Académique Documents
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SECTION 09960:
30/04/05
REV
DATE
KINGDOM
OFSAUDIARABIA
RoyalCommission
forJubail&Yanbu
DESCRIPTION
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PREPARED BY
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SECTION 09960
HIGH-PERFORMANCE COATINGS
TABLE OF CONTENTS
Item No
Title
PART 1
GENERAL............................................................................................................ 1
1.01
1.02
1.03
1.04
REFERENCES..................................................................................................... 3
1.05
DEFINITIONS..................................................................................................... 11
1.06
SUBMITTALS..................................................................................................... 13
1.07
1.08
1.09
DESIGN CRITERIA............................................................................................ 18
1.10
JOB CONDITIONS............................................................................................. 18
1.11
PART 2
PRODUCTS ....................................................................................................... 22
2.01
GENERAL .......................................................................................................... 22
2.02
ACCEPTABLE MANUFACTURERS.................................................................. 24
2.03
2.04
PART 3
EXECUTION ...................................................................................................... 31
3.01
GENERAL .......................................................................................................... 31
3.02
3.03
3.04
APPLICATION OF COATINGS.......................................................................... 36
3.05
Rev 0
Page No
Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
Title
Page No
3.06
REMEDIAL WORK............................................................................................. 43
3.07
PROTECTION.................................................................................................... 44
3.08
CLEAN-UP ......................................................................................................... 44
Rev 0
ii
Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
PART 1
GENERAL
The extent of painting and coating work is shown on the Contract Drawings and
Schedules, and as herein specified.
B.
This Specification covers the total removal of existing paint and coating, surface
preparation, supply and application of materials, and inspection requirements for
painting and/or coating the interior and exterior surfaces of steel and concrete
structures, tanks, pipes etc. for high-performance coating.
C.
Surface preparation of new work, including priming and coats of paint specified
in addition to shop priming required under other Sections of the specifications.
2.
3.
Field painting and coating of all bare and covered tanks, pipes etc. including
color coding specified under the applicable Division 15 Sections and of
hangers, exposed steel and iron work, and primed metal surfaces of
equipment installed under the mechanical and electrical work, except as
otherwise indicated.
4.
Where unfinished items or surfaces are not specifically mentioned, these shall
be painted the same as adjacent similar materials or areas.
5.
In general, the surfaces to be field coated shall consist of, but not be limited to
exterior steel and iron surfaces.
6.
D.
The following categories of work do not require painting or coating and are not
included as part of the field-applied finish work, or included in other Sections of
these Specifications:
a)
Shop Priming
1)
b)
Pre-Finished Items
1)
Rev 0
Unless otherwise indicated, do not include painting when factoryfinish or installer-finishing is specified for such new items as:
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
c)
(b)
Architectural aluminum.
(c)
Insulated surfaces.
(d)
Concealed Surfaces
1)
d)
(a)
2)
B.
C.
D.
E.
Rev 0
A.
Section 01320
B.
Section 01330
Submittal Procedures
C.
Section 01410
Regulatory Requirements
D.
Section 01450
Quality Control
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
E.
Section 01650
F.
Section 01660
G.
Section 03310
Structural Concrete
H.
Section 05120
Structural Steel
I.
Section 07925
Joint Sealants
J.
Section 09910
Paints
K.
Section 09970
L.
Section 09980
1.04 REFERENCES
A.
The referred codes and standards are intended to provide an acceptable level of
quality for materials and products. In case of conflict between these standards and
the text of this Specification, the Specification text shall govern.
B.
The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict, the Contractor shall propose equipment conforming to
one group of codes and standards.
C.
RCBC
D.
ACI
E.
Rev 0
1.
ACI 308
2.
ACI 503R
ASTM
1.
ASTM A780
2.
ASTM C672M
3.
ASTM C811
4.
ASTM D117
5.
ASTM D512
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HIGH-PERFORMANCE COATINGS
Rev 0
6.
ASTM D516
7.
ASTM D522
8.
ASTM D570
9.
ASTM D609
10.
ASTM D740
11.
ASTM D823
12.
ASTM D1002
13.
ASTM D1005
14.
ASTM D1044
15.
ASTM D1186
16.
ASTM D1193
17.
ASTM D1248
18.
ASTM D1400
Standard
Test
Method
for
Nondestructive
Measurement
of
Dry
Film
Thickness
of
Nonconductive Coatings Applied to a Nonferrous
Metal Base
19.
ASTM D1475
20.
ASTM D1535
21.
ASTM D1653
22.
ASTM D1730
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Contract No:
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SECTION 09960
HIGH-PERFORMANCE COATINGS
Rev 0
23.
ASTM D1763
24.
ASTM D2092
25.
ASTM D2240
26.
ASTM D2370
27.
ASTM D2583
28.
ASTM D2794
29.
ASTM D3278
30.
ASTM D4060
31.
ASTM D4138
32.
ASTM D4212
33.
ASTM D4227
34.
ASTM D4258
35.
ASTM D4259
36.
ASTM D4260
37.
ASTM D4261
38.
ASTM D4262
39.
ASTM D4263
40.
ASTM D4285
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HIGH-PERFORMANCE COATINGS
Rev 0
41.
ASTM D4414
42.
ASTM D4417
43.
ASTM D4541
44.
ASTM D4708
45.
ASTM D4752
46.
ASTM D4787
47.
ASTM D5064
48.
ASTM D5137
49.
ASTM D5402
50.
ASTM D6132
Standard
Test
Method
for
Nondestructive
Measurement of Dry Film Thickness of Applied
Organic Coatings over Concrete Using an Ultrasonic
Gage
51.
ASTM D6237
52.
ASTM E104
53.
ASTM E337
54.
ASTM G8
55.
ASTM G11
56.
ASTM G14
57.
ASTM G19
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
F.
ANSI
1.
G.
Rev 0
ANSI A21.52
AWWA
1.
H.
AWWA D102
BSI
1.
