503406-0000-45eg-0004_r00_signoff

Revision PAINTING AND GALVANIZING No. Date

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REVISION HISTORY

Note 1: This document is developed from/ supersedes Phase 1 Document No. 017661-0000-45EG-0004. Environmental

Category for Power Plant and Smelter changed from C5-M to C3 and C4. Grating and stair threads shall be only galvanized. Intermediate coat for S1a and S1b adapted to C3 and C4 respectively. Other minor corrections.

Comments from client document 503406-AD0000-20CRS-0013 been included

00 2010-12-06 Issued for Use 1 SR AT AT BK

No. Date Description Prep’dby

Rev’dby

App’d by

App’d by

App’d by

App’d by


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TABLE OF CONTENTS

1.0 INTRODUCTION ...................................................................................................................5 1.1 General .................................................................................................................................. 5 1.2 Purpose.................................................................................................................................. 5 1.3 Scope..................................................................................................................................... 5 1.4 Environmental Conditions ......................................................................................................5 1.5 Durability ................................................................................................................................ 6 1.6 Definitions .............................................................................................................................. 6 1.7 International Codes and Standards .......................................................................................6 1.8 Project Standard Specifications .............................................................................................8 1.9 Government Regulations .......................................................................................................8 1.10 Code and Standards Conflicts ...............................................................................................8

2.0 WARRANTY AND QUALITY ASSURANCE.........................................................................8 2.1 Warranty ................................................................................................................................ 8 2.2 Quality Assurance.................................................................................................................. 9

3.0 PAINT MATERIALS ..............................................................................................................9 3.1 Mixing and Handling ............................................................................................................10 3.2 Storage of Materials............................................................................................................. 10 3.3 Paint Compatibility ............................................................................................................... 10

4.0 BRIGHT PARTS..................................................................................................................11

5.0 CLEANING AND PREPARATION INSTRUCTIONS ..........................................................11

6.0 PAINTING APPLICATION INSTRUCTIONS ......................................................................11 6.1 General ................................................................................................................................ 11 6.2 Maximum Exposure of Blasted Surfaces .............................................................................12 6.3 Method of Application ..........................................................................................................12 6.4 Climatic Conditions .............................................................................................................. 12 6.5 Time between Coats of Paint...............................................................................................12 6.6 Coating Application .............................................................................................................. 13 6.7 Surface Finish ...................................................................................................................... 13 6.8 Repairs to Welds and Damaged Areas................................................................................13

7.0 TESTING AND INSPECTION..............................................................................................14 7.1 General ................................................................................................................................ 14 7.2 Surface Preparation ............................................................................................................. 14 7.3 Dry Film Thickness .............................................................................................................. 14 7.4 Visual Inspection.................................................................................................................. 15 7.5 Preparation for Transport.....................................................................................................15


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8.0 PAINT SYSTEMS................................................................................................................15 8.1 Operating Environment Conditions ......................................................................................15 8.2 Application Schedule ...........................................................................................................16 8.3 Colour Schedule .................................................................................................................. 16 8.4 Fixings.................................................................................................................................. 16

9.0 GALVANIZED COATING....................................................................................................16 9.1 General ................................................................................................................................ 16 9.2 Design for Galvanizing.........................................................................................................16 9.3 Preparation .......................................................................................................................... 16 9.4 Galvanizing – Structural Steel..............................................................................................16 9.5 Galvanizing – Nuts and Bolts...............................................................................................17 9.6 Transportation and Erection.................................................................................................17 9.7 Repair to Galvanizing........................................................................................................... 17

10.0 SITE PAINTING................................................................................................................... 17

APPENDIX A – PAINT SYSTEM APPLICATION SCHEDULE APPENDIX B – PAINT SYSTEM SCHEDULE APPENDIX C – STRUCTURE AND EQUIPMENT COLOUR SCHEDULE APPENDIX D – OPERATING ENVIRONMENT SCHEDULE APPENDIX E – PAINT PREFERRED SUPPLIERS WITH EXAMPLES


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1.0 INTRODUCTION

1.1 General

This specification sets out the minimum requirements and the standards for surface treatment and painting and galvanizing for EMAL project.

1.2 Purpose

The purpose of this specification is to provide guidelines for corrosion control measures in the design and operations of facilities under the jurisdiction of the EMAL facilities. These guidelines are aimed at providing useful information to be incorporated during design, selection of materials and corrosion control methods, and other related design aspects.

1.3 Scope

This specification provides guidance for selecting adequate preparation and coating system to minimize corrosion. Guidelines are provided in order to promote high level of design quality, as well as uniformity of practices. This specification is confined to corrosion protection for metallic structures (local fabricated and bulk finished overseas), piping and equipment exposed to atmospheric, soil, groundwater, and marine environments.

The most common corrosion control methods, appropriate materials and application requirements are presented in this specification. Also provided is the list of preferred paint manufacturers and products.

This specification is applicable to all carbon steel and low allow (9% chrome or less) steels. Stainless steel, aluminium and high-alloy materials exposed to the saline environment require special protection which needs to be specified and approved on a case by case basis.

1.4 Environmental Conditions

The EMAL plant is located on the coast of UAE, with high salinity, high temperatures and high humidity environment with wind borne salts and sands. Refer to Data Sheet 503406-0000-40ED-0022 (Basis of Design – Geotechnical Data) and 503406-0000-40EC-0003 (Site Conditions) for more details.

These conditions require that steelwork be given a high degree of protection. Its corresponding atmospheric corrosive category in compliance with EN-ISO-12944-2 is mainly C4 “Industrial and Coastal Environment” and C5-M “Offshore Environments”. Appendix ‘’D’’ provides a specific classification of the operating conditions of the facilities.

In general Paint System S1b shall be used for all onshore structural steel works and onshore

equipment located outside and inside production facilities. Refer to Appendices A to E for specific applications.


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1.5 Durability

The required durability range for this project is > 15 years (high). The warranty is covered in Section 3 of this document. This can be clarified by Standard EN ISO 12944-1 which states “The durability range is not a ‘guarantee time’. Durability is a technical consideration that can help the owner set up a maintenance programme. A guarantee time is a consideration that is the legal subject of clauses in the administrative part of the contract. The guarantee time is usually shorter than the durability range. There are no rules that link the two periods of time”.

