork with a design life of 15 years, or more, a conventional 3 coat system shall be used. This will compromise of a zinc primer, high build epoxy intermediate coat and a gloss top coat if required and specified.
No deviations from this specification shall be made without prior consultation with CSBP responsible Officer and written approval received from CSBP. Alternative coating systems may be considered if presented through the existing contract procedures.
2. PURPOSE
All items of equipment or steelwork permanently installed at any location in any CSBP owned facility, except as detailed in Section 6.2, shall have a protective coating to maximise the life of the equipment and steelwork by preventing serious and irrecoverable damage by surface corrosive attack.
Note: To ensure that the full benefits of protective coatings are achieved, correct application of coatings in compliance with the requirements specified in this Standard is vital.
3. DEFINITION OF TERMS
3.1 CONTRACTOR/VENDOR
The Company that provides the equipment and services needed. CSBP expects that the coating manufacturer and the professional applicators are fully conversant with the minimum requirements and procedures of this specification and carry out the work in accordance with this specification.
3.2 SUB-CONTRACTOR
A third party to be employed by the Contractor/Vendor who has been approved by the Superintendent.
3.3 SUPERINTENDENT
CSBP Limited, or authorised representative.
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3.4 CSBP
CSBP Limited.
3.5 WORKS
The Scope of Work that a Contractor is or may be required to execute under an agreement including variations and remedial work.
3.6 ACTIONS
Shall, Will or Must indicates mandatory action
Should indicates preferred/recommended action
May or Can indicates possible or optional action
3.7 LEAD-BASED PAINT
A paint film or component of a coating system containing lead or lead compounds, in which the lead content (calculated as lead metal) is in excess of 1.0% by weight of the dry film.
3.8 LEAD ENCAPSULATION SYSTEM
A coating system that encapsulates an existing aged lead-based coating, avoiding the need to completely remove the existing coating.
4. STANDARDS
The Contractor shall perform the Works in accordance with this Standard, the latest issue of referenced standards and Contractor regulations for on-site work. Should there be a conflict between the Works, Statutory Requirements and the Standards; the Contractor shall notify the Superintendent in writing for resolution. In general, the most stringent requirement will prevail.
CSBP Engineering Standards
ES-14-102-09 Labels & Signs: Plant and Equipment
ES-14-102-13 Surface Treatment of Lead-Based Coatings
ES-14-602-05 Underground Piping
CSBP Guide Manuals
GM-11-031-01 Personal Protective Equipment
GM-11-031-02 Safe Working at Heights
GM-11-031-13 Abrasive Blasting and Spray Painting Safety
GM-11-031-18 Hydrojetting Safety
GM-11-031-23 "Take 5" and Job Safety Analysis Risk Assessment
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GM-11-031-39 Use of High Pressure Water Equipment
GM-11-031-51 Work Permit System
GM-11-031-52 Confined Spaces
GM-11-038-04 Elevated Work Platforms
National Occupational Health and Safety Commission Publications
NOHSC 1012 National Standard for the Control of Inorganic Lead at Work
NOHSC 2015 National Code of Practice for the Control and Safe Use of Inorganic Lead at Work
Australian Standards
AS1214 Hot Dip Galvanised Coating on Threaded Fasteners
AS1216 Class Labels for Dangerous Goods
AS1345 Identification of the Contents of Piping, Conduits and Ducts
AS1580 Paints and Related Materials - Methods of Test
AS1627 Metal Finishing - Preparation and Pre-treatment of Surfaces
Pt 1: Cleaning Using Liquid Solvents and Alkaline Solutions
Pt 2: Power Tool Cleaning
Pt 4: Abrasive Blast Cleaning
Pt 5: Pickling, Descaling and Oxide Removal
Pt 9: Pictorial Surface Preparation Standards for Painting Steel Surfaces
AS2105 Inorganic Zinc Silicate Paint
AS2700 Colour Standards for General Purposes
AS3894 Site Testing of Protective Coatings
Pt 1: Non-conductive Coatings - Continuity Testing - High Voltage Method
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Pt 13: Inspection Report – Daily
Pt 14: Inspection Report – Daily Painting
AS4361 Guide to Lead Paint Management
Pt 1: Industrial Applications
AS4680 Hot-Dip Galvanised (Zinc) Coatings on Fabricated Ferrous Articles
AS4458 Pressure Equipment
5. SAFETY
All Federal and State Occupational Safety & Health Regulations regarding hazards in the workplace, handling of chemical substances, thinning, mixing and application of protective coatings and surface preparation shall be strictly adhered to at all times. Caution notices, warnings and precautions detailed on manufacture’s coating and material labels and data sheets shall be strictly observed. A “Risk Assessment” of the products to be used on site shall be carried out and the possibility of less hazardous or non hazardous products investigated. CSBP Occupational Heath and Environmental Officers shall be informed of any products to be used on any site.
All equipment used by the Contractor including ladders, scaffold, compressors, electrical and pneumatic equipment shall be properly maintained and operated in strict accordance with any safety regulations applicable to that equipment.
Caution notices, warnings and precautions detailed on manufacturer’s coating and material labels and data sheets shall be strictly observed.
All work shall be carried out with adequate ventilation or with appropriate protection so as to remove and disperse solvent vapours and dust particles, avoid fire and explosion, ensure safety of personnel and provide a safe working environment.
Particular attention shall be given to disposal of waste and surplus material including empty containers and rags, which could lead to a fire hazard.
The contractor shall be fully aware, and adhere to all of CSBP’s Health and Safety rules and regulations.
5.1 LEAD-BASED PAINT
Prior to any preparatory work, all existing coating systems pre 1990, and post 1990 where Material Data Sheets are not available, shall be subject to sampling, testing and analysis in accordance with AS 4361.1 for pressure of lead. Refer to CSBP Engineering Standard Surface Treatment of Lead-Based Coatings (ES-14-102-13) for further details.
Where lead presence is confirmed, surface treatment shall be carried out in accordance with CSBP Engineering Standard Surface Treatment of Lead-Based Coatings (ES-14-102-13) and this Standard where applicable.
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5.2 JOB SAFETY ANALYSIS (JSA)
Prior to the commencement of any and all works, the Contractor’s site supervisor and personnel involved shall complete a JSA. A copy of the JSA shall be provided to the Superintendent for review and approval prior to commencement of the task. The JSA shall encompass all aspects of the works and shall be logically laid out. The JSA can in part be “Generic” but must be personalised to the specific project. Refer to CSBP Guide Manual for "Take 5" and Job Safety Analysis Risk Assessment (GM-11-031-23) for details.
For large protective coating jobs where there may be a higher level of hazards, a Team Based Risk Assessment may be required. Refer to CSBP Guide Manual Team Based Risk Assessment (GM-11-030-02) for details.
5.3 WORK PERMITS
Work Permits are required for any non routine tasks. Work Permits are issued for the duration of the job (up to 1 month) but must be validated every time work is being done. Refer to Work Permit System (GM-11-031-51) for details.
5.4 WORKING ON ROOFS
Prior to the commencement of work on any roof a static line shall be installed on the roof. Personnel working on the roof shall at all times wear the appropriate harness that is attached to the static line. Refer to CSBP Guide Manual Safe Working at Heights (GM-11-031-02). Working on roofs may require a Team Based Risk Assessment (GM-11-30-02) prior to the commencement of work.
5.5 ELEVATED WORK PLATFORMS (EWP)
All Elevated Work Platforms brought on site shall be WorkSafe approved and certified. Only competent approved personnel shall travel or work from a EWP. Personnel working from an EWP shall wear an approved harness that is tethered close to the EWP workspace floor. Refer to CSBP Guide Manual Safe Working at Heights (GM-11-031-02) and Elevated Work Platforms (GM-11-038-04)
5.6 ACCESS
Safe access in the form of properly erected scaffold towers and ladders shall be provided to enable personnel to access work areas. Refer to CSBP Guide Manual Scaffolding, Planks and Ladders (GM-11-031-11).
5.7 PERSONAL PROTECTIVE EQUIPMENT (PPE)
All PPE used on site shall be an approved and acceptable quality complying with CSBP Guide Manual Personal Protective Equipment (GM-11-031-01)
5.8 ABRASIVE BLASTING AND SPRAY PAINTING
Abrasive blasting of steel surfaces and spray painting shall be carried out in strict compliance with the safety and operational requirements specified in CSBP Guide Manual Abrasive Blasting and Spray Painting Safety (GM-11-031-13).
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5.9 HIGH PRESSURE WATER BLASTING
High pressure water blasting shall be carried out in strict compliance with the safety and operational requirements specified in the CSBP Guide Manual Hydrojetting Safety (GM-11-031-18) and Use Of High Pressure Water Equipment (GM-11-031-39).