Methods of Test for Paints - Determination of WetScrub Resistance and Cleanability of Coatings
2.
BS 3900-H1
3.
BS 3900-H4
4.
BS 3900-H5
5.
BS 1062-1
6.
BS 1062-3
7.
BS 1062-6
8.
BS 1062-7
9.
BS 1062-11
10.
BS 5493
11.
BS 7079-A1
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SECTION 09960
HIGH-PERFORMANCE COATINGS
Rev 0
I.
J.
ISO
1.
ISO 1461
2.
ISO 2063
3.
ISO 2409
4.
ISO 2808
5.
ISO 8501-1
6.
ISO 8501-2
7.
ISO 8502-3
8.
ISO 8502-6
9.
ISO 8502-9
10.
ISO 8503-1
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SECTION 09960
HIGH-PERFORMANCE COATINGS
Characteristics of Blast Cleaned Steel Substrates Specification for Surface Profile Comparators for the
Assessment of Abrasive Blast-Cleaned Products
K.
Rev 0
11.
ISO 8503-2
12.
ISO 12944-1
General Introduction
13.
ISO 12944-2
Classification of Environments
14.
ISO 12944-3
Design Considerations
15.
ISO 12944-4
16.
ISO 12944-5
17.
ISO 12944-6
18.
ISO 12944-7
19.
ISO 12944-8
20.
ISO 20567-1
21.
ISO 20567-2
NACE
1.
NACE RP0172
2.
NACE RP0184
3.
NACE RP0188
4.
NACE RP0287
5.
NACE RP0288
6.
NACE RP0591
7.
NACE RP0892
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SECTION 09960
HIGH-PERFORMANCE COATINGS
L.
SIS
1.
M.
Rev 0
SSPC
1.
SSPC-SP1
2.
SSPC-SP2
3.
SSPC-SP3
4.
SSPC-SP5
5.
SSPC-SP6
6.
SSPC-SP7
7.
SSPC-SP8
8.
SSPC-SP11
9.
SSPC-SP12
10.
SSPC-SP13
(Surface Preparation
Preparation of Concrete
11.
SSPC-SP14
12.
SSPC-SP15
13.
SSPC-PA1
14.
SSPC-PA2
15.
SSPC-PA Guide 3
16.
SSPC-PA6
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Standards)
Contract No:
Surface
Commercial
SECTION 09960
HIGH-PERFORMANCE COATINGS
Tanks
17.
SSPC- PA7
1.05 DEFINITIONS
Rev 0
A.
B.
adhesion: The ability of dry paint to attach to and remain fixed on the surface without
blistering, flaking, cracking or being removed by tape.
C.
air cure: One method by which liquid coatings cure to a dry film. Oxygen from the air
enters the film and cross-links the resin molecules. Also called Air Dry and
Oxidizing.
D.
alkyd: Synthetic resin modified with oil. Coating that contains alkyd resins in the
binder.
E.
amide: A functional group which can act as an epoxy resin curing agent.
F.
butadiene: A gas which is chemically combined with styrene to create a resin used
in latex binders, styrene-butadiene.
G.
catalyst: Substance whose presence increases the rate of a chemical reaction, e.g.,
acid catalyst added to an epoxy resin system to accelerate drying time.
H.
I.
coat: A continuous layer of metal material or a continuous film of paint, resulting from
a single application.
J.
corrosion inhibitive: A type of metal paint or primer that prevents rust by preventing
moisture from reaching the metal. Zinc phosphate, barium metaborate and strontium
chromate (all pigments) are common ingredients in corrosion-inhibitive coatings.
These pigments absorb any moisture that enters the paint film.
K.
L.
durability: The expected life of a protective paint system to the first major
maintenance painting.
M.
emulsion paint: Coating in which resins are suspended in water, then flow together
with the aid of an emulsifier. Example: latex paint.
N.
enamel: Broad classification of paints that dry to a hard, usually glossy finish. Most
equipment-coating enamels require baking. Enamels for walls do not.
O.
epoxy: Extremely tough durable synthetic resin used in some coatings. Epoxy
coatings are extremely tough, durable and highly resistant to chemicals, abrasion,
moisture and alcohol.
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SECTION 09960
HIGH-PERFORMANCE COATINGS
Rev 0
P.
Q.
R.
S.
material safety data sheet (MSDS): Information sheet that lists any hazardous
substance that comprises 1% or more of the products total volume. Also lists
procedures to follow in the event of fire, explosion, leak or exposure to hazardous
substance by inhalation, ingestion, or contact with skin or eyes. Coating
manufactures are required to provide retailers with an MSDS for every product they
sell to the retailer. Sales clerks should make MSDSs available to retail customers.
T.
U.
V.
primer: First complete coat of paint of a painting system applied to a surface. Such
paints are designed to provide adequate adhesion to new surfaces or are formulated
to meet the special requirements of the surfaces.
W.
protective coating system: The sum total of the coats of metal materials and/or
paints or related products which are to be applied or which have been applied to a
substrate to provide corrosion protection.
X.
protective paint system: The total sum of the coats of paints or related products
which are to be applied or which have been applied to a substrate to provide
corrosion protection.
Y.
Z.
solids: The part of the coating that remains on a surface after the vehicle has
evaporated. The dried paint film. Also called Nonvolatile.
AA.
solvent: Any liquid which can dissolve a resin. Generally refers to the liquid portion
of paints and coatings that evaporates as the coating dries.
BB.
spontaneous combustion: Oils used in many paints can generate heat as they
react with air. A fire can occur when materials soaked with these oils are improperly
handled or disposed of. Follow all label instructions to avoid the risk of spontaneous
combustion.
CC.
DD.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
EE.
vehicle: Portion of a coating that includes all liquids and the binder. The vehicle and
the pigment are the two basic components of paint.
FF.
volatile organic compound (VOC): Organic chemicals and petrochemicals that emit
vapors while evaporating. VOC generally refers to the solvent portion of the paint
which, when it evaporates, results in the formation of paint film on the substrate to
which it was applied.