Codes, Standard Specifications and government regulations

1.6 Definitions

For the purposes of this document, the term and definitions given in BS-EN-ISO 12944 part 1 to 8 and the following terms and definitions apply:

BS British Standards

Client/ Owner EMAL Aluminium Company Limited

Contractor Contractor to EMAL that EPCM Contractor is managing on behalf of Client.

CRSI Concrete Reinforcing Steel Institute

EPCM Engineer Engineer Representative of the EPCM Contractor managing on behalf of the Client

EPCM Contractor Contractor managing on behalf of the Client

ISO International Standard Organization

ITP Inspection Test Plan

Manufacturer Paint Manufacturer

SLII SNC Lavalin International Incorporated

Vendor /Seller Supplier of equipment and or material

1.7 International Codes and Standards

All materials, workmanship and practises shall be in accordance with the latest issue of the international codes and standards as of the 1 July, 2010.

BS 1710: Identification of pipelines and services


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BS 4800: Schedule of paint colours for building purposes

BS EN ISO 2409 Paints and Varnishes. Cross cut test

BS EN ISO 1461: Specification for hot dip galvanized coatings on fabricated iron and steel articles

BS EN ISO 2808, BS3900-C5 Paint and varnishes. Determination of film thickness.

BS EN ISO 4826-2 Paint and Varnishes, Evaluation of degradations of coatings

BS EN ISO 4628-3 Paint and varnishes. Evaluation of degradation of coatings

BS EN ISO 12944 -1 to 8: Paints and varnishes. Corrosion protection of steel structures by protective paints systems.

BS EN ISO 14713: Protection against corrosion of iron and steel in structures. Zinc and aluminium coatings. Guidelines

BS EN ISO 8501-3: Preparation of steel substrates before application of paints and related products

BS EN ISO 8503 Preparation of steel substrates before application of paints and related products. Surface roughness characteristics of blast-cleaned steel substrates.

SIS 05 59 00: Pictorial surface preparation standards for painting steel surfaces

ISO 20340: 2009 Paints and Varnishes – Performance Requirements or Protective Paint Systems for Offshore and related structures

RAL: Colour shades

BS EN ISO 1513 Paints and varnishes. Examination and preparation of samples for testing

ISO 4624 Paints and varnishes -- Pull-off test for adhesion

ASTM D4541 Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers


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1.8 Project Standard Specifications

All materials, workmanship and practises shall be in accordance with the current issue of the listed project standards specification.

503406-0000-42EG-0001 Concrete Works

503406-0000-43EC-0001 Design Criteria - Structural

503406-0000-43EG-0001 Structural Steel Works

503406-0000-45EG-0010 Welded Steel Construction

503406-0000-46EG-0001 Piping Fabrication and Installation

1.9 Government Regulations

All materials, workmanship and practises shall be in accordance with the local agencies that have jurisdiction over the project and Abu Dhabi municipality.

1.10 Code and Standards Conflicts

Any conflicting requirement between the various referenced documents shall be brought to the attention of the Engineer for resolution.

The Contractor shall at all stages inform in writing the Engineer immediately if there appears to be doubts as to the specified requirements. The Contractor shall not proceed with any such aspects of the work until he has received the necessary confirmation in writing from the Engineer.

2.0 WARRANTY AND QUALITY ASSURANCE

2.1 Warranty

The Contractor / Vendor shall obtain a warranty in favour of both the EPCM Contractor and the Contractor / Vendor, on a joint basis from an authorized representative of either the paint Manufacturer or the painter who shall have been approved by the Manufacturer, guaranteeing that the conditions of the painted surfaces shall be, after one year, no worse than the condition “Re 0”, as defined in the European Standard of Rusting, BS EN ISO 4628-3, and no worse than “Re 1” as defined in the standards BS EN ISO 4628-3, BS EN ISO 12944 – 1 to 8 and BS EN ISO 14713 for a period of seven years from the date of issue of the last final certificate.

The guarantee shall contain an undertaking to carry out any treatment necessary to restore the paintwork as outlined in the standards BS EN ISO 4628-3, BS EN ISO 12944 – 1 to 8 and BS EN ISO 14713 at no cost to the EPCM Contractor should the paint work condition be worse than specified at any time during the 7-year period.


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2.2 Quality Assurance

Immediately following the delivery of the notice to proceed, the Contractor / Vendor shall submit a quality assurance program for approval. All paints for the equipment and/or structure on the contract shall be provided by one Manufacturer and preferably shall be manufactured in one country to ensure compatibility. All painting shall be carried out strictly in accordance with the paint system Manufacturer's recommendations by a painter on the Manufacturer's approved list shown in Appendix ‘’E’’.

The application shall be monitored at the site and approved, in writing, by an authorized representative of either the paint Manufacturer or the painter who shall have been approved by the Manufacturer.

The Contractor / Vendor shall be responsible for the quality of Work and shall develop and propose programs and methods of construction and testing to achieve the specified quality to the approval of EPCM Engineer.

The Contractor / Vendor shall provide the necessary Quality Control organization to ensure he meets fully his responsibilities and obligations for quality control of surface preparation and application of protective coatings and paint systems, wherever the execution is performed.

3.0 PAINT MATERIALS

All material supplied shall be from ISO 9001 / 9002 or equivalent accredited suppliers.

Paint materials, when furnished by the Seller / Contractor, shall be in unbroken, original containers bearing the Manufacturer's brand name, batch number and colour designation.

All paint materials shall be lead and chromate free.

All components within a given system (primer, top coat, etc), shall be supplied by the same manufacturer.

Inspection reports shall contain the batch number and date of manufacture of materials used.

At all stages, the latest written instructions from the coatings Manufacturer including Protective Coating System, Product Data Sheets and Product Labels shall be implicitly followed. Superimposed primers and coatings shall be compatible. In the event of conflicts, the Seller/Contractor shall resolve these issues with the different coating manufacturers, and the differences and resolution shall be brought to the attention of the EPCM Contractor for review and clarification.

The preferred list of paint manufacturers for the project is shown in Appendix ‘’E’’.


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3.1 Mixing and Handling

All mixing and handling shall be carried out strictly in accordance with the Manufacturer's recommendations. Mixing shall only be permitted from pre-measured kits.

Pot life of multi-component systems, as recommended by the Manufacturer, shall be strictly observed. Paints exceeding the stated pot and shelf life shall not be used.