6. GENERAL
6.1 STANDARD OF WORKMANSHIP
In general, the paint Manufacturer’s instructions pertaining to mixing, application, drying time, etc., shall be followed. Nevertheless, it is the Contractor’s responsibility to produce a satisfactory end result acceptable to the Superintendent. All work shall be performed in a safe and workmanlike manner and all phases of the work, including preparation, application and inspection shall be carried out by personnel experienced in the work they are performing. Evidence of such experience shall be provided to the Superintendent on request.
6.2 MATERIALS AND SURFACES NOT TO BE COATED
The following surfaces and materials shall not be blasted or coated unless specifically directed. If there is any likelihood of damage from blasting or overspray onto these surfaces or materials, they shall be fully protected by masking, screening or removal. Removal of items and subsequent re-installation after completion of painting shall be carried out by persons skilled in the trades involved and only after approval by the Superintendent on each occasion.
Any damage to any of these installations or equipment shall be at the contractors cost.
a. Jointing surface on flanges
b. Pipe, tube, ducting, cladding, cable ladder, equipment, electrical and instrument enclosures etc., which have been manufactured from stainless steel, titanium, aluminium, cast iron or other corrosion resistant materials.
c. Glass
d. Plastic including:
- Fibreglass reinforced plastic (FRP)
- Plastic pipe including PVC, Polyethylene or ABS, unless UV protection is specified.
e. Electric cables
f. Instruments, instrument fitting, valve stems, grease fittings. Valve bodies shall be painted to the same specifications as the pipe in which they are installed.
g. Identification tags and nameplates. Coating shall be continuous under tags and nameplates if possible, otherwise they shall be edge sealed and masked off.
h. Threads of adjusting screws
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i. Internal surfaces of tanks and other containers of liquid or slurry unless otherwise specified. Note that all solid product transfer chutes, skirts, surge bins and hoppers shall be treated internally to the same specification as applies to the outside surfaces including when the item is to be subsequently lined with mechanically fixed lining material.
j. Field weld margins
k. Friction grip surfaces unless approval is given to apply Inorganic Zinc Silicate
l. Machined surfaces
m. Insulated pipework and equipment surfaces which have an operating temperature over 100°C, except as defined in APPENDIX 3. Insulated pipework and equipment surfaces, which have an operating temperature of less than 100°C, shall be primed coated only to System B.
n. Colourbond, Zincalume or similar protective coated materials.
o. Galvanised surfaces, unless otherwise specified. If painting is required, use System B only.
p. Items that have an existing surface coating, which is to be retained. For example, electric motors have a different paint colour to surrounding steelwork.
6.3 PRODUCT/EQUIPMENT CONTAMINATION
Contamination of products in manufacture and storage areas by dust or residue from blasting operations or by overspray during application of coatings is forbidden. Extreme measures are expected to be taken by the Contractor to prevent product contamination including full screening to completely segregate the work area from the manufacturing equipment or stored product. The contractors should be aware at all times of the weather and wind conditions that may adversely affect any overspray drift.
6.4 MAINTENANCE OR REPAIR OF EXISTING COATINGS
In carrying out maintenance or repair of damage to existing protective surface coatings, the requirements of this Engineering Standard and/or, as applicable, CSBP Engineering Standard Surface Treatment of Lead-Based Coatings (ES-14-102-13), shall apply.
Where extensive failure of the existing coating is evident, surfaces shall be subject to full blast and re-coat as for a new paint application. Where the existing coating is sound, then the area may, at the discretion of the Superintendent, be subject to whip blast or other form of reduced surface preparation prior to application of the new protective coating. Any such preparation shall be carried in accordance with the coating manufacturer’s recommendations. The finished coating shall comply with the requirements of the specified coating system in regard to dry film thickness for each coat and the finished coating shall provide the same level of protection as for a new application.
Particular attention shall be given to paint touch up of localised damage to new paintwork during transport, handling and erection and damage to new or existing paintwork from oxy cutting, welding of cleats, brackets, hand railing and the like during installation. Such areas shall be
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adequately prepared by wire brushing or abrasive blasting, prime coated and finish coated to meet the requirements of the specified coating system.
6.5 GALVANISING
Where specified, galvanising shall conform to the requirements of the applicable Australian Standard and as set out in the Galvanisers Association of Australia Manual and Directory. Galvanising shall be applied by the hot dip process and shall consist of a thickness of zinc coating equivalent to not less than 0.6 kg/m2 of surface area. It shall be free from all lumps, runs, spikes and dross.
Areas of galvanised coatings which are damaged by cutting or welding shall be cleaned by wire brushing or power tools and have 50µm minimum DFT Cold Galv coating applied over the area of damage. All exposed steel following cutting of galvanised items shall be touched up with Cold Galv paint.
If galvanised surfaces are to be painted, the surface shall be thoroughly cleaned in accordance with AS1627 Part 1 (SSPC-SP1) to remove grease and wax, and where possible, shall be given a light whip blast to provide a key for the protective coating. Coating System B shall be used on galvanised surfaces.
If the galvanised surface has been allowed to weather prior to the application of a top coat the surface shall be high pressure water washed and dried prior to coating application. If the galvanised surface is damaged or shows signs of rusting it shall be surface prepared by a “Sweep Blast” to slightly roughen the surface (5-10 microns).
6.6 STAINLESS STEEL COMPONENTS
All austenitic stainless steel subject to welding or mechanical abrasion shall be passivated to reinstate the protective oxide layer.
Stainless steel piping subject to annealing or heat treatment shall be pickled in an acid/water solution comprising of nitric and hydrofluoric acid to remove oxide scale.
Where a stainless steel surface has to be prepared by abrasive blasting only non-metallic abrasive media shall be used to provide the required keyed surface. Any protective coatings applied to stainless steel shall contain no more than 50ppmv of leachable chlorides.
6.7 UNDERGROUND PIPING
All buried steel pipes and components shall have a protective coating applied in accordance with CSBP Engineering Standard Underground Piping (ES-14-602-05).
7. PROTECTIVE COATING MATERIALS
For new projects or major maintenance jobs the contractor shall be required to have a designated coating Manufactures Technical Representative (MTR) assigned to the project. The MTR shall be fully conversant with all aspects of surface preparation and application of the specified products. CSBP Responsible Officer shall approve the MTR and verify that the MTR shall be available for:
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• Site inspections as required
• Currently be a NACE Level II certified Coating Inspector.
• Be available to attend Pre-Job start meetings.
• Carry out approve the inspection of the blasted and coated surfaces
Submit written reports as required to CSBP
All protective-coating materials provided shall be one of the approved coating manufacturers products listed in Appendix 4. Other products will only be accepted when it is proved to the satisfaction of the Superintendent that they are equal in composition, durability, usefulness and convenience for the intended purpose.
All coating materials shall be supplied in their original, unopened containers and stored within the manufacturer’s recommended temperature range. The containers’ labels shall bear the manufacturer’s name, brand, batch number, date of manufacture, dangerous goods class (in accordance with AS1216 Part 1) and any special directions. The colour code should be noted as per AS2700.
Note: Only thinners and driers specified and supplied by the coating manufacturer shall be supplied.
7.1 DATA SHEETS
7.1.1 Manufacturer’s Technical Data Sheets
For each protective coating, the Contractor shall furnish technical data sheets, which specify:
a. Surface preparation recommendations.
a. Maximum dry and wet film thickness per coat in microns (µm).
b. Minimum and maximum curing time between coats.
c. Thinner to be used.
d. General ventilation requirements.
e. Allowable methods of application.
f. Atmospheric conditions during which the coating shall not be applied.
g. Storage temperature range and shelf life.
h. Flammability rating.
7.1.2 Material Safety Data Sheets
The Contractor shall obtain and comply with all relevant Material Safety Data Sheets (MSDS) showing the health and safety precautions to be taken during application of coating materials.
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Copies of all relevant MSDS, shall be provided by the Contractor to the Superintendent prior to commencement of application.
8. SURFACE PREPARATION
8.1 GENERAL REQUIREMENTS
8.1.1 All welded areas shall have welding splatter, laminations and mill scale removed by mechanical means before commencing the specified surface preparation. Welding flux shall be removed from crevices.
All steel edges shall be radiused (not less than 2mm) to ensure adequate paint or galvanising adhesion and thickness.
8.1.2 Oil, grease, wax, dirt and foreign matter shall be removed by cleaning and degreasing prior to commencing the specified surface preparation. All work to be accordance with As1627.1-2003.
Surfaces to be coated shall be rendered dust free prior to coating application by blowing the surface with dry air or by using an industrial vacuum cleaner.
8.1.3 Prior to commencing surface preparation all adjacent surfaces including areas to be finished, areas which have been finished and surfaces not to be painted shall be protected by drop-cloths, masking or by other suitable means. Hardware, gratings, accessories or equipment shall be removed before any materials are applied and replaced upon completion of each area.