GG. volume solids: Solid ingredients as a percentage of total ingredients. The volume of
pigment plus binder divided by the total volume, expressed in percent. High-volume
solids mean a thicker dry film with improved durability.
HH.
1.06 SUBMITTALS
A.
Rev 0
The Contractor shall submit to the Royal Commission, under the provisions of
SECTION 01330, the following items for review and approval before commencing
Work:
1.
2.
3.
4.
Specifications for each material and cross-reference to the specific paint and
finish system and application. Identify by manufacturer's catalog number and
general classification.
5.
The type and characteristics of the specific materials and items proposed to be
used for the work and the sources or facilities for the supply and/or production
of such materials and items.
6.
The document submittal for each type of coating system material which shall
include
the
manufacturer's
complete
product
specification,
technical/performance data and preparation and installation instructions and
recommendations.
7.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
8.
An outline of procedures proposed for execution of the work, and of testing not
covered by Standards and Codes specified herein.
9.
The number, type and capacity of all equipment intended for carrying out the
work and associated testing.
10.
Product Data
a)
11.
Rev 0
2)
3)
4)
5)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
6)
7)
8)
On 300 x 300 mm hardboard, provide samples of each color and material, with
texture to simulate actual conditions. Resubmit each sample as requested until
acceptable sheen, color, and texture is achieved.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
B.
12.
13.
14.
15.
16.
Three copies of the Contractors on-site Quality Control Program outlining the
procedures proposed to be used for the execution and testing of the work as
required by the Specifications.
The Contractor 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 the Royal Commission in accordance with
SECTION 01450.
B.
The Contractor shall develop, as part of his Quality Control Program coating
operation inspection forms as needed to record the relevant inspection and testing
data.
C.
D.
Hold points for inspection shall occur after the following operations, and at any other
points requested by the Royal Commission:
1.
Rev 0
15 of 45
Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
2.
3.
4.
5.
Completion of the full system prior to putting back into service, i.e. final
inspection.
E.
The Contractor shall maintain a qualified supervisor on site during all coating
application operations in accordance with SECTION 01450.
F.
The Contractor shall conduct the following test to ensure conformance with the
requirements of this Specification:
G.
1.
Surface profile.
2.
3.
4.
Adhesion of coating.
5.
6.
H.
Pipes, fittings, valves and other equipment of iron or steel shall be tested at the
place of manufacture in accordance with the relevant standard specifications
unless otherwise stated.
Paint Compatibility
1.
2.
Provide finish coats which are compatible with the prime paints used.
a)
b)
c)
Rev 0
16 of 45
Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
3.
Prior to beginning any painting work, review applicable painting systems with
qualified representatives of the selected finish paint manufacturer.
4.
2.
3.
Contractor
a)
Rev 0
B.
In the absence of any of the above, best accepted industry practice shall be
employed throughout.
C.
Sufficient mechanical forced ventilation shall be provided for the duration of blasting,
coating and curing operations inside tanks or other confined areas.
D.
Proper lighting, without creating shadows or glare, shall be provided during coating
application. The lighting fixtures shall be explosion proof, safety type system.
E.
Positive pressure helmets and goggles shall be worn by workmen during blasting
operation inside tanks or other confined areas.
F.
Spraying equipment shall be grounded and all precautions shall be taken to prevent
buildup of static electricity.
G.
All sources of ignition and persons smoking shall be kept at least 50 m away during
mixing, coating and curing operations.
H.
When blasting in confined areas or inside tanks, all blasting nozzles shall be
equipped with "dead man" or remote controls for automatic shutoff.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
The paint and coating systems shall be suitable for the intended service conditions
and environments. Special importance is given to its durability under exposure to oil,
gasoline, diesel, chemicals, acids, waste water, potable water, sun, abrasive sand
and dust storms, and high humidity seacoast air.
B.
The Contractor shall be aware of the above mentioned requirements and assure that
all materials, preparation and methods of application shall ensure full performance of
all coating systems. Full performance shall mean to provide full protection to the
material coated and maintain an acceptable appearance for a period of 10 years with
no abrasions, which occurs as a result of operations. Failure of coating system due to
preparation, application, materials, natural or service environment shall not be
considered full performance.
C.
The Contractor shall provide a 10 years guarantee for the coatings applied under the
work of this Contract. During this period, the Contractor shall repair or replace, as
directed by the Royal Commission, all coatings which fail to perform as specified.
Failure shall include any lessening of protection to the material coated, degradation
of integrity of the coating material or deterioration of surface condition beyond normal
wear and weathering due to any cause other than damage to the coating during
normal operations, such as nicks or abrasion.
B.
General
1.
The Contractor shall not apply exterior paint or coating during sand storms,
rain, or fog.
2.
The Contractor shall not apply paint or coating when the relative humidity
exceeds 85%, or to damp or wet surfaces, unless permitted by the paint
manufacturer's printed instructions.
3.
The Contractor shall not apply any coating when the substrate surface
temperature is below 3C above the dew point (condensation level).
The Contractor shall not apply coating when the surfaces to be painted and the
surrounding air conditions are outside the limits following below:
1.
b)
Rev 0
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
2.
Other Coatings
a)
b)
permitted
by
the
paint
C.
Paint may be applied during inclement weather if the areas and surfaces to be
painted are enclosed and heated or air conditioned within the temperature and
relative air humidity limits specified.
D.
E.
The Contractor shall not apply finishes unless the moisture content of surfaces is
below the following maximum:
F.
1.
Plaster: 5%.
2.
Rev 0
The materials and conditions for metal spraying shall be in accordance with
ISO 2063.
G.
The Contractor shall read and follow carefully the label instructions on each container
in regards to minimum and maximum allowable surface temperature for each specific
product prior to application.
H.
I.
High intensity flood or spot lights are required for visibility. All lighting equipment shall
be low voltage and explosion-proof.
J.