All colouring of paint shall be by the Manufacturer in accordance with the project specification.

3.2 Storage of Materials

All paint materials shall be stored in strict accordance with the Manufacturer's recommendations. When on the construction site, at no time must paint materials be stored or left exposed to direct sunlight. A register of all materials, quantities and Material Safety Data Sheets (MSDS) shall be developed and maintained.

3.3 Paint Compatibility

The Contractor / Vendor shall:

Verify that all paints in a painting system shall be supplied by the same paint manufacturer. If paints from different manufacturers are planned to be used, prior approval for compatibility must be obtained from the EPCM Contractor.

Provide coats which are compatible with the coats already used or to be used.

Review other Sections of these Specifications in which coats are to be provided to ensure compatibility with the total coating system on the various substrates.

Provide barrier coats over incompatible primers or remove and re-prime as required.

Notify the EPCM Contractor in writing of any anticipated problems using the coating systems specified on substrates pre-primed.

For repainting of existing painted surfaces, the Contractor / Vendor shall provide surface preparation and new primers and/or undercoats which will ensure the compatibility, adhesion, and coverage of specified finish paints as a total system. The Contractor / Vendor shall:

Verify existing paint coating materials by site examination and testing, if required. Notify the EPCM Contractor for direction as to obtaining access and samples.

Commencement of painting shall be considered acceptance of the suitability of existing substrates.

Prior to beginning any painting work, review applicable painting systems with qualified representatives of the selected paint manufacturer.


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4.0 BRIGHT PARTS

All bright parts and non painted surfaces shall be coated with grease, oil or other approved rust preventative before dispatch and during erection. This protective coating shall be cleaned off and the parts polished before being handed over.

5.0 CLEANING AND PREPARATION INSTRUCTIONS

The surfaces to be painted shall be cleaned and prepared in accordance with the more stringent of the paint system schedule in this specification or the Manufacturer’s requirements.

Weld spatter and laminations shall be removed and sharp or rough welds rounded and contoured. Sharp edges shall be rounded or chamfered.

Surfaces to be coated shall be cleaned of dirt and dust, free of all salt, grease, oil, loose rust, and loose mill scale. Oil and grease shall be removed by solvent cleaning methods.

Where lapped or butted joints form part of an assembly, which is assembled or part assembled prior to final painting, the jointed surfaces shall be cleaned free from all scales, loose rust, dirt and grease and given one brush applied coat of Zinc Phosphate Primer before assembly.

Steel sections and plates shall be free from surface flaws and laminations prior to blast cleaning and shall not be in worse conditions than the pictorial standard B of the Swedish standard SIS 05 59 00; and

Under no circumstances should abrasive cleaning and painting be carried out simultaneously when there is a possibility particulate matter from the cleaning will contaminate the paint being applied.

Subsequent to the blasting operation and immediately prior to the application of the primer coat, the blasted surface shall be blown down with dry, clean air to remove dust and any other loose particles.

6.0 PAINTING APPLICATION INSTRUCTIONS

6.1 General

The painting of the works shall be carried out in accordance with the schedules in this specification.

The schedules indicate standards of surface preparations and painting, which are intended to give a minimum life of 10 years in a coastal environment.

The EPCM Engineer may consider alternative paint schemes to meet the requirements of fabrication using modern automated material handling systems, provided they offer the same standards of surface protection and service life as those intended by the schedules.


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6.2 Maximum Exposure of Blasted Surfaces

It is the Contractor / Vendor's responsibility to ensure that the prime coat is applied to the blast-cleaned surface before any surface deterioration occurs. The maximum time period between abrasive blast cleaning and priming shall be four (4) hours. This time is dependent on prevailing conditions and may need to be reduced, particularly in marine environments. In these circumstances, the Manufacturer’s and or EPCM Contractor’s direction should be sought.

6.3 Method of Application

All paints shall be applied by brush, roller or spray in accordance with the schedule, except for priming coats for steel floors, galleries and stairways where dipping is permitted.

Where paint is to be applied by spray, the painter shall demonstrate that the spray technique employed does not produce paint films containing vacuoles.

6.4 Climatic Conditions

Paint shall not be applied to surfaces, which are superficially or structurally damp and condensation must be absent before the application of each coat.

Painting shall not be carried out under adverse weather conditions, such as low temperature (below 4°C) or when the surfaces are less then 3°C above dew point, during rain or fog or relative humidity above 90% or during sandstorms.

6.5 Time between Coats of Paint

Manufacturer's recommendations for re-coating times should be strictly observed to ensure good adhesion, after taking account of the existing climatic conditions. When painting hot surfaces, Seller/Contractors are reminded that curing time decreases as temperature increases and the time between coats needs to be adjusted to suit.

Contamination between coats shall be avoided by minimizing time between coats. Should any contamination occur, then the painted surfaces shall be cleaned by scrubbing with copious quantities of clean water or by using a high-pressure water blast. Where the contamination (e.g. oil and grease) cannot be removed completely, a suitable solvent shall be obtained from the paint manufacturer and used, followed by scrubbing and washing as above.

Detergents may be required depending on the nature of the contamination, however, the use of detergents or solvents will only be at the specific approval of the EPCM Engineer. Where the surface has become dirty (as opposed to contaminated) or has been exposed in the open air for more than two days, it shall be scrubbed down with a 2% solution of Teepol and hosed with clean water.

Paint shall not be applied to wet or damp surfaces.


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Contamination by solid particles shall be removed by rubbing down with emery paper or in severe cases, by "whip" blasting. If either method is unsuccessful, then blasting back to bare metal will be required. It is the Vendor's responsibility to take precautions to prevent contamination during the application of paint.

Paint coats found to contain contaminants distributed through the film shall be blasted back and re-coated to this specification.

6.6 Coating Application

Coating application shall comply with the paint manufacturer’s recommendation and specification.

Thinners may only be used when following the manufacturer’s recommendations.

On sheltered or unventilated horizontal surfaces on which dew may linger, more protection is needed and to achieve this, an additional top coat of paint shall be applied.

All paint film thicknesses given are minimum values and refer to the dry film condition.

The Contractor / Vendor shall generally provide finished colors, which match, as near as is practical, the colors of similar items in the existing installation.

6.7 Surface Finish

All coated surfaces shall be uniform in colour, free from missed areas, pinholes, sags, runs, drippings, or other imperfections likely to result in premature failure of the protective coating.