Surface preparation shall not be carried out in wet or excessively hot, humid or windy conditions or in the presence of water spray or of industrial fall-out which, in the opinion of the Superintendent is excessive.
Where abrasive blast cleaning and painting operations must be carried out in the same area, the blasting work shall only be allowed when the paint film is dried to the extent where the abrasive does not adhere to or damage the coated surface.
8.1.4 The Contractor shall repair and replace all accessories or surfaces that are damaged directly, or indirectly, as a result of its work.
8.2 ABRASIVE BLAST CLEANING OF STEEL SURFACES
8.2.1 Standards
Abrasive blast cleaning of steel surfaces shall comply with AS1627.4 all abrasive blast equipment must be in good working order and well maintained.
In certain circumstances wet blasting as specified in AS1627.4 may be permitted for site work with prior approval of the Superintendent. Water used shall be normal scheme water.
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8.2.2 Materials
Blasting abrasive shall be dry, clean, free from contaminants and of a type and size adequate to give surface amplitude or anchor pattern of 25 to 50µm, unless otherwise specified. The abrasive shall contain not more than 75ppm chloride by weight.
Note: Blast cleaning with silica sand shall not be permitted.
Compressed air used for abrasive blasting shall be free of water and oil. Adequate separators and water traps shall be provided by the Contractor and shall regularly be kept free of water and oil. Accumulations of water and oil shall be regularly purged from the air receiver and disposed of in an environmentally acceptable manner. Under no circumstances shall CSBP plant air be used for abrasive blasting or for blowing down.
Unless otherwise stated the abrasive media shall be discharged with a pressure of 700kPa, measured at the nozzle with a hypodermic pressure gauge. Under no circumstances should the nozzle pressure fall below 550kPa.
8.2.3 Compressed Air
Compressed air used for abrasive blasting shall be free of water and oil. Adequate separators and water traps shall be provided by the contractor and shall regularly be kept free of water and oil. Accumulations of water and oil shall be regularly purged from the air receiver and disposed of in an environmentally acceptable manner. Under no circumstances shall CSBP plant air be used for abrasive blasting or for blowing down.
8.2.4 Breathing Apparatus
During abrasive blasting and industrial coating application the appropriate air-fed mask and filtration system shall be used. Other personnel working in the vicinity shall wear suitable respiratory protection and PPE as required. Particular attention should be paid to the location of the inlet suppling the air-fed helmets as not to provide contaminated air.
8.2.5 Operating Conditions
Blast cleaning shall not be conducted when the surfaces are less than 3°C above dew point or when the relative humidity of the air is above 90%.
Abrasive blasting shall not be performed in areas close to painting operations and freshly coated surfaces in order to prevent dust and grit contamination. Abrasive blasting shall only be permitted during the daylight hours. Pre or rough grit blasting shall normally be allowed during the night with the prior approval of the Superintendent, provided that the surface shall be given a light blasting to the specified standard in daylight prior to painting.
Particular attention shall be paid to preventing damage to electrical and mechanical equipment by ingress of dust or blasting residue. Wrapping and taping up shall protect these items.
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8.2.6 Rework
Blast cleaned surfaces shall not be left uncoated overnight. Should it not be possible to coat these surfaces within the specified period, they shall be re blasted before painting to remove any dust or contamination. In high pressure water blasting or wet abrasive blasting operations, the use of corrosion inhibitor in the blast water may be considered to avoid rust formation prior to application of coating, but its use is subject to submission of detailed procedure specifications and written approval by the Superintendent.
Blast cleaned steel which is not primed and then wet by rain or moisture shall be re blasted.
Where extensive rectification is necessary on abrasive blast cleaned surfaces, the dressed areas shall be re blasted to remove all rust and slag, and to provide an adequate paint key. The blast cleaning shall carry over onto the secure surrounding coating for not less than 25mm all round.
Surface defect such as slivers, laminations or excessive pitting exposed by abrasive blasting shall be reported to CSBP for evaluation. Defects deemed as structurally deleterious shall be removed or repaired by CSBP. Defects likely to be detrimental to the coating system shall be removed and the area re-blasted. Coating material shall be applied to a blasted surface within 4 hours of the completion of abrasive blasting. If the 4 hour period expires the surface must be “Whip Blasted” back into specification
8.2.7 Residue
All residues from blasting operations shall be progressively cleaned up and disposed of in an environmentally sound manner to avoid product contamination. WESCEF Environmental Department shall require documentation to ensure of proper disposal.
No grit or dust shall be left embedded or lying on the steel prior to coating. Air used for, “blowdown” purposed shall be clean, dry and free of contaminates, i.e. blast or helmet air.
8.3 OTHER CLEANING METHODS FOR STEEL SURFACES
For site locations where abrasive blast cleaning is impractical or unsuitable, as determined by the Superintendent, steel surfaces may be mechanically cleaned using power tools such as disc grinders, wire brushes, flap or disc sanders and needle guns, or high pressure water blasting as in Section 8.5.
Power tool cleaning shall be performed according to AS1627.2-2002, with surface finish to AS1627.9-2.
Pickling of new steel surfaces may be used as an alternative cleaning method. Pickling shall be performed to AS1627.5-2003.
8.4 CLEANING OF WOOD SURFACES
Wood surfaces to be painted shall be cleaned of dirt, oil or other foreign substances with mineral spirits, scrapers, and sandpaper or wire brushes.
Planning or sandpapering shall make exposed surfaces smooth.
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8.5 HIGH PRESSURE WATER BLASTING
In areas where existing paint coatings are general sound and where other forms of surface preparation such as abrasive blasting and mechanical cleaning are not permitted, such as where the existing coating contains lead, consideration may be given to preparation of the surface for re-coating using high pressure water blasting.
8.5.1 Approval
Approval for high pressure water blasting shall be subject to submission of detailed procedures covering such issues as equipment operation, training of personnel, safety, contamination, clean up, coating system specifications, et cetera, and requires written approval by the Superintendent before blasting operations start on site.
High-pressure water blasting operations shall be carried out in strict compliance with Section 5.9.
8.5.2 Operational Requirements
During water blasting operations, to prevent damage to stored product or equipment, screening and bunding as required shall contain residue water.
If water blasting cannot be carried out because of the possibility of damage to plant, equipment or stored product from water residue, then complete encapsulation and abrasive blasting must be considered.
8.5.3 Surface Finish
The standard of surface preparation by high pressure water blasting prior to the application of paint coating shall be judged against the International Paints Hydro blast standard with a HB 2.5 being the minimum acceptable level. The contractor shall have access to this standard and make it available to CSBP. Coating application shall not start until the surface preparation has been compared with the standard and accepted by the Superintendent.
8.6 CONTAMINATION TESTS
Surfaces to be coated shall be subject to surface contamination tests. Tests shall be carried out on all steel, previously coated or not, that has been in contact with a corrosive environment.
After surface preparation and prior to the application of the nominated coating system the contamination tests shall be carried out. Levels of below 50mg/m2 for steel subjected to normal atmosphere and below 25mg/m2 for immersed conditions for surface salts and a ph of between six and eight would be acceptable. In the event of high contamination levels or pH, outside limits, high pressure water washing shall be required until levels are within specification. All testing shall be witnessed by a CSBP representative and the results recorded in the Contract QC documentation. After contamination levels are at an acceptable level coating application can begin.
The SCATS system of testing is accurate and “user friendly” in the field.
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9. COATING APPLICATION
9.1 GENERAL
9.1.1 Coating System
Surfaces shall be coated with the paint system detailed in the appropriate “Coating System Specification Sheet” defined in Appendix 1 or as specified for the particular work being carried out.
Note: Coating containing metal zinc particles shall never be applied to or over sprayed onto stainless steel surfaces
Note: Carbon or alloy steel components which will be heated above 425°C during fabrication or service shall not be contaminated by non-ferrous metals or sulphur compounds. Paint, labels, or tools used for identification or fabrication in such processes shall not contain lead, copper, zinc or tin in excess of 250 parts per million. Iron oxide, titanium or aluminium based paints are satisfactory for material marking.
9.1.2 Manufacturer’s Recommendations
The paint shall be applied in accordance with the paint manufacturer’s recommendations. The manufacture’s product data sheets and specifications for mixing, application and curing shall be considered an integral part of this standard. In particular, attention should be paid to thinning, mixing and to curing times between subsequent coats. The contractor shall be responsible for obtaining the product data sheets and MSDS of each product used and provide CSBP responsible Officer with copies. Any deviations from the manufacture’ recommendation should be brought to CSBP Responsible Officers attention and addressed prior to the commencement of works.
Blast cleaned or power tool cleaned surfaces shall be coated with the primer specified within four hours of blasting, or such other time limits as may be specified by the manufacturer.
Each coating shall be allowed to dry thoroughly at least for the specified time as per manufacturer’s instructions, prior to application of a succeeding coat. If the manufacturer’s suggested maximum over coating times are exceeded, the surface of the preceding coating must be prepared to the satisfaction of the Superintendent, before any other coating is applied i.e. solvent wash or whip blast.