All personnel entering tanks after abrasive blasting shall wear rubber soled shoes
with clean disposable shoe covers sweat bands and lint-free gloves.
K.
L.
When coating existing tanks and/or when work location is in restricted areas, the
schedule of work shall be coordinated with the O & M Contractor and the Royal
Commission to obtain access to the work areas.
M.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
1.
2.
Rev 0
The Contractor shall deliver, handle and store equipment and material units in
accordance with SECTIONS 01650 and 01660, as well as the following
requirements:
1.
2.
3.
Manufacturer's name.
4.
Manufacturing standard.
5.
6.
Thinning instructions.
7.
Application instructions.
8.
9.
10.
B.
Store materials and equipment in a designated storage space on the site. Keep
storage space neat, clean, and accessible at all times. Protect floors from paint
spillage. Comply with fire safety requirements for flammable materials.
C.
Provide adequate, enclosed and well ventilated storage facilities separate from
storage of other building materials. Store paint material at a minimum ambient
temperature of 7C.
D.
Containers of paint or components shall not be opened except for immediate use.
Materials older than the manufacturers recommended shelf life shall not be used and
shall be removed from the site.
E.
F.
At the end of daily work, all containers in use shall be closed tightly and removed
from site.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
G.
Rev 0
The Contractor shall not dispose solid and liquid wastes from its work down to any
sanitary fitting, sink and drains. All waste materials shall be removed from the site in
airtight containers and disposed as directed by the Royal Commission.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
PART 2
PRODUCTS
2.01 GENERAL
A.
All goods and products covered by these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Royal Commission.
B.
Proprietary names used to designate colors or materials are not intended to imply
that products of the named manufacturers are required to the exclusion of equivalent
products of other Saudi Arabian manufacturers.
C.
Coatings shall be premixed and formulated, except for the 2-component on-site
catalyzed coatings. Pigments shall be capable of being readily and uniformly
dispersed to provide a homogenous mixture for the selected method of application,
i.e. brush, roller, conventional air assisted spray or airless spray methods, as
recommended in the manufacturer's application data sheets. Coatings shall not be
thinned except as indicated in the manufacturer's product data sheets and then only
using the manufacturers recommended thinner.
D.
Provide only absolutely pure linseed oil, turpentine, shellac, and other like material
that are of the highest quality with identifying labels intact and seals unbroken.
E.
Use only primers and under coaters that are suitable for each surface to be covered
and that are compatible with the finish coat required.
F.
If ferrous metals are shop primed, the Contractor shall make every effort to determine
the type of primer used. If this is not possible or the primer is not compatible with the
proposed finish coat, a barrier coat as recommended by the coating manufacturer
may be required prior to application of finish coat.
G.
H.
Rev 0
b)
The use of sand for surface preparation is not permissible unless the
sandblasting takes place in a totally enclosed area equipped with
particulate emission control measures.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
I.
Rev 0
Use products of the same manufacturer for succeeding coats with the possible
exception of the following:
1.
Where shop primed materials are to be finish painted or prime coat materials
are by a different manufacturer than finish coat materials, confirm compatibility
of the primers with the manufacturer of the finish coat paints.
2.
J.
Provide paints of durable and cleanable quality. Use paint materials which will
withstand normal washing as required removing pencil marks, ink, ordinary soiling,
and related conditions without showing discoloration, loss of gloss, staining, or other
damage.
K.
Organic Coatings
1.
The type and quality of the coating must be chosen with regard to the
corrosive properties of the media to be transported or stored, and to the
extreme climatic conditions. The coating shall have a high abrasion resistance,
excellent adhesion and a low water and gas permeability.
2.
The materials used for the coating must be free from low temperature volatile
solvents or other constituents which can cause evaporation and peeling during
storage.
3.
The organic coatings used for internal and external insulation shall have a
softening point (by the ring and ball method) higher than 110C.
4.
The coating shall have a dry film thickness of not less than specified.
5.
Primer materials shall be rust inhibitive and fully compatible with finish coat
materials.
6.
Shop applied finish coatings on steel shall consist of zinc galvanize, alkyd
enamel or epoxy paint systems.
7.
8.
9.
The materials used for the coating of (steel) pipes used for transporting of
drinking water or equipment located in drinking water must be sufficiently free
from low temperature volatile solvents or other constituents which can cause
evaporation and peeling during storage or can cause taste or odor in the
drinking water.
10.
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
a)
Alkyd Enamel:
125 micron.
b)
500 micron.
c)
Epoxy Enamel:
500 micron.
d)
Polyurethane:
500 micron.
e)
Organic Coatings:
300 micron.
f)
80 micron.
2)
80 micron.
3)
120 micron.
11.
The coatings shall be free from voids, missed spots and pinholes.
12.
The type and quality of the coating must be chosen with regard to the
corrosive properties of the fluid to be transported and/or stored, and to the
extreme climatic conditions. In view of the presence of abrasive particles and
conditions producing high water velocities, varying media pressures and the
prevailing wind and sand conditions, the coating shall have a high abrasion
resistance, excellent adhesion and a low water and gas permeability.
Prior to beginning the work, the Contractor shall submit to the Royal Commission for
approval sample color chips and a Color Schedule for all surfaces to be painted and
finished. Colors may not necessarily be the manufacturers standard colors. Special
colors shall be provided as required.
B.
Use representative colors when preparing samples for the Royal Commissions
review. Final acceptance of colors will be from sample mock-ups applied on the job.
C.
Color Pigments
1.
Rev 0
Pure, non-fading types to suit the substrates and service indicated. Lead
content in pigment, if any, shall not exceed more than 0.5% lead, based on the
total non-volatile, dry-film, of the paint by weight. This limitation shall extend to
all interior surfaces and those exterior surfaces, such as stairs, decks,
porches, railing, windows, and doors which are readily accessible to children
under 7 years of age.