6.8 Repairs to Welds and Damaged Areas

Areas affected by welding and the weld itself shall be, where possible, abrasive blast cleaned in accordance with this paint system schedule.

All traces of spatter, flux, oxides and other residues shall be removed prior to painting. Painting must not proceed until these impurities are removed.

It is expected that weld profiles be smooth and present a reasonable surface for painting. Local grinding of unsatisfactory profiles may be required.

Areas damaged in handling or transport shall be locally repaired by blasting and painting in accordance with this specification (re-instated to full coating system – primer to topcoat). All adjoining paint films shall be "feathered" carefully to ensure maximum adhesion.

Any damage made to other’s equipment, piping or steelwork during any part of delivery or installation shall be rectified by the Contractor / Vendor who made the damage.


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Should abrasive blast cleaning not be possible, then power tool cleaning may be employed, subject to the EPCM Contractor’s approval. This is a non-preferred method and if applied, shall produce a finish equivalent to that of abrasive blast cleaning.

7.0 TESTING AND INSPECTION

7.1 General

Complete inspection and test records shall be maintained for all work carried out. Inspection certificates and reports, or in the case of accredited quality systems, compliance certificates, shall be provided to the EPCM Contractor at the completion of work.

It is the Contractor / Vendor's responsibility to ensure that all the requirements of this specification are achieved and the quality control is in compliance with the approved ITP of the package. The EPCM Contractor reserves the right to carry out on-going inspections throughout the course of the work, however, this does not imply acceptance in the event of subsequent defective work being found. Should the EPCM Contractor’s inspection identify defects in the work, the Contractor / Vendor shall rectify any such sub-standard work.

The Contractor / Vendor shall be responsible for ensuring that detailed inspection and tests are performed in accordance with the relevant Codes and Standards. None of the EPCM’s inspections, or others not noted, will relieve the Contractor / Vendor of responsibility for Contractor / Vendor’s own required inspection activity and acceptance program.

Where preparation and application are outside the approved quality system, third party supervision shall be implemented by the Contractor / Vendor, acceptable to the EPCM Contractor.

For thickness 250 μm and above pull off testing shall be performed.

7.2 Surface Preparation

Priming coats of paint shall not be applied until the surfaces have been inspected and preparatory work has been approved.

Profile measurements for abrasive blast cleaned surface shall be made with a Keane Tator Profile Comparator, Clemtec Anchor Profile Chips, Testex Press-O-Film or other method suitable for the abrasive being used and approved.

See appendix “B” for required profile amplitudes.

7.3 Dry Film Thickness

Dry film thickness shall be measured and recorded after each coat. Dry film thickness measurements shall be made in accordance with BS EN ISO 2808, for methods, determinations and number of readings.


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7.4 Visual Inspection

All painting shall be checked prior to issue of the final certificate and no visible corrosion or spotting shall be present. The surface shall be no worse than those defined under surface condition of the standards BS EN ISO 4628-3, BS EN ISO 12944 – 1 to 8 and BS EN ISO 14713.

If upon visual inspection, loss of adhesion is suspected or found, an adhesion test (cross cut and pull off, depending of the thickness) shall be performed in accordance to BS EN 2409 or ISO 4624. The entire part/equipment coating exhibiting less than 15 kg/cm2 adhesion shall be rejected and repaired.

7.5 Preparation for Transport

Packing instructions shall be in accordance with the requirements detailed in the Commercial Notes of the Material Requisition.

Where items are required to be painted prior to delivery, suitable arrangements shall be made to ensure that damage is not sustained to the coating during handling and transport.

Contractor / Vendors shall provide an adequate quantity of touch-up paint to effect minor repairs on site. A copy of the Manufacturer’s Safety Data Sheets (MSDS) shall be with the shipment as well as issued with the packing list.

Equipment and components shall not be handled until the coating has completely cured and dried hard.

Particular care shall be taken to avoid damage to coatings in handling and transport. To this end, rubber coated or softly padded slings shall be used and soft pads placed beneath and between items when they are stacked and transported. Similar measures shall be taken with ropes etc. used for holding items down during transport.

Wherever possible, supports in contact with coated steel during transport and storage shall be covered with a soft material such as rubber or cloth to minimise damage to the coating. Hessian sacks and bags may be used during transportation between coated items and holding down chains to prevent damage to the coating.

The Contractor / Vendor shall specify any recommended protection procedures for equipment that is to be stored on site for long periods of time.

8.0 PAINT SYSTEMS

8.1 Operating Environment Conditions

The EMAL plant is located on the coast of UAE, with high salinity, high temperatures and high humidity environment. Its corresponding atmospheric corrosive categories in compliance with EN-ISO-12944-2 are listed in Appendix ‘’D’’.


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8.2 Application Schedule

Surface preparation, priming and finish coating shall be in accordance with the schedule shown in Appendix ‘’A’’, ‘‘B’’ and ‘’B Alt ‘’. Only the products listed shall be used, unless alternative products are approved in writing by the EPCM Contractor.

8.3 Colour Schedule

The colour of finish coats shall be in accordance with the schedule shown in Appendix ‘’C’’.

8.4 Fixings

After fixing, bolt heads, washers and nuts shall receive two coats of zinc rich paint. All galvanized bolts and hardware will be touched-up with a galvanized coating. Connections between galvanized surfaces and copper, copper alloy or aluminium surfaces shall be protected by suitable tape wrapping to the EPCM Engineer's approval.

9.0 GALVANIZED COATING

9.1 General

All items shown on the drawings as galvanized are to be hot-dip galvanized and unless otherwise specified shall conform in all respects with standard BS EN ISO 1461.

9.2 Design for Galvanizing

The detail design of members shall be in accordance with standard BS EN ISO 14713. Adequate provisions for filling, venting and draining shall be made for assemblies fabricated from hollow sections. Vent holes shall be suitably plugged after galvanizing.

9.3 Preparation

All surface defects in the steel, including cracks, surface laminations, laps and folds shall be removed. All drilling, cutting, welding, forming and final fabrications of unit members and assemblies shall be completed before the structures are galvanized. The surface of the steelwork to be galvanized shall be free from welding slag, paint, oil, grease and similar contaminants.

Structural steel items shall be initially grit blasted to the standard BS EN ISO 8501-3, second quality (SA 2.5).