Note: Precautions shall be taken to avoid dust, dirt or dry spray settling on wet paint and previous paint coats shall be cleaned of dust and dry spray before further paint is applied. In particular, any surfaces that have been exposed to the weather for some weeks between coats (e.g. between coats before erection and the finish coats subsequent to erection), shall be thoroughly washed and cleaned before further paint is applied.
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9.1.3 Paint Limits
All areas that will be subject to welding after painting shall be masked after blast cleaning. Masking shall be with suitable adhesive tape and shall extend at least 50mm on all sides of the intended weld area.
On completion of ongoing abrasive blasting works an area of a minimum of 100mm shall be left uncoated. This will ensure that no un-blasted area is coated.
For joints with high strength structural bolts and inorganic zinc silicate primer, topcoats shall be stopped 150mm short of the joint area.
9.1.4 Environmental Conditions
Coatings shall not be applied:
a. When the surfaces are less than 3° C above the dew point.
b. When the relative humidity of the air is greater than 90%.
c. When there is the likelihood of a change in weather conditions within two hours after application that would result in air temperatures below those specified, or deposition of moisture in the form of rain, condensation or other, upon the surface.
d. When surface temperature exceeds 50°C at the time of application.
e. During fog, mist or rain, or when these conditions are imminent, unless coating operations are performed undercover.
Inorganic zinc silicate coatings shall not be applied when the relative humidity is outside the range of 40 - 90%.
Epoxy coatings shall not be applied when the relative humidity is outside the range of 20 - 85%.
9.2 MIXING OF COATING MATERIALS
Prior to the commencement of works the pump, pot and mixer shall be free of past coating materials and thoroughly clean. All coating material shall be thoroughly stirred in a pressure pot with a power mixer for a time sufficient to thoroughly mix the pigments and vehicles.
Coating materials that have livered, gelled, past expiry dates (shelf life), or otherwise deteriorated during storage shall not be used. However, thixotropic materials that may be stirred to obtain normal consistency will be accepted.
Coatings containing heavy or metallic pigments that have a tendency to settle must be kept in suspension in the pressure pot by a mechanical stirrer.
If a coating material requires the addition of a catalyst, the pot life must not be exceeded and the catalyst shall only be added to full tins to ensure correct mixing proportions. When the pot life limit is reached, or there are other indications that the pot life of the product has expired i.e. thickening
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or application problems, the spray pot must be emptied, the material discarded in accordance with CSBP Works Procedures, the equipment cleaned and new material catalysed.
9.3 SPRAY APPLICATION
Paint coatings shall be applied by spraying, wherever possible, in strict compliance with Section 5.8.
Before a contractor carries out industrial coating works on an existing coating system the coating system must be identified and checked for compatibility with the proposed new system. Adhesion tests on the existing coat to substrate should be carried out and consultation with the coating manufacturers to determine suitability of the proposed system. If possible the same generic system should be used on the aged coating.
Spay painting generates fumes and paint mist and can interfere with other CSBP operations. The contractor shall ensure that all appropriate personnel are informed and permits in place
9.3.1 Equipment
Spray units shall be grounded and non-conductive lines used. The Contractor shall take such further precautions, as may be required, to avoid build up or static electricity.
An adequate moisture trap shall be installed between the air supply and each pressure pot. Air shall be free of oils and water.
A supply of tips, with varying spray angles and washers, shall be available as recommended by the coating manufacture for each specific steel configuration to be coated.
The pressure pot, material hose and spray gun shall all be kept at as nearly the same elevation as possible.
Suitable pressure regulators and gauges shall be provided for both the air supply to the pressure pot and the air supply to the spray gun. Spray equipment and operating pressures shall comply with the recommendations of the coating manufacturer.
The compressor shall be of adequate size for the work to be done and in good condition.
9.3.2 Application Pattern
Large surfaces shall receive two passes at right angles to each other (cross-hatched). Spray shall be applied in a heavy, wet coat.
Each coat shall be applied uniformly and completely over the entire surface. All runs and sags shall be brushed out immediately or the paint shall be removed and the surface re-sprayed.
The spray gun shall be held perpendicular to the work piece at a distance required fro proper application of the coating material. Arcing of the spray gun shall not be permitted. Conventional spray guns shall be held at a distance of between 150 to 300mm from the work piece. Airless spray guns shall be at such a distance from the work piece that a 300mm fan dispersal is not exceeded.
Each spray pass shall overlap the preceding pass by 50%.
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9.4 BRUSH AND ROLLER APPLICATION
Coatings shall be applied by brush or roller to areas that cannot, for whatever reason, be spray applied i.e. environmental conditions, material choice or complex geometric configurations. Surfaces not accessible to brushes shall be coated, by other suitable means to ensure a uniform coating film of adequate thickness.
Brushes used in brush application shall be of a style and quality that will permit proper application of paint. Round or oval brushes generally are considered most suitable for bolts, irregular surfaces and rough or pitted steel. Brush applications should be carried out with a minimum of 2 passes at right angles to one another thus ensuring smooth uniform coating thickness and appearance.
9.4.1 Surface Finish
Brushing shall be done such that a smooth coat, as nearly uniform in thickness as possible is obtained. There should be no deep or detrimental brush marks. Paint shall be worked into all crevices and corners. Runs or sags shall be brushed out. Visual streaking and overlaps shall not be accepted.
9.4.2 Stripe Application
During the application of each coat all areas such as corners, edges, welds, small brackets, nuts, bolts, pits deeper than 3mm and interstices shall receive an additional hand stripe application of coating material, thus ensuring the minimum DFT required and continuity of coating. Stripe coating shall be such that it provides a continuous coating film to the specified DFT, not to exceed the maximum DFT.
All welds and steel with sharp edges shall be brush or roller stripe coated (10mm either side of the weld or edge) prior to the application of the coating system. Edges of beams, UB’s, UC’s, RSJ’s, channels, angles and irregular or recessed surfaces shall be stripe coated.
9.5 THERMAL SPRAY ALUMINIUM (TSA)
The application of TSA is suitable for immersion, buried surfaces or systems with a life expectancy of 25 years.
9.5.1 Surface Preparation
All edges coated shall be ground to a minimum of 2mm radius. Abrasive blast with garnet to produce a surface profile of 75 to 110 micron. Cleanliness shall be in accordance with AS1627.4 Sa3. It is imperative that all dust be removed from the surface to be treated with TSA.
9.5.2 Coating Application
The thermal-spray equipment shall be set-up, calibrated and operated according to the technical manual of the manufactures or the TSA applicator. Material selection can be:
• Aluminium
• Zinc-Aluminium (85/15)
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All three systems, when applied in an appropriate manner and to the required specifications are equivalent for use under atmospheric conditions. A typical DFT for this application is 250 microns
9.5.3 Top Sealing Coat
A top sealing coat of epoxy sealer may be required. This coating shall be applied at a DFT of 40micron and within 6 hours of completion of spraying.
9.5.4 Quality Control
Surface contamination testing and results shall be as in section 8.6 of this procedure. Environment condition suitable for TSA are the same as industrial coating regarding dew point, substrate temperature relative humidity etc. All specification regarding adhesion, bent and test coupons shall conform to Thermal Spray Coatings of Aluminium and 85/15 Zinc/Aluminium Alloy DEP 30.48.40.31-Gen
9.6 REPAIR OF DEFECTS
9.6.1 Coating Systems
Different generic coating systems and coating applications require different repair procedures. The contractor shall submit in writing to CSBP Responsible Officer a repair procedure, approved by the coating manufacturer, detailing the procedure for CSBP approval.
Before application of any further coats of material, damage to the previous coats shall be repaired.
Areas of inadequate coating thickness shall be thoroughly cleaned and abraded if necessary, before application of additional material to achieve the desired specifications. The abrasion can take the form of abrasive blasting; sand paper, flap discs, hand file and the preferred method shall be nominated in the repair procedure. These additional coats shall blend in with the final coat on adjoining areas.
Surfaces to be over coated, which have become contaminated or passed their over coating time, shall be cleaned by light brush blasting to remove contamination. After brush blasting, any residual contaminants shall be removed by clean dry compressed air or wiped with clean dry rags.
Damage to a coating system, but not exposing the substrate shall be lightly brush blasted and contaminates removed. The coating around the damaged area shall be feathered back and approved by a Superintendent prior to the system being re-applied to the original specification.
Damage to a coating system exposing the substrate shall be re-blasted and the original system applied in accordance with the specifications. The re-blasting shall carry over to secure and sound coating not less than 25mm all around. Edges shall feathered back and approved by a Superintendent approved method.
Where welding occurs after coating application the coating shall be removed by abrasive blasting to 100mm beyond the heat affected zone. After welding the coating system shall be re-instated to the original specification.