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SECTION 09960
HIGH-PERFORMANCE COATINGS
Coating materials are given herein by generic type for application on ferrous and
concrete substrates. However, when performing isolated patch repairs on small
areas, the Contractor may propose to use other coatings, which shall be consistent
with environment and compatible with the original coatings. The generic coating
systems are given as guidance when no specific requirements are given to the
Contractor.
B.
For potable water storage tanks, the coating materials shall be approved for potable
water usage.
C.
All material and systems proposed will be subject to review and acceptance by the
Royal Commission.
D.
Generic coating systems for steel and concrete surfaces. The coating systems are
sectioned into field of application:
1.
OR
b)
OR
c)
1500 micron.
OR
d)
2.
1500 micron.
OR
b)
3.
OR
b)
OR
Rev 0
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SECTION 09960
HIGH-PERFORMANCE COATINGS
c)
4.
OR
b)
OR
c)
5.
Potable, Irrigation, Reclaimed and Sewage Water Above Grade Steel Tanks
a)
Internal Surfaces
1)
2)
Primer
(a)
3)
b)
External Surfaces
1)
2)
Primer
(a)
3)
4)
Intermediate Coat
(a)
Top Coat
(a)
c)
Two-component
high
gloss,
recoatable
polyurethane; 1-coat of minimum 75 micron DFT.
Acrylic
Color
1)
Rev 0
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SECTION 09960
HIGH-PERFORMANCE COATINGS
2)
6.
Potable, Irrigation, Reclaimed and Sewage Water Tanks of Concrete (New and
Existing)
a)
General
1)
b)
c)
Surface Filler
1)
Internal Surfaces
1)
Primer
(a)
2)
d)
External Surfaces
1)
Primer
(a)
2)
3)
Intermediate Coat
(a)
Top Coat
(a)
e)
Color
1)
Rev 0
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2)
7.
Primer
(a)
2)
3)
The average total DFT of the lining system shall be 1500 microns.
Marine Structures
a)
Steel
1)
2)
Primer
(a)
3)
b)
Concrete
1)
Primer
(a)
2)
Rev 0
Fiber glass reinforced epoxy lining system comprising twocomponents, solvent free, amine cured epoxy; 2-coats shall
be applied to fully embed a 300 g/m2 open wave fiberglass
mat and a 30 g/m2 tissue mat on top. Chopped fiberglass of
equivalent weight per square meter may be used instead of
the open wave mat as an alternative.
Top Coat
(a)
4)
Intermediate Coat
(a)
8.
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SECTION 09960
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Galvanized Steel
(a)
2)
(b)
(c)
Top Coat
(i)
Concrete
1)
Primer
(a)
2)
3)
Intermediate Coat
(a)
Top Coat
(a)
10.
Intermediate Coat
(i)
b)
Two-component
high
gloss,
recoatable
polyurethane; 1-coat of minimum 75 microns DFT.
OR
b)
OR
Rev 0
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Acrylic
SECTION 09960
HIGH-PERFORMANCE COATINGS
c)
11.
Chemical Tanks
a)
OR
b)
OR
c)
Rev 0
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Contract No:
SECTION 09960
HIGH-PERFORMANCE COATINGS
PART 3
EXECUTION
3.01 GENERAL
A.
This Section covers the shop priming and painting of steel and concrete structures
including surface preparation, materials, workmanship, protection of surface, and
other appurtenant work. The Contractor shall furnish all materials, tools, equipment
and labor and do all painting work specified herein.
B.
Unless otherwise stated, all cast iron, ductile iron and steel surfaces shall be
protected by suitable paint or coatings applied in the shop. Surfaces to be field
painted after equipment installation shall be shop painted with 1 or more coats of a
primer which will be adequately protect the equipment until finish coats are applied.
Electric motors, pumps, speed reducers, starters, and other self-contained or
enclosed components shall be shop finished with a high grade, oil resistant enamel.
C.
Steel equipment not in contact with the media such as framework, pipe supports,
hangers, support structures for equipment, anchor bolts for machines, loose flanges
for piping, bolts, nuts etc., shall be hot dip galvanized before delivery to the site.
D.
Machined, polished, and non-ferrous surfaces which are not normally painted by the
supplier shall be coated with rust preventive compound.
E.
2.
3.
Nickel or chromium.
4.
5.
Rev 0
If nothing else specified in this Specification, tanks shall be banded and labeled in
Arabic and in English to meet the following criteria:
1.
500 mm.
2.
500 mm.
3.
330 mm.
4.
160 mm.
5.
500 mm.
6.
330 mm.
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SECTION 09960
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B.
C.
At Contractors request, a sample detail of the bands and lettering schedule will be
furnished by the Royal Commission.
D.
E.
The color of the finish coat to be applied to the tank exterior steel or concrete
surfaces shall be light blue. The color of the bands and lettering shall be dark
blue.
The color of the finish coat to be applied to the tank exterior steel or concrete
surfaces shall be "Celtic green." The color of bands and lettering shall be
white.
Rev 0
General
1.
All surfaces shall be dry when coated and cleaned from dirt, dust, sand, mud,
oil, grease, rust, mill scale, and other substances that may interfere with proper
adhesion of coating. However, in case of difficult areas where proper surface
preparation cannot be achieved, the Contractor shall use special primers with
rust inhibitors or use rust conversion primers as approved by the Royal
Commission. Primers applied over such areas shall be very highly viscous and
highly penetrating.
2.
3.
When top coating existing coated areas, the new coating materials shall be
compatible with the original coating system. Surface preparation of sound
existing coating, which will be top coated, shall be carried out as approved by
the coating material's manufacturer and the Royal Commission. Any
requirements for cleaning by pressure washing or abrading by sweep blasting
shall be carried out at pressure that will not damage the existing coating.
4.
The compressed air supply shall be free of moisture, oil and other
contaminants. Blotter tests shall be performed in accordance with
ASTM D4285 at the start and every 4 hours of operations. The Contractor
shall provide traps, separators and dehumidifiers and other equipment as
required to maintain the required air quality.
5.