9.4 Galvanizing – Structural Steel

The minimum average coating weight shall be as specified in the standard BS EN ISO 1461 or as stated below, whichever is greater. The minimum average coatings weight on steel sections 5 mm thick and over shall be 925 g/m² (130 microns). The minimum average coating for hand railing and open grid flooring shall be 610 g/m² (85 microns).


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On removal from the galvanizing bath, the resultant coating shall be smooth, continuous, free from gross surface imperfections, such as bare spots, lumps, blisters, and inclusions of flux, ash or dross.

Galvanized contact surfaces to be joined by high strength friction grip bolts shall be roughened before assembly so that the required slip factor is achieved. The roughening shall be confined to the net area of the adjoining surface.

When painting is required over galvanized surfaces, the galvanized surface shall be roughened by sweep blasting or chemical treatment prior to painting.

9.5 Galvanizing – Nuts and Bolts

Structural bolts, anchor bolts, nuts and washers, including general grade high strength friction grip bolts shall be hot-dip galvanized and subsequently centrifuged in accordance with the standard BS EN ISO 1461. Nuts shall be tapped up to 0.4 mm oversize after galvanizing and the threads oiled to permit the nuts to be finger-turned on the bolt for the full depth of the nut.

No lubricant, applied to the projecting threads of a galvanized high strength friction grip bolt after the bolt has been inserted through the steelwork, shall come into contact with the adjoining surfaces.

9.6 Transportation and Erection

During off-loading and erection, the use of nylon slings shall be employed. Galvanized work, which is to be stored in the shop or on the site, shall be stacked so as to provide adequate ventilation to all surfaces and to avoid wet storage staining (white rust).

9.7 Repair to Galvanizing

Small areas up to one square meter of the galvanized coating damaged in any way shall be restored by:

Cleaning the area of any weld slag and thoroughly wire brushing to give a clean surface.

The application of two coats of zinc rich paint, or the application of a low melting point Zinc Alloy repair rod or powder to the damaged area, which is heated to 300°C after.

Large damaged areas shall be cleaned and regalvanized in galvanizing shop.

10.0 SITE PAINTING

In addition to the requirements listed in this specification, the following requirements apply to Site Painting:


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Paints, catalysts and thinners shall be stored in well ventilated buildings, free from excessive heat, sparks, flames and direct sunlight. Paints stored for short times on the job site shall be protected from direct sunlight. A register of all materials, batch number, date of manufacture quantities and Material Safety Data Sheets (MSDS) shall be developed and maintained, and submitted for approval before start of painting work.

Containers of paint, catalysts and thinners shall not be opened prior to use, except for spot inspection. They shall then be tightly resealed after inspection.

Coatings and primers delivered to the job site shall be in the original, unopened containers bearing the manufacturer's name, product designation, batch number and date of manufacture. Before application, they shall be stirred or agitated until the ingredients are completely mixed. Materials which have exceeded the manufacturer's recommended shelf life shall not be used and shall be removed from the site. Materials shall be used on a first in, first out basis.

Any material that arrives on site in opened or damaged containers shall be immediately quarantined and removed from the site to prevent its use.

During construction, pressure pack containers will be permitted for some applications. However, once commissioning of smelter operations have commenced, all pressure pack containers shall be registered and logged in and out of the site and all empty packs shall be accounted for.

Precautionary measures (use of drop sheets and shields) shall be taken to prevent damage caused by wind-blown overspray or spatter on adjacent equipment/structures.

Precautionary measures shall be taken to protect nameplates, nametags, glasses on temperature indicators, pressure gauges, level instruments, etc., by masking or applying a heavy coat of lubricant. Operating mechanisms, such as valve stems and valve positioners must also be protected. Masking, protective coverings and lubricant shall be removed after completion of all work.

Prior to coating, equipment piping and structural steel shall be cleaned, including removal of dirt and dust which normally accumulates during storage and construction.

Although it is preferred that all equipment, piping and structural steel be fully painted prior to arrival on site, for equipment, piping and structural steel that has received a shop primer coat only, the Contractor shall touch up the shop primer coat where damaged and apply additional coats in accordance with the coating schedule. The Contractor shall ensure compatibility between shop and field applied paint systems.

Sands shall not be used in any blast cleaning operations, either on site or off site, for lack of efficiency, economic, and dust generation. Copper slag and nickel slag are an acceptable abrasive.


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Appendix “A” – PAINT SYSTEM APPLICATION SCHEDULE

Item Application Painting System (per Appendix ‘’B’’

Notes

1 Mechanical, electrical and instrumentation equipment and component

S1a,S1b,or S1c

1. Some Proprietary equipment components, such as mass produced pumps, gearboxes etc, shall generally be painted to the Manufacturer’s standard paint specifications. However, Vendors shall ensure the specifications are fit for the intended service and environment and shall advise the EPCM Contractor of the details of the proposed system to be used.

2. Machinery components e.g. Drives, Instruments and associated Valves may be finish coated with manufacturer’s standard coating systems.

3. The warranty period as specified in Section 3.1 shall continue to be in effect.

2 Steel tank (water only) S1a,S1b,or S1c for

External & Roof top

S7 for tank underside

S8 for internal surface

1. The underside of steel tank bottoms shall be coated as per painting schedule S7. An alternate coating using Coal Tar Epoxy may be used unless otherwise strictly specified on drawings.

2. The Contractor shall comply and be in strict accordance with all the safety requirements specified by the manufacturer in the handling and application of this product.

3. Prior to application, the Contractor shall take specific note whether catholic protection is to be applied and ensure that the appropriate form of coating is selected and used. The Coal Tar Epoxy specified is for non-cathodically protected tanks only

3 Storage silos, chutes, hoppers (all for dry materials)

S1b for external and internal

surfaces S7 for silos underside

1. The underside of steel silo bottoms shall be coated as per painting schedule S7. An alternate coating using Coal Tar Epoxy may be used unless otherwise strictly specified on drawings.

4 Marine Piles S1c


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Notes

5 Structural steel work

S1a,S1b,or S1c or

S1a Alt , S1b Alt for finished 0versea steel structure

(refer to Appendix B Alt).

1. Shop Connections: all shop weld areas and shop bolted or riveted connections shall be blast cleaned to the same standard as adjacent steel. All weld slag and spatter shall be removed.

2. Contact surfaces of connections to be assembled with black bolts shall each receive one coat of inorganic zinc rich primer immediately before being assembled.