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Where extensive pin holing or holidays occur it may be caused by “Gassing” due to surface contamination. In this case the area affected should be re-blasted, substrate examined and coating system re-applied to the original specifications.
Coatings, not including inorganic zinc, which have to be over coated and have become contaminated with oil, grease or other contaminates shall be cleaned with water soluble biodegradable cleaner followed by a clean water wash.
9.6.2 Thermal Spray Aluminium (TSA)
Areas of insufficient thickness of TSA shall be rectified by further applications of TSA prior to final sealing coat, if specified.
Areas of damage or defective coating, including sites of former adhesion testing, shall be repaired as followed:
• Seal coat shall be removed by abrasive blasting
• Damaged or defective TSA coating shall be removed by abrasive blasting
• Repair areas of defective coating shall be surface prepared by vacuum blasting or power flap disc.
• TSA coating shall be re-instated as per this specification Thermal Spray Coatings of Aluminium and 85/15 Zinc/Aluminium Alloy DEP 30.48.40.31-Gen.
9.7 OVERSPRAY
The contractor shall have in place an “Overspray Policy”. This shall include, but is not limited to signage, weather and wind direction monitoring, encapsulation where appropriate, systems to protect vehicles and equipment and a method of dealing with overspray claims. The contractor should have appropriate insurance to cover any overspray incidents.
During site painting operations, every reasonable precaution shall be taken by the Contractor to eliminate the likelihood of paint overspray drifting outside the area of work, if there is a possibility that overspray could cause damage to CSBP or private property. In particular, no spray application of paint coatings shall proceed if the wind speed and direction will carry overspray outside the site boundary fence or into designated car parking areas on or around the site. Wind speed and direction shall be frequently monitored at a number of locations around the work area using an appropriate measuring instrument to determine if it is safe to continue spray painting.
In windy conditions where overspray damage could occur, coatings shall be applied by some other means such as by roller, subject to the approval of the Superintendent.
9.8 WARNING SIGNS
At all times when spray painting operations are being planned, warning signs shall be erected around the work area and at the entrance to the site and to all car parking areas to clearly indicate that painting is in progress. The signs shall remain visible throughout the entire period that spray-painting operations are in progress. The signs shall be covered or removed when spray painting is not being carried out.
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10. INSPECTION AND TESTING
10.1 GENERAL REQUIREMENTS
Minimum requirements of the contractor with regards to Quality Control personnel are NACE level II. Consideration will be given to ACA Coating Inspector depending on past experience.
All test and Quality Control equipment used shall have a current Calibration certificate and be in good working order. Spray painters shall have the ability to check their own DFT’s as they progress through the works.
The contractor shall develop and implement a Quality Plan to ensure all phases of the surface preparation and industrial coatings operation are in full compliance with the requirements of the standards. Details of the contractor’s quality assurance system and Quality Plan shall be provided to the Superintendent. This shall be in the form of a Quality Plan, which shall be subject to review and approval by the Superintendent prior to the commencement of any work. The Quality Plan shall include detailed Inspection and Test Plans (ITP) covering all aspects of the work. Inspection ’Hold Points’ shall be specified in the ITP. Inspection and Test Record sheets shall be maintained by the Contractor and provided to the Superintendent for review daily or when requested. The completed ITP and Inspection and Test records sheets shall form part of the Quality Assurance handover records. The Quality Plan will include, but not limited to the following:
• Sequence of events relevant to the total works.
• Detailed scope of work referencing the surface preparation and coating system required.
• Itemised list of coating materials and consumables.
• List of coating material to be brought on site.
• Access methods
• Personnel to be brought on site with their name, responsibilities and lines of communication.
• Medical Checks and Certificates
• Details of test and inspection procedures
• Calibration methods of inspection equipment
• Details of the documentation trail
CSBP may engage the services of a Coating Inspector who shall act for CSBP and observe all -application procedures for the duration of the works. The Inspector shall approve the surface preparation, application of any coatings and approve the condition of each coat prior to the application of the following one.
Inspection shall include, but not limited to the following items:
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• Surface preparation, i.e. class and cleanliness of blast and physical measurement of the surface profile.
• Contamination checks, i.e. pH, chlorides and soluble iron salts.
• Abrasives, size and contaminants within the abrasive media.
• Coating material, i.e. batch numbers, correct product, mining and storage conditions.
• Environmental conditions, i.e. relative humidity ambient temperature, dewpoint and substrate temperature.
• Final inspection.
The contractor shall ensure that updated product technical data sheets and MSDS are obtained from the manufacturer and available on site.
The contractor shall keep CSBP Responsible Officer aware at all times of the daily schedule. CSBP must be informed of any changes at least 4 hours before the changes are implemented. CSBP must be given ample time so that inspections can be carried out and the work progress.
CSBP reserves the right to reject any work that does not comply with the contract specifications. It also reserves the right to reject any tools, equipment, materials, testing equipment, PPE, staging or scaffolding that does not conform to Australian standards or is deemed unsafe by CSBP Responsible Officer.
10.2 INSPECTION AND TESTING METHODS
10.2.1 Contractor Obligations
The contractor shall supply the inspection personnel with all inspection equipment necessary to ensure that the specifications and quality are achieved. The Contractor shall be responsible for the proper calibration and functioning of all its testing measuring and calibration equipment. CSBP shall randomly check calibrations and certification of test equipments.
The Contractor shall ensure that skilled, competent personnel are operating all testing and inspection equipment. CSBP shall require evidence that the Quality Control personnel are competent and qualified.
CSBP shall retain the right to reject any tools, instruments, materials, staging equipment or work not conforming to this Standard. Any rejection by CSBP shall be replaced or rectified by the Contractor, to the satisfaction of the Superintendent, at no additional cost to CSBP.
10.2.2 Inspection Detail
Prior to the commencement of any surface preparation or industrial coating the ambient conditions shall be measured and documented. These measurements include, but not limited to, ambient temperature, relative humidity, dew point, steel temperature and visual weather conditions.
A profile comparator in accordance with ISO 8503 shall assess the blast cleaned surface profile. This assessment shall be carried out at random locations over the whole structure to provide an
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accurate assessment of the surface profile. Where the surface profile is less than specified, the surface shall be re-blasted at no additional cost to CSBP. Adequate lighting shall be made available (minimum 500Lux) to visually inspect blast surface. Surface profile shall be measured by replica tape and physical measurement. The replica tape shall be attached to the quality control documentation and be part of the quality system. There is a four hour window of opportunity available to apply coating to a steel surface after abrasive blasting, after this period of time the blast surface will have to be re-worked. They may be individual occasions where, after inspection by CSBP, this 4 hour period may be extended.
The completed coating system shall be free of visual defects such as sags, runs, pinholes, bubbles voids, dust/grit inclusions or any other deleterious anomalies.
It is expected that the spray painter will be continually checking the Wet Film Thickness (WFT) with a comb gauge as the work progresses. CSBP shall randomly carry out WFT testing.
The coating film thickness shall be checked in accordance with AS3894.3. (Magnetic Induction Method). For measurement of DFT the digital magnetic induction are first preference and Eddy current gauges for non magnetic substrates. Calibrations of gauges are to be carried out in accordance with AS3894.3 appendix D.
Surface Area or Linear Length Minimum Number of Spot Measurements.
M2 or M (Each spot measurement is 3 off individual measurement within 10cm circle)
Up to 1 Unit 5
>1 and up to 3 units 10
>3 and up to 10 units 15
>10 and up to 30 Units 20
>30 and up to 100 units 30
>100 Units For areas greater than 100 units multiples of the measurement shall be used i.e. 220 Units requires 80 off spot measurements.
Where any single spot measurement is less than 80% of specified DFT the system will be rejected and additional coating material shall be applied at the contractors cost. The maximum DFT acceptable of individual coating layers shall be 1.2 times the maximum specified DFT. The exception to this will be corners, overlaps and difficult areas, in these cases the maximum will be 1.5 times the maximum specified DFT. Consultation with coating manufacturers may be required in determining acceptable levels of maximum and minimum DFT. In such cases written verification from the contractor and coating manufacturer will be required.
In determining the degree of cure of a coating system, or individual coat, the solvent rub test as per AS3894.4 method C shall be used.
For the inspection for internal tanks, vessels or a coating system that requires Holiday testing for pinholes Continuity testing shall be carried out as per AS3894.1 or AS3894.2 which ever is applicable.
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Adhesion testing coating systems shall be Pull-Off test in accordance with ASTM D4541 using a self aligning hydraulic, or pneumatic tester. Adhesion test acceptable values shall be determined by recommendation from the coating manufacturer. Prior to the commencement of projects adhesion testing of the complete coating system shall be carried out in the contractor’s premises at their cost. The test coupons will be 300mmm x 300mm of the same substrate as the project. The coupons shall be abrasive blasted, primed, intermediate coated and top coated. CSBP shall witness the abrasive blasting and each application of coating material and be present at the adhesion tests. Adhesion testing shall only be carried out after the coating system has sufficiently cured as per the manufacturers recommendations. Random adhesion testing of the works will be carried out, both Pull-Off and Cross hatch as per AS3891.9.