Blast air pressure shall be 580 to 690 kPa at the nozzle. Nozzles shall be
10 mm venture carbide. The pressure shall be verified regularly with
hypodermic needle air pressure gage.
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HIGH-PERFORMANCE COATINGS
B.
6.
7.
The Contractor shall indicate the surface profile achieved on steel surfaces.
Surface profile may be assessed using replica tape.
8.
After blasting and/or grinding just prior to application of coatings, all debris and
dust remaining on the cleaned surface and adjoining surface shall be removed
by suction cleaner methods to leave a clean surface.
9.
10.
The use of solvent-type cleaner shall not be permitted. If oil, grease etc., has
contaminated a surface, it shall be removed by use of an approved emulsion
cleaner, flushing with clean (potable grade) water and complete drying before
blast-cleaning.
11.
12.
At all times after cleaning, the Contractor shall protect both cleaned and
painted surfaces from contamination and damage from any cause whatsoever,
including contact between the surface and human skin, clothing or other fabric
or sweat drops or other substances.
13.
In repairing isolated damaged coating, the same original number of coats and
coat thickness shall be applied during the repair procedure. In small repair
areas, application of coating by brush is permissible; however, large isolated
areas shall be coated by spraying, except the primer shall be applied by brush.
The coating shall be applied from the substrate out over the feathered edge of
the coating and on to a lightly abraded area beyond the feathered edge.
14.
Painters and their assistants and inspectors who necessarily have to walk on
or traverse cleaned floor surfaces shall wear soft soled footwear, and all such
traffic shall be kept to a minimum.
15.
Blast cleaning or other surface preparation shall not be performed at the same
time as painting or whenever flammable vapor from paint solvents may be
present in the atmosphere.
16.
If not specified, all surface defects such as blemish, cracks, etc., shall be filled
with an approved filler material. The method of application shall be as
approved by the manufacturer.
Rev 0
All steel surfaces shall be prepared for coating by being thoroughly cleaned by
blasting as specified in this Specification. The surface profile after blast
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SECTION 09960
HIGH-PERFORMANCE COATINGS
C.
2.
The primer shall be applied within 4 hours of blast cleaning and before any
surface deterioration occurs.
3.
Shop primed and galvanized surfaces shall be cleaned of oil, grease and other
contaminants by cleaning agent, rinsed and allowed to dry before further
surface preparation or coating operations.
4.
Surface of welds shall be ground smooth as necessary to remove all slag and
weld spatter. Sharp points and edges shall be rounded to radius of 3 mm or
greater before coating. The use of chipping tools which produce cuts, burrs, or
excessive roughness is not acceptable. Paint made brittle by heat of welding,
or which has been otherwise damaged, shall be removed and the edges of
undamaged paint feather-edged so that patches will not be noticeable when
the painting has been completed. Before any field painting is done, all field
welded seams and joints, together with all surface of plates and structural
members not previously painted and surfaces from which damaged paint has
been removed, shall be prepared for painting by blasting. All lapped joints shall
be sealed internally to eliminate crevices.
5.
6.
Grinding shall also be used to smooth off all sharp edges and rough welding
seams and to remove spatters on welded details.
7.
Surface cleaning after possible grinding and degreasing prior to hot dip
galvanizing shall be made by pickling and washing in water.
2.
3.
Rev 0
Clean unpainted galvanized metal surfaces of all oil, grease, and other
contaminants in accordance with the applicable requirements of SSPCSP1 Solvent Cleaning and pretreatment in accordance with SSPC-PT2
Cold Phosphate Surface Treatment, prime with Polyamide epoxy
primer and Polyurethane topcoat finish paint with UV protection coating
system.
Clean unpainted galvanized metal surfaces of all oil, grease, and other
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SECTION 09960
HIGH-PERFORMANCE COATINGS
contaminants in accordance with the applicable requirements of SSPCSP1 "Solvent Cleaning" and pretreat in accordance with SSPC-PT2
"Cold Phosphate Surface Treatment," prime with a zinc dust, zinc oxide,
or alkyd paint.
D.
Rev 0
4.
5.
Concrete Surfaces
1.
Coatings shall be applied to the concrete surfaces only after the concrete has
completely cured.
2.
Surface Condition
a)
b)
c)
After all blast cleaning and repairs to unsound concrete have been
completed by approved procedures, the concrete surfaces shall be
swept to remove loose debris and dust particles. All concrete surfaces to
be coated shall be washed free of salt. Any oil/grease contamination
shall be removed using degreasing agents. Further contamination of
surfaces prior to the application of the primer sealer coat shall be
avoided.
d)
Areas of concrete repairs must be dry. The primer sealer coat shall be
applied immediately after vacuum cleaning of the surfaces to remove
dust and debris and within 3 days of blast cleaning. Moisture levels of all
concrete (existing and repaired) shall be less than 5% to a depth of
approximately 75 mm. The actual depth and the method of moisture
measurement shall be in accordance with the coating manufacturer
recommendations and shall be approved by the Royal Commission.
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3.
Test Area
a)
4.
Surface Filling
a)
E.
2.
If form oils or incompatible curing compounds are used, the surface shall
receive a sweep sandblast.
3.
4.
Do not paint over surfaces where the moisture content exceeds 5%, unless
otherwise permitted in the manufacturer's printed directions.
5.
Cut out cracks, holes, indentations and other imperfections in cement plaster
surfaces to the extent necessary to provide a good bonding surface; fill with
patching plaster and sand smooth and flush with adjacent surfaces with fine
sandpaper.
Rev 0
General
1.
Coating materials shall not be applied when there is moisture, dirt or other
deleterious material on the surface, when dust is present which can
contaminate freshly applied material or when the surface temperature is not in
the range specified in this Section or as recommended by the manufacturer.
The application temperature shall be determined prior to beginning of coating
operations and every 4 hours afterwards until the application is complete. See
also par. 1.10 in this Specification.
2.