3. Inaccessible Areas: areas of steel inaccessible after erection shall be treated during fabrication, so that they receive the full treatment specified.

4. Site connections: Joints shall be painted with the specified materials to give the standard of protection achieved on adjacent steel. Stripe coats shall be used, particularly to seal all edges of steel and gaps between adjacent steel surfaces.

5. High Strength Friction Grip Bolted Connections: No paint or contaminants shall be allowed on the contact surfaces of high strength friction grip bolted joints. Only after the full permanent connections have been made and inspected shall the joint be protected in accordance with the specification.

6. Site Welds: Site welds and adjacent areas shall be cleaned to remove all welding slag, spatter and flux residues by chipping, blast cleaning and washing, before painting commences.

7. Cleaning of Jointing Bolts: Bolted joints shall be thoroughly cleaned to remove all oil and grease, before painting.

8. Plated bolts and nuts shall be primed with an etch primer suitable for use on the particular type of surface unless galvanised.

6 Flooring, grating and stair treads

S4a for flooring, grating and stair

treads.

1. Flooring, grating and stair treads shall be galvanized to paint system S4a and shall not be painted.

2. If additional slip protection is required, a non skid powder or coarse silica sand may be applied after application of the mid coat and prior to applying the final top coat (must be specified on the drawings).

7 Hand railing, ladders, kick plates and purlins

S4b unless specified otherwise

on drawings

1. Hand railings, ladders, kick plates and purlins shall be galvanized and painted as per paint system S4b.

8 Pipe work general – Above ground. (Piping,valves & fittings)

S1a,S1b,S1c for non-insulated

S2a,S2b,S2c for high temperature

non-insulated S2d,S2e for high

temperature insulated or fireproofed

S4c for Galvanized

1. The painting system for “off the shelf” valves may be manufacturer’s standards, subject to EPCM Contractor approval. The system must be capable of withstanding the environmental conditions for a period of 7 years (min) to ‘Re 1’ on the European Scale of degree of rusting.

9 Fire hydrants and fire equipments

Same as Pipe works


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Notes

10 High temperature equipment such as: Pot room Superstructures, Hot bath processing equipment, Furnaces and associated structure, Heat exchangers, etc.

S2a for (>4000C up to

6000C) S2b for

(>2400C up to 4000C) S2c for

(>1200C up to 2400C)

11 Pot room gas treatment plant and ducting

S3 up to 120°C continuous

temperature and peak to 135°C

12 Baking furnace waste gas main ducts

S5 for internal surfaces

S6 for external surfaces

Note: Where particular items are not specifically referred to in the application schedule, the Contractor / Vendor shall propose a system or submit data sheets and procedures to EPCM Contractor’s Engineer for review and approval.


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Appendix ‘’B’’ – PAINT SYSTEM SCHEDULE

System Application 2 Minimum Surface preparation

Prefabrication primer 6 & 7

Primer Coat (min. DFT)1 & 7

Intermediate Coat(s)

(min. DFT) 1

Finish Coat (min. DFT) 1

Overall Minimum

DFT1

S1a

Steel – C3 Mildly Corrosive Condition 2 (not concrete encased) (below 1200C- un-insulated)

Blast clean to BS EN ISO 8501 Sa 2½, Profile amplitude: 40-60 µm

Weldable holding Zinc Primer for

12 months protection 25µm

Two Pack Inorganic

Zinc Silicate Primer 50µm

(Note 7)

Two Pack High Solids, High Build Micaceous Iron Oxide

Epoxy 100 µm

Two Pack Polyurethane

Finish 50µm

200µm

S1b

Steel – C4 High Corrosive Condition2

(not concrete encased) (below 1200C- un-insulated)




Two Pack Inorganic


(Note 7)


Epoxy 150 µm


Finish 50µm

275µm

S1c

Steel – C5-M Severely Corrosive Condition2

(not concrete encased) (below 1200C- un-insulated) Submerged CS and CS in splash zone




Two Pack High Build Glass Flake Epoxy 225 µm or Polyester Glass Flake 750 µm

Two Pack High Build Glass Flake Epoxy 225 µm or Polyester Glass Flake 750 µm

450 µm

or

1500 µm

S2a

Hot surfaces (>4000C up to

6000C) un-insulated or

insulated


Apply primer coat within 4

hours or Weldable holding

inorganic Zinc Primer for 12

months protection

25µm

High Temperature

Silicone Aluminium

20µm

High Temperature Silicone Aluminium 20µm

40µm5

S2b

Hot surfaces (>2400C up to 4000C) (un-insulated)


Per System S2a Two Pack Inorganic


(Note 7)

High Temperature

Silicone Aluminium

25µm

High Temperature

Silicone Aluminium

25µm

125µm

S2c

Hot surfaces (>1200C up to 2400C) (un-insulated)




(Note 7)

High Temperature Silicone Acrylic 25µm

High Temperature Silicone Acrylic 25µm

125µm


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(min. DFT) 1


Overall Minimum

DFT1

S2d

Hot surfaces (>1200C up to

4100C) (insulated or fireproofed)




(Note 7)

75µm

S2e

Hot surfaces (up to 1200C) (insulated or fireproofed)


Per System S2a Two Pack High Build High Solids

Epoxy 150µm

150µm

S3

Hot surfaces up to 120°C continuous temperature and peak to 135°C




Two Pack Zinc Rich

Epoxy Primer 50µm

Two Pack, surface

tolerant, high build Epoxy, containing aluminium pigment 125µm

Two-pack, surface

tolerant, high build Epoxy, containing aluminium pigment 125µm

300µm

S4a

Galvanized Flooring4 (Stair treads,open grid, grating)

Blast clean to BS EN ISO 8501 Sa 2½, After galvanizing, degrease, sweep blast or etch using a T-wash.