10.2.3 Quality Assurance Records
As a minimum, Inspection and Test Record Sheets, AS3894.10, AS3894.11, AS3894.12, AS3894.13 and AS3894.14 or Superintendent approved equivalent, covering all items included on the ITP’s shall be competed by the Contractor. During the course of the Works ‘Hold Points’ nominated in the ITP’s shall be progressively signed off to acknowledge inspection has been carried out, the results are satisfactory and authorisation has been given to proceed. The Works shall not process beyond any CSBP inspection ‘Hold Point’ until signed off by the Superintendent.
The contractor shall submit Inspection Reports not less than once a week detailing all aspects of the weather, surface preparation and coating. This report shall also include an updated schedule and estimated completing date.
Prior to final or part acceptance of the Works, the Contractor and the Superintendent, or their nominated representatives shall inspect the work and if accepted both parties shall sign an Inspection Report submitted by the Contractor.
Any inspection performed by CSBP, or their nominated representative, shall not relieve the Contractor of the responsibility to provide a quality job or perform inspections and record data in the QA documentation required under the contract.
10.2.4 Final Inspection
A final inspection shall be carried out prior to the contractual acceptance of completion of work. The inspection will include, but not limited to, visual inspection, DFT checks, QC/QA paperwork and verification that the work is complete.
The contractor and CSBP Responsible Officer shall both be represented at the final inspection and if the work is acceptable sign the appropriate documentation and warranty agreement. A report shall be prepared by the contractor as part of the acceptance procedure detailing as a minimum, the following items:
General.
• Name of Main Contractor and Key personnel.
• Scope of Work
• Commencement and completion dates of contract
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• Copies of Quality Plan
• Any deviations generated during the work
Inspection Equipment.
• Make and Model of all test equipment used
• Proof of calibration i.e. copies of calibration certificates
Coating Application
• Quality Control Documentation relating to, but not limited to, product name, batch numbers DFT and adhesion testing
• Spray equipment used
• Coating inspection reports
Inspection Reports
• Good quality copies of all Inspection Reports from the contractor.
• Inspection reports from any third party inspection services.
All Reports shall be supplied in new 2 ring lever arch files identifying the contents in a logical and methodical method
11. HANDLING AND STORAGE OF FINISHED PRODUCT
To reduce damage to the coating, at least five days curing time shall be allowed for it to harden before the steelwork is handled.
Special care shall be taken to avoid damage to coating systems during loading, transportation, unloading, storage and erection. All slings, ropes and chains shall be protected with rubber sheaths. It is the contractors responsibility to ensure that all treated steelwork arrive at the nominated CSBP site in a good undamaged condition. Any damaged items will be returned to the contractor’s yard, at their cost, for re-work
Timber blocking shall be provided when stacking coated members.
Members shall be stacked off the ground on suitable dunnage.
Any damage to the coating system shall be repaired to the paint specification requirements.
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12. COATING SYSTEMS
12.1 GENERAL
The same coating manufacturer shall manufacture all protective-coating materials for each coating system. If there is a requirement to use alternative supplier products the contractor shall inform CSBP Responsible Officer, in writing, of the proposed supplier change and reasons for the change. CSBP will respond to the contractor, in writing, of their decision.
The Contractor shall ensure that the proposed coating system complies with the Coating System Specification Sheets in Appendix 1 and the requirements of the contract in regard to the specified system and colour.
12.2 APPROVED COATING SYSTEMS
The coating systems listed in Appendix 1 are approved for application in the areas and in the conditions defined in Appendix 3. No variation may be made to any of the approved systems listed in Appendix 1 without written approval from the Superintendent.
Approval may be given for coating systems not included in Appendix 1 for special application areas where an approved system does not provide adequate protection. The contractor shall submit full details of any proposed system to the Superintendent for assessment.
If a coating system is not specified in the Works, Appendix 3 shall be used to select an appropriate coating system, subject to the approval of the Superintendent prior to use.
WARNING
COAL TAR EPOXY SHALL NOT BE USED IN ANY PAINT SYSTE M APPLIED OFF SITE OR ON SITE.
COLD TAR EPOXY SHALL NOT BE REMOVED BY ABRASIVE BLA STING
ACRYLIC MODIFIED POLYURETHANE MAY BE OFFERED IN PAI NT SYSTEMS APPLIED OFF SITE BUT THIS IS NOT ACCEPTABLE FOR
APPLICATION ON SITE.
TREATMENT OF EXISTING LEAD-BASED COATINGS SHALL BE CARRIED OUT STRICTLY IN ACCORDANCE WITH CSBP ENGINEERING ST ANDARD
SURFACE TREATMENT OF LEAD-BASED COATINGS (ES-14-102-13).
12.3 PAINT COLOUR
Paint colours shall be in accordance with Appendix 2 unless otherwise specified. Fully cured coating colour shall accurately match the nominated Australian Standard colour.
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For purposes of inspection and quality control, prime coats and subsequent coats shall be alternatively tinted to a different colour shade, which will enable each coat to be readily distinguished from the previous coat. The topcoat colour shall comply with this specification.
13. APPROVED COATING MANUFACTURERS
The following protective coating manufacturers are approved. Alternative Manufacturers must be approved in writing by the Superintendent:
Akzo Nobel Pty Ltd/International Paints
Carboline Coatings
JJG Coatings
Hardfords Eng Aluminising (Workshop Only)
Jotan
Dulux Australia Ltd
Wattyl
Wasser
Altex Coatings
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APPENDIX 1 – COATING SYSTEM INDEX
SYSTEM A (Withdrawn. Use System B if specified.)
SYSTEM B STEELWORK - NON CORROSIVE AREAS
SYSTEM C STEELWORK - MODERATELY CORROSIVE AREAS
SYSTEM D STEELWORK - HIGHLY CORROSIVE AREAS
SYSTEM E STEELWORK - ENCAPSULATION OF EXISTING LEAD-BASED COATING
SYSTEM F MAINTENANCE SYSTEM WHERE ABRASIVE BLASTING IS NOT APPROPRIATE OR POSSIBLE
Note (This replaces an earlier System F which was withdrawn in 1995. If System F was specified before 1995, use System B.)
SYSTEM G STEELWORK - HIGH TEMPERATURE TO 400OC
SYSTEM H (Withdrawn. Use System D if specified.)
SYSTEM I (Withdrawn. Use System D if specified.)
SYSTEM J (Withdrawn. Use System C if specified.)
SYSTEM K FIBREGLASS - EXTERNAL SURFACES
SYSTEM L TIMBERWORK - MILDLY CORROSIVE AREAS
SYSTEM M METAL SPRAY ALUMINISING
SYSTEM N (Withdrawn. Use System B if specified.)
SYSTEM O ELECTRICAL AND INSTRUMENTATION ENCLOSURES IN INTERNAL NON-CORROSIVE AREAS.
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APPENDIX 1 - COATING SYSTEM B
APPLICATION AREA: Internal or external steelwork in non corrosive areas. Galvanised surfaces generally.
CORROSION RESISTANCE: pH 5 min pH 12 max
HEAT RESISTANCE: Up to 100°C
SURFACE PREPARATION: Abrasive blast-clean to AS1627.4 Class 2 to achieve a blast profile of 25 - 50µm.
For galvanised surfaces, solvent clean all surfaces to remove oil and other surface contaminants and lightly whip blast, where possible.
COATING MATERIAL: PRIMER SECOND COAT TOP COAT
Polyamide Cured Zinc Phosphate Epoxy primer
None Recoatable Catalysed Acrylic - see Note
COLOUR: Red Oxide Refer Appendix 2
FINISH: Matt Full gloss
APPLICATION: Spray Spray
DRY FILM THICKNESS: 75µm minimum 50µm minimum
VOLUME SOLIDS: 50% minimum 40% minimum
No OF PACKS: 2 2
TOTAL DRY FILM THICKNESS:
125µm minimum if topcoat applied. 75µm otherwise.
NOTES: 1. Topcoat shall be applied if steelwork is visible after installation. Topcoat is not required for concealed steelwork unless otherwise specified.
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APPENDIX 1 - COATING SYSTEM C
APPLICATION AREA: Steelwork in moderately corrosive areas.
CORROSION RESISTANCE:
pH 5 min pH 12 max
HEAT RESISTANCE: Up to 100°C
SURFACE PREPARATION: Abrasive blast clean to AS1627.4 Class 2½ to achieve a blast profile of 25 - 50µm.
COATING MATERIAL: PRIMER SECOND COAT TOP COAT
Polyamide Cured Zinc Phosphate Epoxy primer
Polyamide Cured High Build Epoxy
Recoatable Catalysed Acrylic - see Note
COLOUR: Red Oxide Refer Appendix 2 Refer Appendix 2
FINISH: Matt Semi-Gloss Full gloss
APPLICATION: Spray Spray Spray
DRY FILM THICKNESS: 75µm minimum 175µm minimum 50µm minimum
NOTES: 1. Topcoat shall be applied only when specified for good appearance or to achieve correct colour not available in second coat. If not specified, topcoat is not required. See also notes in Appendix 3.
2. Topcoat shall be applied to all handrailing, preferably using airless spray equipment after handrailing has been installed to achieve best finish.
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APPENDIX 1 - COATING SYSTEM D
APPLICATION AREA: Steelwork in high corrosion areas.
CORROSION RESISTANCE:
pH 4 min pH 12 max
HEAT RESISTANCE: Up to 100°C
SURFACE PREPARATION: Abrasive blast clean to AS1627.4 Class 2½ to achieve a blast profile of 25 - 50µm.
COATING MATERIAL: PRIMER SECOND COAT TOP COAT
Polyamide Cured Zinc Phosphate Epoxy primer
Amine Adduct Curing High Solids High Build Epoxy
Recoatable Catalysed Acrylic - see Notes 1 & 2
COLOUR: Red Oxide Refer Appendix 2 Refer Appendix 2
FINISH: Matt Semi-Gloss Full gloss
APPLICATION: Spray Spray Spray
DRY FILM THICKNESS: 75µm minimum 400µm minimum See Note 2.
475µm minimum or 525µm minimum with topcoat 575µm minimum for submerged steelwork. See note 2.
NOTES: 1. For steelwork and pipework, topcoat shall only be applied when specified for good appearance or to achieve correct colour not available in second coat. If not specified, topcoat is not required. See also notes in Appendix 3.
2. For steel submerged in product, increase second coat DFT to 500µm minimum over prime coat up to 3m above product level. No topcoat required.
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APPENDIX 1 - COATING SYSTEM E
APPLICATION AREA: Maintenance encapsulation system for steelwork with an existing lead-based coating - See Note 1.
CORROSION RESISTANCE: pH 4 min pH 12 max
HEAT RESISTANCE: Up to 90°C
SURFACE PREPARATION: High-pressure water blast, hand or power tool clean.
COATING MATERIAL: Specifically designed lead encapsulation coating systems See - Note 2.
COLOUR: Refer Appendix 2
FINISH: Semi-gloss
APPLICATION: Brush, roller, conventional and airless spray
FILM THICKNESS: Will vary dependant on system selected.
VOLUME SOLIDS: Will vary dependant on system selected.
No OF PACKS: Will vary dependant on system selected.
NOTES: 1. CSBP approved Altex Coatings or Wasser (Wattyl) lead encapsulation coatings systems, as per CSBP Engineering Standard Surface Treatment of Lead-Based Coatings (ES-14-102-13), shall be used. Each application shall be individually assessed and scoped.
2. Total Dry Film thickness shall be the final measured thickness, which includes thickness of sound existing coating.
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APPENDIX 1 - COATING SYSTEM F
APPLICATION AREA: Maintenance System where abrasive blasting is not appropriate or not possible.
CORROSION RESISTANCE:
pH 4 min pH 12 max
HEAT RESISTANCE: Up to 90°C
SURFACE PREPARATION: High pressure water wash, hand power tool clean.
DRY FILM THICKNESS: 40µm minimum 400µm minimum See Note 2.
50µm minimum
VOLUME SOLIDS: 100% 75% minimum 44% minimum
No OF PACKS: 2 2 2
TOTAL DRY FILM THICKNESS:
400µm minimum or 450µm minimum with topcoat 500µm minimum for submerged steelwork. See note 2.
NOTES: 1. For steelwork and pipework, topcoat shall only be applied when specified for good appearance or to achieve correct colour not available in second coat. If not specified, topcoat is not required. See also notes in Appendix 3.
2. For steel submerged in product, increase second coat DFT to 500µm minimum over prime coat up to 3m above product level. No topcoat required.
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APPENDIX 1 - COATING SYSTEM G
LOCATION: Steelwork - high temperature to 400°C
CORROSION RESISTANCE:
pH of 6 min
pH of 8.5 max
HEAT RESISTANCE: Up to 400°C - See Notes
SURFACE PREPARATION: Abrasive blast clean to AS1627.4 Class 2½.
COATING MATERIAL: PRIMER INTERMEDIATE TOP COAT
Inorganic Zinc Silicate to AS2105
Inorganic Butyl Titanate
Inorganic Butyl Titanate
COLOUR: Grey Aluminium Aluminium
FINISH: Flat Flat Flat
APPLICATION: Spray Spray Spray
DRY FILM THICKNESS: 75µm minimum 25µm 25µm
VOLUME SOLIDS: N/A 47% minimum 47% minimum
No OF PACKS: 2 1 1
TOTAL DRY FILM THICKNESS:
125 µm minimum
NOTE: 1. This system is not suitable for use in a strongly acidic or alkaline environment.
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APPENDIX 1 - COATING SYSTEM K
LOCATION: Fibreglass - external surfaces.
CORROSION RESISTANCE:
Acids to pH 4 min. Alkali to pH 14 max.
HEAT RESISTANCE: Up to 100°C
SURFACE PREPARATION: Clean surface thoroughly. Sand down to achieve a smooth surface and remove gloss to provide key.
COATING MATERIAL: PRIMER INTERMEDIATE TOP COAT
Polyamide Cured High Build Epoxy
None Recoatable Catalysed Acrylic
COLOUR: As selected Refer Appendix 2
FINISH: Semi-Gloss Full gloss
APPLICATION: Spray Spray
DRY FILM THICKNESS: 100µm minimum 50µm minimum
VOLUME SOLIDS: 80% minimum 40% minimum
No OF PACKS: 2 2
TOTAL DRY FILM THICKNESS:
150 µm minimum
NOTE: 1. Provides protection against UV.
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APPENDIX 1 - COATING SYSTEM L
LOCATION: External and internal timberwork. Mildly corrosive areas.
CORROSION RESISTANCE:
Acids to pH 6 min. Alkali to pH 8 max.
HEAT RESISTANCE: Up to 80°C
SURFACE PREPARATION: Clean surface thoroughly. Sand down to achieve a smooth surface.
COATING MATERIAL: FIRST COAT TOP COAT
Waterborne Acrylic Waterborne Acrylic
COLOUR: Any As specified
FINISH: Gloss Gloss
DRY FILM THICKNESS: 40µm minimum 40µm minimum
VOLUME SOLIDS: 40% 40%
No OF PACKS: 1 1
TOTAL DRY FILM THICKNESS:
80 µm minimum
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APPENDIX 1 - COATING SYSTEM M
APPLICATION AREA: Internal steelwork in sulphuric acid hot gas ducting and vessels.
CORROSION RESISTANCE: Extends duct life through formation of aluminium oxide surface in an oxidising atmosphere.
HEAT RESISTANCE: Up to 600°C
SURFACE PREPARATION: Abrasive blast clean to AS1627.4 Class 3 to achieve a blast profile greater than 75-110µm.
COATING MATERIAL: Aluminium Wire
COLOUR: Silver
FINISH: Matt
APPLICATION: Arc sprayed using three passes
FILM THICKNESS: 250 - 300µm minimum
VOLUME SOLIDS: N/A
No OF PACKS: N/A
TOTAL FILM THICKNESS: 250 - 300 µm
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- Within Chemical Process Plants (Refer Note 6) Light Grey Blue B44
- All other areas such as fertiliser plants, storage and despatch.
Where doubt exists in the area classification, CSBP are to be consulted and CSBP will advise the colour selection
Cream Y34
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APPENDIX 2 - PAINT COLOURS - PAGE 2 OF 2 - NOTES
1. Marking, banding and colour coding of pipes, conduits and ducts shall comply with AS 1345 and CSBP Engineering Standard Labels & Signs: Plant and Equipment (ES-14-102-09), except that the identification colour for all pipework and equipment in Ammonia service (liquid or vapour), shall be white. Banding or colour coding shall be done with the same coating system as specified for the topcoat.
As an option, it is permissible to paint the entire pipe route with the identification colour rather than provide the colour band only. Topcoat is not required if second coat can be tinted to required finish colour.
2. A procedure exists in the ammonia loading area for identifying regular inspection of hoses by colour banding. The following colours are used in rotation to identify the year in which the equipment is inspected:
Black Dulux HT300 Black Hi Gloss Enamel 381-00070 or equal
Turquoise AS2700S No. T15
Orange AS2700S No. X15
These colours should not be used to mark equipment in any way that may cause confusion in this process.
3. Where a fuse board or circuit breaker board is fed from a UPS source, then that fuse board or circuit breaker escutcheon shall be Bright Blue B23 colour. GPO’s supplied by UPS shall be manufacturer’s standard colour closest to B23.
4. Kickrails that are attached to handrail stanchions shall be colour-yellow Y14. Kickrails that are an integral part of the supporting steelwork shall be painted the same colour as the steelwork. Kickrails integral with floor grating shall be finished the same as the grating.
In order to distinguish between Hazardous Area and Non-hazardous rated electric motors the following topcoat, which is to be applied according to this Standard, shall apply:
Metric Motors - ALL new motors and repaired existing metric motors.
Non-Hazardous Area motors shall have a topcoat colour G13 Emerald Green.
Hazardous Area motors (Ex ‘e’, Ex ‘n’ and Ex ‘d’ ratings) shall have a topcoat colour X15 Orange.
Note: For Hazardous Area rated electric motors which are held in the store or are currently installed, which are painted Green, a bold distinguishing stripe of X15 Orange paint shall be applied in situ using a spray can or brush.
Imperial Motors – existing
Non-Hazardous Area rated motors shall have a topcoat colour N53 Blue Grey.
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Hazardous Area rated electric motors shall have a topcoat colour N53 Blue Grey with two stripes 100mm wide colour X15 Orange painted around stator.
6. Pipework, equipment and steelwork within the battery limits of chemical process plants shall be coloured B44 Light Blue Grey. Pipes, pipe racks and other services connecting the plant to other parts of the site or to facilities outside the battery limits shall be coloured Y34 Cream. The colour change occurs at the battery limit, except in the case where the pipe or pipe rack is between two chemical process plants in which case the pipe rack and pipework shall be coloured B44 Light Blue Grey.
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APPENDIX 3 - SELECTION OF PROTECTIVE COATING SYSTEM S
The following is provided to assist in the selection of protective coating systems for particular applications. If coating system is not already specified, the Superintendent shall approve the selection of a coating system prior to its use.
SYSTEM B STEELWORK - NON CORROSIVE AREAS
1. Internal building: steelwork, stairways, etc. - in office buildings, workshops and stores.
2. External non-corrosive areas remote from process plants and storage areas on steelwork such as gates, signs, railing, etc where corrosion is likely to occur at a very slow rate.
3. Galvanised surfaces in all areas, if painting is specified.
4. Apply System B prime coat only to all steel pipework and other steel surfaces that are to be insulated and have operating temperature less than 100°C.
SYSTEM C STEELWORK - MODERATELY CORROSIVE AREAS
1. Default coating system for all steel items in plant and storage areas, which may be exposed to moderately corrosive conditions and where long protection life is required. Includes structural steel, walkways, pipe supports, brackets, floor plate, guards, conveyors, pipe racks, mechanical equipment, process equipment and vessels - except as defined under System D below.
Generally applies to steelwork and equipment outside of manufacture plants and outside storage buildings where corrosion levels are lower. Applies to all despatch areas for dry product.
2. Default system for handrailing in all areas. Topcoat is required to achieve smooth finish. For handrailing in extreme chemical corrosion areas, wet areas and marine environments, use System D.
3. Default coating system for above ground pipework outside manufacture plant areas. Refer to CSBP Engineering Standard Underground Piping (ES-14-602-05) for below ground pipe protective coating.
4. Electrical cabinets and enclosures installed outside controlled environment equipment rooms. Topcoat shall be applied prior to installation.
5. Mobile equipment - Topcoat required.
6. Bulk liquid storage tanks in all areas.
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SYSTEM D STEELWORK - HIGHLY CORROSIVE AND MARINE AREAS
1. Structural steel, walkways, above ground pipework, pipe supports, brackets, handrailing, miscellaneous steelwork, floor plate, process equipment, steel piling, etc. in high corrosion areas and where maximum protection is required. Applies particularly to steelwork in areas exposed to corrosion from chemical attack, subject to regular wash down, or likely to come in contact with seawater.
2. Specific areas for which System D shall be used are as follows:
a. All chemicals and fertiliser manufacture plants
b. All areas of Prill plant
c. All structural steelwork and equipment inside bulk product storage sheds. Note additional film thickness applies for buried steelwork.
d. Wharf area generally
e. Conveyors from wharf to C transfer bin.
f. Bulk liquid Loading facilities all areas
g. Effluent containment facilities
Handrailing in all of the above areas shall be coated to System D. Topcoat required to achieve smooth finish.
3. Electrical and instrumentation enclosures installed in highly corrosive and marine areas. Topcoat shall be applied.
4. Default coating system for ALL new and repaired electric motors in ALL areas. Topcoat shall be applied.
Note: Particular colour requirements are detailed in Appendix 2.
SYSTEM E STEELWORK - ENCAPSULATION OF EXISTING LEAD-BASED COATINGS
1. Use when existing coating contains lead, surface preparation can only be done by high pressure water blasting and existing coating is to be encapsulated, avoiding the need to completely remove the existing coating.
Safety precautions, surface preparation and application of encapsulation system shall be in accordance with CSBP Engineering Standard Surface Treatment of Lead-Based Coatings (ES-14-102-13) and this Standard where applicable
Note: If existing lead-based coating is completely removed, the new protective coating system shall be selected from Appendix 1 for the particular application area.
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SYSTEM F STEELWORK – MAINTENANCE SYSTEM
Use when recoating existing steelwork where abrasive blasting is not appropriate or not possible.
SYSTEM G STEELWORK - HIGH TEMPERATURE TO 400OC
1. Use on uninsulated high temperature surfaces on pipework, exhausts, flues, hot gas ducting, equipment, etc. with operating temperature between 100°C and 400°C.
2. On insulated high temperature steel surfaces with operating temperature between 100°C and 400°C, apply System G prime coat only when any of the following circumstances exists.
a. When the insulated surfaces will be exposed to moisture or corrosive atmospheres for a significant period of time prior to insulating during construction and commissioning, and are not protected by other means,
b. Where the surfaces are not in continuous service, eg stand-by equipment, and are in a location where they may be subject to corrosive attack,
c. Where the surfaces are in an area where high rates of corrosive attack may occur when the plant is shut down.
Otherwise, insulated high temperature surfaces do not require protective coating.
3. This System is not suitable for use in strongly acid or alkaline environments.
4. This System may not be suitable for use in wet hot/cold cyclic conditions, which under some circumstances can result in loss of protection and increased rate of corrosion. Refer to coating manufacturer for recommendation.
SYSTEM K FIBREGLASS - EXTERNAL SURFACES
1. Use only where specified on fibreglass items e.g. Scrubbing system in Granulating plant.
2. To be used for UV protection on fibreglass and PVC items where UV protection is specified.
SYSTEM L TIMBERWORK - MILDLY CORROSIVE AREAS
1. Use on all exterior woodwork not protected by other means.
SYSTEM M METAL SPRAY ALUMINISING
1. Internal steelwork in sulphuric acid hot gas ducting and vessels.
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SYSTEM O ELECTRICAL AND INSTRUMENTATION ENCLOSURES IN INTERNAL NON-CORROSIVE AREAS.
1. Default coating for all electrical and instrumentation enclosures, cabinets and switchboards inside switchrooms and control rooms with controlled atmospheres. Not for use in process areas or external installations - SYSTEM C or SYSTEM D shall be used.
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APPENDIX 4 - APPROVED PRODUCTS FOR COATING SYSTEMS
SYSTEM SUPPLIER FIRST COAT SECOND COAT TOP COAT
B Dulux Durepon P14 Acrathane IF
Akzo Nobel/ International Intergard 251 Interfine 629
Carboline Coatings Carboguard 504 Carboguard 2929
JJG Sigmacover 256 Sigmadur 540
Jotun Penguard Special Jotacote Hardtop CA
Wattyl Epinamel 360ZP Paracryl IFC
C Dulux Durepon P14 Durebild STE Acranthane IF
Akzo Nobel/ International Intergard 251 Intergard 345 Interfine 629
Wattyl Galvit ES 600 Heatkote Aluminium Heatkote Aluminium
K Dulux Durebild STE Acrathane IF
Akzo Nobel/ International Intergard 345 Interfine 629
Carboline Coatings Carboguard 690 Carboguard 2929
JJG Sigmacover 640 Sigmadur 540
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SYSTEM SUPPLIER FIRST COAT SECOND COAT TOP COAT
Jotun Jotacote 605 Jotacote Hardtop CA
Watty Epinamel HSE 707 Paracryl IFC
O Orica/Dulux Durepon P14 Acrathane IF
Akzo Nobel/ International Interzinc 315 Interpon 610
Ameron Multietch 302 Amercoat 450 SGK
Jotun Penguard HB Hardtop AS
Note: When wet abrasive blasting and using Jotun Penguard Special as a primer, ALFLOC 918 inhibitor or Sodium Nitrate diluted to 0.2% shall be used in the water.