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SECTION 09960
HIGH-PERFORMANCE COATINGS
surface treatments, and remove oil and grease with clean cloths and cleaning
solvents, prior to mechanical cleaning. Cleaning solvents shall be of low
toxicity with a flashpoint in excess of 40C. The cleaning and painting shall be
programmed so that dust and other contaminants from the cleaning process
will not fall on wet, newly painted surfaces.
Rev 0
3.
Paint shall not be applied, except under shelter, during wet, damp, or foggy
weather or when windblown dust, dirt, debris or insects will collect on freshly
applied paint. See par. 1.10 in this Section for more details.
4.
Apply paint and coatings with brush, roller, airless spray, or other acceptable
practice in accordance with the manufacturer's directions and at a uniform rate
that will produce the required DFT.
a)
Use brushes best suited for the type of material being applied.
b)
c)
5.
6.
Spread paints evenly and smoothly without runs, streaks, or other defects.
Make edges of paint adjoining other materials or colors sharp and clean,
without overlapping. Allow sufficient time between coats to ensure proper
drying.
7.
Paint films showing sags, checks, blisters, teardrops or flat edges will not be
accepted. Paint containing any of these defects shall be entirely removed and
the surface repainted.
8.
Do not apply succeeding coats until the previous coat has completely dried.
Allow a minimum of 24 hours between applications on any surface unless
otherwise specified by the coating materials manufacturer.
9.
Concrete Surfaces
a)
b)
c)
Coating shall not be applied on surfaces, which is not fully cured and
has not attained the specified strength.
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SECTION 09960
HIGH-PERFORMANCE COATINGS
B.
C.
e)
The cured surfaces shall be visually examined for film defects. Runs,
sags, drips, blistering and any loss of adhesion shall be subject to repair
at Contractor's expense.
f)
The finish coat shall be dense and of uniform texture and free from
sharp protuberances. Blemishes of any kind covering more than 5% of
the coated area will result in the rejection of the whole area.
g)
The surfaces shall be blast cleaned with specified anchor profile and shall be
free of all dust, salts and other contaminants.
2.
3.
4.
Apply an intermediate coat of epoxy to the primed surface. Apply glass fiber
mat and work out all wrinkles, folds and entrapped air by means of ribbed
rollers to ensure full saturation of the mat.
5.
Abrade the entire surface lightly to remove protruding glass fibers and vacuum
clean the entire surface.
6.
Apply one more intermediate coat of epoxy to the work surface. Apply glass
fiber tissue mat and embed in the epoxy by means of rollers.
7.
8.
Where bottom floor is included in the lining system, the floor lining shall be
finished after the walls and other areas have been completed. The lining shall
extend to 300 mm above the top of the floor surface.
9.
For application of lining on floor, blast to feather into the prelaminated wall
surface. The lamination of the floor shall follow the same application procedure
as specified above.
Steel Surfaces
1.
Rev 0
d)
The main primer coat shall be applied soon after the steel surfaces have been
blast cleaned. The primer or primary coat shall be applied within 4 hours after
blast cleaning. Care shall be taken to ensure that contamination does not
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SECTION 09960
HIGH-PERFORMANCE COATINGS
D.
2.
For large surface areas, the sequence of blast cleaning shall be carried out in
stages so that the application of primer occurs within the 4 hours period.
3.
4.
Paint shall be worked into all crevices and corners. All areas such as corners,
edges, welds, small brackets, bolts, nuts and interstices shall receive an
additional stripe coat of the parent coating material to ensure that these areas
have at least the minimum specified film DFT and the continuity of the coating.
Tinting
1.
E.
Alkyd Enamel
1.
F.
H.
Zinc Coating
1.
G.
2.
3.
Rev 0
The Contractor shall protect the newly applied coating from damage.
Where coating was damaged from his operations or from testing, repair
procedures shall be as follows:
1)
2)
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SECTION 09960
HIGH-PERFORMANCE COATINGS
I.
J.
K.
Rev 0
3)
4)
Organic Coatings
1.
The coating shall have a total dry film thickness of no less than 300 micron and
be applied at the place where the pipe material is manufactured either by
liquid-spraying, electrostatic powder-spraying of by dipping the part to be
coated in a fluidized bed of coating powder.
2.
3.
The coatings shall be free from flaws such as blisters, cracks, voids, missed
spots and pinholes, etc. All flaws shall be carefully repaired.
4.
Parts which are to be installed above ground shall be given a white or lightcolored coating in order to keep down surface temperature on exposure to
sunlight.
Polythene Encasement
1.
2.
The polythene encasement on straight DCI pipes shall be applied during the
course of pipe laying, in accordance with method A in ANSI A21.5, in order to
prevent direct contact between the coated pipe and the surrounding water,
soil, backfill and bedding material. Overlaps shall be secured by the use of
adhesive tape or plastic strings.
3.
4.
The polythene tubes during storage and transport, shall be protected from
direct sunlight.
Prior to Contract completion, the Contractor shall provide a detailed coating matrix
describing as-built coating systems applied to the facility. This matrix shall be all
inclusive. See par. 1.06 B for more details.
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SECTION 09960
HIGH-PERFORMANCE COATINGS
The Contractor shall be responsible for inspection and testing of the areas coated to
verify conformance with the requirements of this Specification.
B.
C.
The installed coating system shall present smooth workmanlike appearance and
shall be free of voids, blisters, pinholes, cracks, pits, bubbles, soft spots, disbanding,
open seams, lifted edges or any other defects that will impair its usage. Evidence of
poor workmanship shall be cause for rejection.
D.
2.
Checking WFT
a)
3.
4.
Checking DFT
a)
The thickness of the built-up dry film after each paint coat applied to
steel or other magnetic surfaces shall be measured systematically, with
an Elcometer dry thickness gage.
b)
The thickness of the built-up dry film after each paint coat applied to
non-magnetic surfaces shall be measured by a pit gage or micrometer.
c)
The number and location of test areas for checking of DFT shall be
agreed upon and approved by the Royal Commission before work
commences. All tests shall be witnessed by the Royal Commission.