Hot dip galvanized 610 g/m² minimum (85 microns) If Steel ≥5mm thick 925 g/m² minimum (130 microns)

S4b

Galvanized Hand railing 3

Ladders, kick plates and purlins




Epoxy 100µm

Two Pack Polyurethane Finish 50µm

150µm

S4c

Galvanized Pipe work




Epoxy 130µm

Two Pack Polyurethane Finish 50µm

180µm


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(min. DFT) 1


Overall Minimum

DFT1

S5

Internal surfaces of baking furnace waste gas main ducts


Weldable holding Inorganic Zinc Primer for 12

months protection 25µm

Two Pack Inorganic


(Note 7)

75µm

S6

External surfaces of baking furnace waste gas main ducts

Blast clean to BS EN ISO 8501 Sa 2½, Profile amplitude: 25-35µm

Weldable holding Inorganic Zinc Primer for 12


Two Pack Inorganic


(Note 7)

High Temperature

Silicon Acrylic 30µm

105µm

S7

Tanks & Silos underside Alternate Coating System for non-cathodically protected tanks & Silos only




Two Pack High Build

Epoxy Mastic 125µm

or Two Pack Coal Tar Epoxy 200µm

Two Pack High Build

Epoxy Mastic 125µm

or Two Pack Coal Tar Epoxy 200µm

150µm

S8

Water Tanks – Internal surfaces




Two Pack Phenolic Epoxy 150µm

Two Pack Phenolic Epoxy 150µm

300µm

Note 1: Min. DFT: Minimum Dry Film Thickness, the actual DFT shall not be less than the DFT stated in Appendix “B” for each location,

coat and for the paint system. Additionally the maximum DFT thicknesses should not exceed the specified total DFT or of each individual coat by more than 30% unless otherwise specified.

Note 2: Refer to Appendix A for application and Appendix D for application of operating environment Note 3: Ladders, handrails, kick plates, purlins shall be galvanized and painted to the required operating environment coating schedule.

(S4b). Note 4: Flooring, grating and stair treads shall be galvanized as per S4a. Note 5: With High temperature Silicone Aluminium curing can be obtained when the coated surfaces are put into service at 1500C or higher

to fully cure. Note 6: Pre-fabrication primer applied by Airless spray (or any other method recommended by the Manufacturer) one full coat of Weldable

holding inorganic zinc primer for short term protection of 10 ~ 12 months to a dry film thickness of 25 microns with no reading above 30 microns.

Note 7: After fabrication is completed, when the steel is taken for full coating system the following instruction shall be implemented as per the manufacturer’s recommendations.

If the full paint system has a Primer which is Inorganic Zinc Silicate then the shop primers shall be completely removed and steel be cleaned to Sa 2 ½ standard. (Include thorough high pressure fresh water washing to remove any zinc salts and other contamination.) This instruction is made as there would be no chemical or mechanical adhesion over densely packed Zinc dust of the previously applied Shop primer. Inorganic Zinc Silicate is a quick drying paint system and does not penetrate deep within the previously dried film of Inorganic Zinc Silicate to establish an effective bonding.


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Appendix ‘’B – Alt ’’ - PAINT SYSTEM SCHEDULE FOR OVERSEAS FINISHED STRUCTURE Note 2



Primer Coat (min. DFT)1


(min. DFT) 1


Overall Minimum

DFT1

S1a (Alt)

Steel – C3 Mildly Corrosive Condition 2 (not concrete encased) (below 1200C- un-insulated)

Blast clean to BS EN ISO 8501 SA 2.5, Profile amplitude: 40-60 µm

Weldable holding Zinc Primer for 12


Two Pack Inorganic


(Note 4)


Epoxy 100 µm


Finish 50µm

225µm

S1b (Alt)

Steel – C4 Very High Corrosive Condition2

(not concrete encased) (below 1200C- un-insulated)

Blast clean to BS EN ISO 8501 SA 2.5, Profile amplitude: 40-60 µm



Two Pack Inorganic


(Note 4)


Epoxy 150 µm


Finish 50µm

275µm

S1c (Alt)

Steel – C5-M Severely Corrosive Condition2

(not concrete encased) (below 1200C- un-insulated) Submerged CS and CS in splash zone




Two Pack High Build

Glass Flake Epoxy 225

µm or

Polyester Glass Flake

750 µm

Two Pack High Build

Glass Flake Epoxy 225

µm or

Polyester Glass Flake

750 µm

450 µm

or

1500 µm

Note 1: Min. DFT: Minimum Dry Film Thickness, the actual DFT shall not be less than the DFT stated in Appendix “B-Alt” for each location,

coat and for the paint system. . Additionally the maximum DFT thicknesses should not exceed the specified total DFT or of each individual coat by more than 30% unless otherwise specified.

Note 2: The above alternate paint system schedule applies to bulk structural steel, fabricated and coated for delivery by sea voyage in the finished state. The coating shall be applied in strict accordance with the manufacturer’s recommendations for the conditions in which the coating is being applied. The steel shall be individually plastic wrapped and packed with appropriate dunage and strapping to minimize damage during transportation to site. In addition to the use of the following products, the steel fabricator shall engage the presence of full time technical service representative at the application site to ensure quality is assured.

The above alternate paint system schedule has been specified based on the criteria for application in climates where conditions may be cold, high humidity and where a reasonably fast recoat time and overall drying time is required as well as good impact and scratch resistance for transport and erection. Manufacturer’s guidelines must be followed.

Note 3: Pre-fabrication primer applied by Airless spray (or any other method recommended by the Manufacturer) one full coat of Weldable holding inorganic zinc primer for short term protection of 10 ~ 12 months to a dry film thickness of 25 microns with no reading above 30 microns.

Note 4: After fabrication is completed, when the steel is taken for full coating system the following instruction shall be implemented as per the manufacturer’s recommendations.

If the full paint system has a Primer which is Inorganic Zinc Silicate then the shop primers shall be completely removed and steel be cleaned to Sa 2 ½ standard. (Include thorough high pressure fresh water washing to remove any zinc salts and other contamination.) This instruction is made as there would be no chemical or mechanical adhesion over densely packed Zinc dust of the previously applied Shop primer. Inorganic Zinc Silicate is a quick drying paint system and does not penetrate deep within the previously dried film of Inorganic Zinc Silicate to establish an effective bonding.


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Appendix ‘’C’’ – STRUCTURE AND EQUIPMENT COLOUR SCHEDULE

Equipment Colour Code per RAL and BS4800

Mechanical and electrical equipment, Pressure Vessels (Air) , Pressure Vessels (associated with Dense Phase), Airlifts, Air slides and related.

Mid-grey RAL 7032

Heat Exchangers, Heaters. Mid-grey for up to 1200C Aluminium for 1200C and above

RAL 7032 RAL 9006

Storage silos, chutes, hoppers, stacks, Dust collectors and associated ductwork. Grey RAL 7005

All Main Steel Structures and Secondary Steel Structures including Miscellaneous Structural Steelwork, for Equipment Platforms and Equipment Support Structures.

Stone Grey RAL 7030

Cold rolled purlins and side rail Stone Grey (to match structural steel)

RAL 7030

Flooring Stone Grey RAL 7030

Cladding (roofing and siding) Grey white RAL 9002

All machine guards kick plates, stair riser nosings and handrailing.

General Hoists, Trolleys and Cranes and all miscellaneous lifting equipment.

Yellow RAL 1003 or 08E51

Tapping & Miscellaneous Assemblies (TMA) Cathode Transport Assembly (CTA) Miscellaneous Transport Assemblies (MTA) Pot Tending Assemblies (PTA)

“Refer to Equipment Specifications for specific colour details”

Pipework general Piping, Valves and Fittings. (Refer Note 1) Per piping specification 503406-0000-46EG-0001 Appendix ‘’E’’

Fire hydrants and fire equipments Red RAL 3020 or 04E53

High temperature equipments, ducting, stacks and components such as: Potroom superstructures, Hot bath processing, Fume and Gas Treatment Plant and associated ducting, Induction furnaces fume ducting.

Aluminium RAL 9006

Note 1: In addition pipe shall be painted with bands to enable identification of contents. Refer to Specification 503406-0000-46EG-0001 Appendix ‘’E’’


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Appendix ‘’D’’ – OPERATING ENVIRONMENT CONDITION Note 1

A – Category C3 - Mildly Corrosive Environment Areas considered to be a mild corrosive environment are:

• Interior of non process buildings, maintenance shops and electrical buildings sheltered from outside environment for which the corrosion stresses are generally insignificant. However due to long exposure during the construction phase and entry of fresh air through the ventilation system the atmospheric corrosive category is considered as C3 ‘’medium’’.

C – C5-M Severely Corrosive Marine Environment Areas considered to be a severely corrosive environment are:

• Marine ‘Splash Zone’ • Marine structures close to sea level • Other immersed structures or those subject

to constant or intermittent wetting and drying or damp conditions.

• All marine piles (jetty, dolphins, ropeway trestles etc.)

• Structural steelwork below jetty/access roadway deck

• Launch landing platform • Launch jetty

Corrosion protection in ISO 12944 C5-M “Offshore Environments” is being addressed via new standard (ISO 20340) dedicated to this environment.

B- Category C4 – High Corrosive Marine Environment (coastal areas with moderate salinity) Areas considered to be a very high corrosive marine environment are:

• Marine structures higher than sea level, away from ‘’Splash Zone’’

• Production area inside semi covered building (e.g. Industrial Production shop)

• Exposed element outside industrial shop and buildings (not covered or partially covered) e.g. structural steelwork, chillers, dust collector, conveyor, steel tank, pipe rack, etc.

Note 1: The Corrosive categories are in compliance with EN-ISO-12944-2


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Appendix ‘’E’’ – PAINT PREFERED SUPPLIER with examples

Equivalent may be used with written approval from EPCM Contractor

TYPE Jotun Hempel International Ameron Sigma

Two pack Inorganic Zinc Silicate Primer Resist 78 Galvosil 15780 Interzinc 22 Dimetcote

6,9,11

Sigmacap Zinc Silicate - greenish grey - Production Code 7658

Two Pack Zinc Rich Epoxy Primer Barrier 77 Hempadur Zinc

15360 Interzinc 52 Amercoat 68 Sigmazinc 102 HS - redbrown - Production Code 7702

Two Pack High Build High Solids Epoxy Penguard HB Hempadur Mastic

45880/45881 Interseal 670HS Amercoat 385, Amerlock 400

Sigmacover 435 - Production Code 7465

Two Pack High Solids, High Build M.I.O. (Micaceous Iron Oxyde) Epoxy

Penguard Midcoat MIO

Hempadur Mastic 45880/45881 (MIO Version)

Interguard 475 HS (MIO Version)

Amerlock 400 MIO

Sigmacover 410 (MIO version) - Production Code 6823

Two Pack Polyurethane Finish Coat

Hardtop Flexi or Hardtop AS

Hempathane Topcoat 55210 Interthane 990

Amercoat 450SG Amershield HG

Sigmadur Gloss - Production Code 7528

High Temperature Silicone Acrylic Solvalitt Midtherm Silicone Acrylic

56940 Intertherm 875 Amercoat 891

Sigmatherm 350 - Aluminium (max. temp: 350 deg C.) - Production Code 7565

High Temperature Silicone Aluminium Solvalitt Silicone Aluminium

56910 Interthem 50 (540 deg. Max) Amercoat 878

Sigmatherm 540 - Aluminium (max. temp. 540 deg. C.) - Production Code 7564

Two Pack Coal Tar Epoxy (for submerged steel and tank bases)

Coal Tar Epoxy 83 Coal Tar epoxy 35670

Use equiv – Interzone 954 (1x400)

Amercoat 78 Sigmacap Coaltar EP - Production Code 7686

Two Pack High Build Epoxy Mastic (for submerged steel and tank bases)

Primastic Universal Hempadur 45881 Interseal 670HS Amerlock 2/ 400

Sigmacover 620 - light grey - Production Code 6825 to be used for underside bottom plate with cathodic protection. 7430 Sigmacover 630 to be used for submerged steel.

Two Pack Phenolic Epoxy (for internal of water tank) Tankguard Storage Hempadur Phenolic

Epoxy 85671 Interline 850 Amercoat 90

Sigmaguard 730 Sigma Phenguard System (alternate) - Production Code 7459, 7409, 7435, 7436

Two Pack High Build Glass Flake Epoxy (for marine piles)

Marathon Hempadur Glass Flake 35851 Interzone 505 Amerlock 2/400

GFK

Sigmashield 460 - Production Code 7952

Polyester Glass Flake (for marine piles) Baltoflake Hempels Polyester

GF 35920 -------------------- Permaclad VE504 GF EPL -------

Weld able holding zinc primer MUKI Z 2001 Hempel shop primer

ZS 15890 Interplate 937/997 Amercoat 139 Sigmaweld 199 - redbrown - Production Code 7177

503406-0000-45eg-0004_r00_signoff

Documents

revision painting

date page

client document

quality assurance

paint materials

revision history note

environmental category

standards conflicts