Local areas where continuity of coating surface had been disrupted by
testing shall be repaired.
Concrete Surfaces
a)
Rev 0
Regular mill scale detection tests shall be carried out using the "Copper
Sulfate" method of test.
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SECTION 09960
HIGH-PERFORMANCE COATINGS
b)
5.
Rev 0
The number and location of test areas for checking adhesion shall be
agreed upon and approved by the Royal Commission before work
commences. All tests shall be witnessed by the Royal Commission.
Local areas where continuity of coating surface had been disrupted by
testing shall be repaired.
b)
Coated areas shall be spark tested for pinholes leaks using a high
potential spark tester adjusted to 15,000 and 20,000 V or recommended
by the coating manufacturer.
6.
Coated surfaces shall be inspected for blisters (trapped air), pulls or lifted
edges at seams and surface defects. Any dimensional tolerances required
should also be checked. All defects noted in the coating shall be repaired and
retested to the satisfaction of the Royal Commission or its authorized
representative.
7.
The number of pinholes and surface imperfections repair shall be recorded for
each area or item.
E.
The Royal Commission may engage the services of his designated Independent
Testing Laboratory to sample any of the paint being used. Samples of materials
delivered to the Project site will take, identified and sealed, and certified in the
presence of the Contractor.
F.
Abrasion resistance.
2.
Apparent reflectivity.
3.
Flexibility.
4.
Washability.
5.
Absorption.
6.
Accelerated yellowness.
7.
Recoating.
8.
Skinning.
9.
Color retention.
10.
Alkali resistance.
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SECTION 09960
HIGH-PERFORMANCE COATINGS
11.
G.
If any of the test results show that the material being used does not comply with the
specified requirements, the Contractor shall be directed to stop the painting work and
remove non-complying paint; bear the financial costs associated with laboratory
testing; repaint the surfaces coated with the rejected paint; remove rejected paint
from previously painted surfaces if, upon repainting with the specified paint, the
coatings are non-compatible.
H.
Certificates and tests performed throughout the coating operation and all inspection
service involved shall be submitted to the Royal Commission. Documentation shall
consist of, but not be limited to the following:
1.
Material supply.
2.
Surface inspection.
3.
Surface preparation.
4.
5.
6.
I.
The above documentation shall be dated and signed by the Contractor and submitted
to the Royal Commission.
J.
Rev 0
A.
All damaged coating and other defects shall be repaired to the entire satisfaction of
the Royal Commission before application of the next coat or before acceptance of the
final coat.
B.
Areas with inadequate coating thickness shall be thoroughly cleaned and abraded to
provide adequate key for the coating to be applied. Additional compatible coats shall
be applied until the specified film thickness is achieved. The additional coats shall
blend in with the final coat on adjoining areas.
C.
Areas with pinholes and excessive holidays shall be blast cleaned to remove
defective coating completely and recoated. The recoated area shall carry over on to
the adjoining coating for not less than 50 mm all around and the edges shall be
feathered.
D.
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SECTION 09960
HIGH-PERFORMANCE COATINGS
3.07 PROTECTION
A.
Protect work of other trades, whether to be painted or not, against damage by the
painting and finishing work. Leave all such work undamaged. Correct damages by
cleaning, repairing or replacing, refinishing, or repainting, as necessary and as
acceptable to the Royal Commission.
B.
Provide "Wet Paint" signs as required to protect newly painted finishes. Remove
temporary protective wrappings provided by others for protection of their work after
completion of painting operations.
C.
Provide sufficient drop cloths, shields and protective equipment to prevent overspray
from surfaces not being painted.
D.
Materials which may constitute a fire hazard shall be enclosed in metal containers
and removed from site daily.
E.
Remove all electrical plates, surface hardware, fittings and fastenings, prior to paint
application. These items are to be carefully stored, cleaned and re-installed on
completion of work in each area. Do not use solvent that may remove permanent
lacquer finish to clean hardware. Items which are not practical to remove shall be
taped over. Do not use any tape containing chlorides on stainless steel surfaces.
3.08 CLEAN-UP
Rev 0
A.
During the progress of the work, remove from the site all discarded paint materials,
rubbish, cans, and rags at the end of each work day.
B.
As work proceeds and upon completion of painting work, promptly remove and clean
paint-spattered surfaces. Remove spattered paint by proper methods of washing
and scrapping, using care not to scratch or otherwise damage finished surfaces.
C.
At the completion of work of other trades, touch-up and restore all damaged or
defaced painted surfaces.
D.
During progress of work keep premises free from any unnecessary accumulation of
tools, equipment, surplus materials and debris.
E.
Upon completion of work, leave premises neat and clean, to the satisfaction of the
Royal Commission.
F.
After completing all works, including testing and painting, the interior of the
tank shall be thoroughly cleaned and disinfected.
2.
The Contractor shall not start to clean and disinfect the tank until protective
coatings have fully cured, and in any event not until at least 1 week has
elapsed after completion of all interior coating.
3.
Prior to starting any disinfection work, the Contractor shall submit to the Royal
Commission a detailed outline of the procedures proposed, the coordination
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SECTION 09960
HIGH-PERFORMANCE COATINGS
and sequence of operation, and the manner of filling and flushing the tank. All
procedures shall be approved by the Royal Commission.
4.
The Contractor shall furnish all cleaning and disinfecting materials and all
equipment and labor necessary for the cleaning and disinfecting operations. All
water used in disinfecting the tank shall be disposed of in a manner acceptable
to the Royal Commission.
5.
Water containing 50 mg/L chlorine shall be placed in the tank to such a depth
that, when the tank is filled, the resultant chlorine content will be at least
2 mg/L, but not more than 3 mg/L.
6.
7.
After disinfection the tank access manholes shall be kept closed and personnel
access into the tank shall not be permitted without the express permission in
writing of the Royal Commission.
END OF SECTION
Rev 0
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Contract No: