Technical Specification

TS4 Project and Maintenance Coating

CBH Engineering Pty Ltd

P | (08) 9236 5350
F | (08) 9236 5370
www.cbh.com.au
TS4 Project and Maintenance Coating

Document Control
Document owner: Manager Coatings

Change Control Policy

Any amendment to this standard must be recorded in the table below.

If substantial changes are made a new version of the document shall be created to preserve an audit trail.

Review Date Author Description of amendments

A 21/05/2009 T. Tyler Reformatting, CBH changed to BWE, updating reference codes
and Standards
B 20/7/2009 T. Tyler Previously TS 8 & 9
C 07/10/2009 T. Tyler Change BWE back to CBH
D 30/04/2010 T. Tyler Rebranding
E 29/07/2011 S. Note added to 6.8 Colour Schedule
Bracegirdle
F 30/11/2012 J. Watson General updates
G 13/08/2013 J. Watson Addition of coating system PC10
H 18/11/2014 J. McMiles Updates styling and formatting.

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Contents

1. Scope ......................................................................................................................................................... 4
2. Intention of Specification............................................................................................................................ 4
3. Reference Codes & Standards .................................................................................................................. 5
4. Contractor Responsibilities ........................................................................................................................ 7
5. Quality Control & Inspection ...................................................................................................................... 8
6. Approved Coatings & Coating Specifications .......................................................................................... 10

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1. Scope
This Specification covers the minimum requirements for:

Contractor responsibilities
Quality Control, Inspection and Testing
Approved coatings, coating systems and colour coding
Surface preparation
Application of coatings
Acceptance criteria and treatment of defective work
Safe work practices on site

2. Intention of Specification
It is the intention of this Specification to ensure all Project (new Shop and Site touch-up) and Maintenance
surface treatment work, is performed in accordance with the Coating Manufacturers Product Data Sheets
and to the highest possible industry standards. Generally and as far as practicable, all steelwork shall be
prepared for painting and have the coating system applied and inspected to ensure compliance with this
specification and/or applicable standards.

The aim of this specification is to provide project and maintenance coating systems that shall provide a
minimum Design/Service Life as per AS/NZS 2312 irrespective of the service environment and/or location
and also have a minimum of 10 years before first maintenance.

Where reference is made within this specification to Co-Operative Bulk Handling (CBH) this shall include any
nominated representative of the CBH Group, including CBH Engineering Pty Ltd.

In the event of conflict, inconsistency or ambiguity between the Contract, this Specification, Statutory
requirements, codes and Standards referenced in this Specification or any other documents, the Contractor
shall refer to the Principal (CBH Group) or its nominated representative, whose decision shall prevail and be
binding.

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3. Reference Codes & Standards

All works shall conform to the latest edition of the following standards or their approved equivalent. If any
standard listed below has been superseded, the relevant new standard shall be read in lieu of the
superseded standard.

AS 1345 Identification of the contents of Pipes, Conduits and Ducts

AS 1580.408.2 Paints and Related Materials Method of Test - Adhesion Knife Test
AS 1580.408.4 Paints and Related Materials Method of Test - Adhesion (Cross Cut)
AS 1580.408.5 Paints and Related Materials Method of Test - Adhesion Pull-Off Test
AS 1627.0 Metal Finishing Preparation and Pretreatment of Surfaces Method
Selection Guide
AS 1627.1 Metal Finishing Preparation and Pretreatment of Surfaces Removal of Oil,
Grease and Related Contamination

AS 1627.2 Metal Finishing Preparation and Pretreatment of Surfaces Power Tool

Cleaning
AS 1627.4 Metal Finishing Preparation and Pretreatment of Surfaces Abrasive Blast
Cleaning of Steel
AS 1627.9 Metal Finishing Preparation and Pretreatment of Surfaces Pictorial Surface
Preparation Standards for Painting Steel Surfaces

AS 2700 Colour Standards for General Purposes

AS 3894.0 Site Testing of Protective Coatings Introduction and List of Test Methods
AS 3894.1 Site Testing of Protective Coatings Non-conductive Coatings Continuity
Testing - High Voltage (Brush) Method
AS 3894.2 Site Testing of Protective Coatings Non-conductive coatings Continuity
testing Wet Sponge Method

AS 3894.3 Site Testing of Protective Coatings Determination of Dry Film Thickness

AS 3894.4 Site Testing of Protective Coatings Assessment of Degree of Cure

AS 3894.5 Site Testing of Protective Coatings Determination of Surface Profile

AS 3894.6 Site Testing of Protective Coatings Determination of Residual Contaminants

AS 3894.7 Site Testing of Protective coatings Determination of Surface Temperature

AS 3894.8 Site Testing of Protective Coatings Visual Determination of Gloss

AS 3894.9 Site Testing of Protective Coatings Determination of Adhesion

AS 3894.10 Site Testing of Protective Coatings Inspection Report Daily Surface and
Ambient Conditions

AS 3894.11 Site Testing of Protective Coatings Equipment Report

AS 3894.12 Site Testing of Protective Coatings Inspection Report Coating

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AS/NZS 2310 Glossary of Paint and Painting Terms

AS/NZS 2312 Guide to the Protection of Structural Steel against Atmospheric Corrosion by
the Use of Protective Coatings
AS/NZS 3750.9 Paints for Steel Structures - Organic Zinc-Rich Primer
AS/NZS 3750.15 Paints for Steel Structures - Inorganic Zinc Silicate Paint

AS/NZS 4233.1 High Pressure Water (Hydro) Jetting Systems Guidelines for Safe Operation
and Maintenance

AS/NZS 4680 Hot Dipped Galvanised (Zinc) Coatings on Fabricated Ferrous Articles

SSPC Painting Manual Volume 1: Good Painting Practice

SSPC Painting Manual Volume 2: Systems and Specifications

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4. Contractor Responsibilities
The Contractor shall:

4.1 Supply all coating materials, transport, labour, abrasives, consumables, safe storage
facilities, equipment, inspection and safety equipment to perform the work scope in strict
accordance with this Specification and best industry standards.

4.2 Provide CBH with written details of all equipment (all test equipment must have a valid
calibration certificate every 12 months from last calibration date, as per manufacturers
recommendations or applicable Australian standards listed in section 3.0 of this
specification, and be available onsite. The project management structure, relevant work
experience of the site supervisor/inspector, and provide a detailed Gantt chart of the
proposed work schedule, Inspection and Test Plan (ITP) documentation, and Work
Instructions for each procedure.

4.3 Provide a list of those items, activities or approvals required to be supplied or performed
by CBH prior to the commencement of any work.

4.4 Ensure all staff has a thorough understanding of all the conditions applying to this
Specification, the contents of Coating manufacturers Product Data Sheets and Material
Safety Data Sheets.

4.5 Ensure that all QA/QC Staff have relevant qualifications to perform all inspections/testing
in accordance with the relevant Australian standards.

4.6 Be responsible for co-ordinating all on-site work activities with other Contractors or CBH
activities in the general work area.

4.7 Ensure the availability of technical assistance from the Coating manufacturer or other
authority approved by CBH.

4.8 Protect CBH product, equipment and personnel from contamination, damage or injury
caused by the Contractors activities on-site.

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5. Quality Control & Inspection

The Contractor is required to:

5.1 Maintain quality records in accordance with the AS3894 series - Site Testing of Protective
Coatings.

Part 10 - Inspection Report Daily Surface and Ambient Conditions

Part 11 - Equipment Report
Part 12 - Inspection Report - Coating

Copies of all records shall be submitted to CBH at the completion of work or as requested
by CBH or its representative.

5.2 Provide CBH with a copy of the Work Instruction (WI) and Inspection and Test Plan (ITP)
documents to be used for each coating system. CBH reserve the right to request
amendments (at any time though out the project) to WI or ITP documents which shall be
amended as required.

5.3 Provide inspection equipment, such as, but not limited to:
Surface temperature gauge
Ambient temperature gauge
Hygrometer
WFT gauge (comb type)
DFT measuring instrument such as the Elcometer or approved equivalent
Surface profile replica tape such as Testex tape and micrometer
Residual contamination testing equipment (i.e. equipment for the measurement of
soluble salt concentrations).
HV Holiday Tester
LV Holiday Tester

5.4 Where requested, provide CBH with details of the proposed daily work schedule and the
approximate timing for the following inspection stages:
high pressure pre wash or solvent cleaning to remove product and grease/oil
contaminants from the area to be treated
on completion of the abrasive blast cleaning
on completion of brush stripe coating.
on completion of the application of each coat in the coating system
on completion of repairs

5.5 Provide CBH with access to the work area while work is in progress or on completion.

5.6 Work not conforming to this Specification shall be reinstated at no cost to CBH.

5.7 Accept that where there is conflict with any provisions of this Specification and the Coating
manufacturers product Data Sheet or recommended coating systems, the issue shall be
resolved by adopting the highest standard acceptable to the principal or its representative.

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5.8 Prior to commencement of work, CBH may request the Contractor to prepare at no cost to
CBH, 3 sample panels or items for each coating system.

The test panels and items shall be prepared in accordance with the Contractors proposed
Work Instruction and Test Plan documents. The Contractors nominated Coating
manufacturer and or representative shall witness the surface preparation and coating
application of each system and acknowledge in writing the conformance of each prepared
test panel and item.

Two test panels or Items shall be retained by CBH for use as quality references in the event
of a dispute, or on completion of the work scope. The Contractor shall retain one test panel
or item as a quality reference for work in production.

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6. Approved Coatings & Coating Specifications

6.1 Only coatings approved by CBH shall be used. Other coating materials may be considered
for use provided such a request is made in writing and supported by relevant case
histories.

6.2 All coatings and thinners used within a coating system shall be sourced from one Coating
manufacturer. Mixed systems, unless stated otherwise, shall be rejected and reworked in
accordance with this Specification at no cost to CBH. All paint materials shall be delivered
to the shop or site in the coating manufacturers original containers with labels and seals
unbroken.

6.3 All coating materials shall be supplied in their original containers and are to be sealed,
damage free, uniquely marked for Identification giving the following information as a
minimum;
Manufacturers name;
Type and identification
Batch number
Expiry Date

6.4 For areas and coating systems not specifically mentioned in this Specification, the coating
Manufacturer's representative shall be required to inspect the proposed work scope and
supply a specific coating specification and written endorsement for the suitability of their
proposed coating system. Non-specified coating systems or procedures shall not be used
without the written approval of CBH.

6.5 Contractors are responsible for selecting coating products from the approved
Manufacturers whose products best suit the Contractors commercial and practical
requirements.
Approved coating Manufacturers are:

Akzo Nobel Pty Ltd (International)

Ameron Coatings (Australia)(PPG) Pty Ltd
Jotun Australia Pty Ltd
Dulux Protective Coatings
Resene Paints (Australia) Ltd (Altex)
Wattyl Australia Pty Ltd
Hempel Paints

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6.6 Approved Coating Products

Generic Type Altex PPG/Ameron Dulux International Jotun Wattyl Hempel

Inorganic Zinc Rich Ethyl Silicate Carbozinc 11 Amercoat D9 Zincanode 304 Interzinc 215 Resist 86 AU Galvit ES 600 Galvosil 15700

Epoxy Zinc Rich Primer Friction Carbozinc 858 Amercoat 471 Pending Certification Interzinc 315 Pending Pending Certification Pending Certification
Grip Certified Certification

Epoxy Zinc Rich Primer Carbozinc 858 Amercoat 471 Zincanode 402 Interzinc 52 Barrier Galvit EP 100 Hempadur Zinc 17360

Zinc Phosphate Epoxy Primer (2 Altra-Prime 504 Amercoat 182 ZPK Durepon P14 Intergard 251 Penguard Epinamel PR 250 Hempadur Fast Dry 15560
Pack) Express ZP

High Build / High Solids Epoxy Carboguard 690 Amerlock 400/2K Durebild HSE Interzone 954 Jotamastic Epinamel DTM 985 Hempadur Multi- Strength
(CP Compatible) 87/90 45540

Surface Tolerant Epoxy Carboguard 690 Amerlock 400/2K Durebild STE Interzone 954 Jotamastic Epinamel DTM 985 Hempadur mastic 45880/1
87/90
Epoxy High Build MIO Carboguard 690 Amerlock 400 /2K MIO Ferreko no 3 Interplus 1180 Jotamastic 87 Epinamel DTM 985 Hempadur mastic 45880/1
MIO MIO MIO 50 MIO 1243
(80% content MIO)
Gloss Acrylic (Two pack) E-Line 929IF Amercoat Iso-Free 977 Acrathane IF Interfine 629 Hardtop CA Paracryl 540 IF Hempels Pro-Acrylic
55880
Zinc Phosphate Primer (1 pack)
Duraprime Amercoat 185K Luxaprime ZP Interprime 198 Pilot QD Duranamel PR10 Hempaquick Primer 13640
Gloss Finish (1 pack)
Isotal Enamel Styralux 220 Metal Shield Premium Interlac 665 Pilot 11 Kill Rust Enamel Hempaquick Enamel
UV Resistant Enamel 53840
Topcoat

Water Borne Gloss Acrylic

N/A Amercoat 288 955 Acrashield Intercryl 988 N/A Sunfast Gloss/Low N/A
(1 pack) HB Sheen
Marine coating System (classified
as E-M as per AS2312) N/A Amercoat 471 (75m) Zincanode 402 (75m) Intershield 300 Barrier 77 Galvit EP100 (75m) Hempadure Zinc 17360
(175 m) (65m) (75m)
All DFTs are in accordance with Amerlock 400 MIO Duramax GPE MIO Epinamel DTM 985 MIO
manufacturers recommendations (200m) (200m) Interthane 300 Jotamastic (300m) Hempadure Mastic 45881
(175m) 80/87MIO (125m)
PSX 700 (125m) Weathermax HBR (350 m) Paracryl IF540 (50m)
(100m) Interthane 990 Hempathane HS 55610
(60m) Hardtop XP (125m)
(75 m)

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6.7 Item, Environment and Coating Systems

Item or Area to be Environment Atmospheric Coating

coated Corrosivity Category (Based on AS 2312 System
- Section 2.3)
Storage cells and
Category E: Very High (Coastal) PC3/PC10*
supporting structure
Category B: Low (Inland) PC2
Category E: Very High (Coastal) PC1/PC10*
Structural steelwork
Category B: Low (Inland) PC5
Conveyors, stringers,
Category E: Very High (Coastal) PC3/PC10*
supports, hoppers,
elevator casings,
chutes, garner bins,
Category B: Low (Inland) PC6
internal surfaces of boot
pits

Galvanised steel field

All environments PC7
welds ONLY

Galvanised steel (colour

All environments PC8
coded)

Structural steel, tanks

and piping. Buried,
immersed or in All environments PC4
conjunction with
Cathodic Protection
Equipment, motors,
All environments PC8
gear boxes.
Vendor-supplied.
Propriety equipment
colour coding over All environments PC9
manufacturers standard
finish.
Category E: Very High (Coastal) PC1*
Friction grip bolted faces
Category B: Low (Inland) PC5*

* See Notes; page 13

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6.8 Project Coating Systems

Coating Surface Preparation Coat 1 DFT Coat 2 DFT Coat 3 DFT Total DFT
System # Method and Standard Generic Type (m) Generic Type (m) Generic Type (m) in m
PC1* Abrasive blast clean to Epoxy Zinc Rich Primer 75 High Build MIO 150 High Build MIO 150 375
AS1627.4 class 2.5
PC2 Abrasive blast clean to Inorganic Zinc Rich Ethyl Silicate 75 Epoxy Zinc Rich 75 WB Acrylic HB 150 300
AS1627.4 class 2.5 (weld areas)
PC3 Abrasive blast clean to Epoxy Zinc Rich Primer 75 High Build Epoxy 200 Gloss Acrylic (two 50 325
AS1627.4 class 2.5 pack)
PC4 Abrasive blast clean to HB/HS Epoxy 200 HB/HS Epoxy 200 400
AS1627.4 class 3 (CP Compatible) (CP Compatible)
PC5* Abrasive blast clean to Inorganic Zinc Rich Ethyl Silicate 75 75
AS1627.4 class 2.5
PC6 Abrasive blast clean to Zinc Phosphate Epoxy Primer 75 Gloss Acrylic 50 125
AS1627.4 class 2.5 (two pack) (two pack)
PC7 Power tool clean to Epoxy Zinc Rich Primer 100 100
AS1627.2 class 2
PC8 Acid etch or whip blast or Zinc Phosphate Epoxy Primer 75 Gloss Acrylic 75 150
power tool class 2 (two pack) (two pack)
AS1627.2
PC9 Solvent wipe and abrade Zinc Phosphate Primer 75 Gloss Enamel 40 Gloss Enamel (one 40 155
(one pack) (one pack) pack)
PC10 Abrasive blast clean to Epoxy Zinc/Surface tolerant Epoxy See High Build See Gloss Polyurethane See See below*
AS1627.4 class 2.5 (dependant on manufacturer chosen) belo MIO/Surface belo Acrylic or below
w* tolerant Epoxy w* Polysiloxane *

*For friction grip joints apply Certified for Friction Grip Joints Epoxy Zinc Rich Primer 50-75 microns for PC1 and for PC5, 50-75 microns of Inorganic Zinc Rich Ethyl
Silicate

*For coating systems marked PC10 please refer to manufacturers recommended coating thicknesses stated in table 6.6

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6.9 Colour Schedule*

Items to be painted AS2700 Colour Number and

Name

Storage cells and supporting structure. Y35 - Off White

Internal surfaces of boot pits

Compressed Air Line B25 Aqua

Electric Motors
Gearboxes
Conveyors, stringers, supports and take up G21 - Jade
frames
Elevator casings
Spouts and chutes
Garner bins and hoppers
*Hand Rails Galvanised
*Ladder Cages (Where safety colour coding
required finish in Y14)
All moving parts (pulleys, hand wheels, levers,
couplings)
Machine guards (interior and exterior) Y14 - Golden Yellow
Inspection door (dust)
Grain treatment lines
CLS Stacker Boom
J Pit
B21 - Ultramarine
CLS Stacker Chassis
Structural Steelwork N 53 - Blue Grey
Zinc Silicate finish (Natural Zinc)
Woodwork (interior and exterior) N45 - Koala Grey
Conduits
Cable ducting X15 - Orange
Cable trays
Switches
Switch boxes (exterior) G44 - Palm Green
Switch boxes (interior) White
Fire Service
Emergency Valves R13 - Signal Red
Hazardous items
Dust Ducting X42 - Biscuit
Engine Fuel Hydraulic Lines X53 - Golden Tan
Gas X31 - Raffia
Fresh water B15 - Mid Blue
Pre-cast concrete panels As nominated by the Principal

* Colour schedule is a guide only, colour changes made during the planning stage of manufacturing new
equipment is at the discretion of the Engineering Services and Senior Projects Managers of Network and
Engineering.

*All hand rails including Stanchions, Kick Plates ladders and cages shall be colour coded to Y14 Golden
Yellow, unless otherwise stated by the Principal or its representative.

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7. Surface Preparation
7.1 General

This section details the approved surface preparation methods, equipment and
materials. As a general rule, abrasive blast cleaning is the only acceptable surface
preparation method. Surface preparation by high pressure water jetting may also be
acceptable however only with the approval of CBH. Other methods such as hand or
power tool cleaning shall only be used for small or repair areas with the approval of
CBH.

In general steel shall be cleaned of all grease, dirt, grit, dust, fingerprints, salt residues,
weldscale, corrosion product, loose millscale and other foreign particles or residues
which are likely to effect the performance of any subsequent protective coating system.

7.2 Surface preparation shall be performed in accordance with the current editions of the
following Australian Standards:
1627.0 Metal Finishing Preparation and Pretreatment of Surfaces Method
Selection Guide

1627.1 Metal Finishing Preparation and Pretreatment of Surfaces Removal

of Oil, Grease and Related Contamination

1627.2 Metal Finishing Preparation and Pretreatment of Surfaces Power

Tool cleaning

1627.4 Metal Finishing Preparation and Pretreatment of Surfaces Abrasive

Blast Cleaning of Steel

1627.9 Metal Finishing Preparation and Pretreatment of Surfaces Pictorial

Surface Preparation Standards for Painting Steel Surfaces

7.3 Prior to the commencement of any abrasive blasting, all compressed air shall be free of
oil, condensed moisture or any other contaminates and shall conform to the
requirements of ASTM D 4285. These checks shall be conducted daily at the start of
each shift or any time there is a change of air supply lines or equipment.

7.4 Prior to commencing surface preparation, any oil and grease on the surfaces to be
treated shall be removed using suitable solvents or non-ionic detergents in accordance
with the requirements of AS1627.1.

7.5 Prior to the application of coatings, all surfaces shall be inspected by the Contractors
representative for compliance with this Specification. CBH shall be given the opportunity
to inspect prepared surfaces prior to the application of coatings.

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7.6 Surface Defects to be Removed Prior to Abrasive Blast Cleaning

Sharp edges shall be ground to a minimum 3mm radius
Weld spatter and weld slag shall be removed prior to abrasive blasting
Laminations shall be ground out and the affected area re-treated
Inaccessible areas, which cannot be treated in accordance with the Specification,
shall be brought to the attention of CBH.
Any other welding defects that may be detrimental to the subsequent coating
processes.
For sake of completeness, any other defects not already mentioned which may be
detrimental to the coatings, must be brought to the attention of the Principal or its
representative (these defective areas will be assessed on a case by case
situation).

7.7 Abrasive Blast Cleaning

Heavily corroded and pitted steelwork shall be initially abrasive blast cleaned to
AS1627.4 class 2, followed by High Pressure fresh water to remove water-soluble
corrosive compounds from the pitted steel surface. All steelwork shall then be abrasive
blast cleaned to the specified standard of the nominated protective coating system.

7.8 Abrasive blast cleaning shall be performed during daylight hours only. All blasted steel
surfaces must be prime coated within 4 hours of blasting or before flash rusting
occurs. Coatings shall only be applied to surfaces that meet the minimum specified
standard as detailed in Section 7 of this Specification.
o
7.9 Abrasive blast cleaning shall cease if the steel surface temperature drops to within 3 C
of the dew point temperature, or the relative humidity exceeds 85%.

7.10 Areas to be spot blasted shall have the surrounding coating feathered over a
minimum width of 50mm.

7.11 Non-silica abrasives (i.e. garnet, ilmenite or aluminium oxide) shall only be used for
Site work. Spent abrasive shall not be re-used.

Shop blasting shall be performed using steel grit or other approved materials to provide
a conforming surface profile. Abrasives shall be free of oil, grease, salts, moisture and
any other contaminants likely to be detrimental to the treated steel surface.

7.12 Surface profiles of 35 to 65 microns (average 50 microns) shall be consistently

produced. Nevertheless, the surface profile height of the blasted surface shall be
within the range to suit the manufacturers protective coating system to be applied.
Surface profile shall be appropriate for the coating system. Refer coating
manufacturers Product Data Sheet.

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7.13 Compressors used for abrasive blasting shall have effective moisture and oil
separators fitted. Air lines shall be fitted with oil and water filters which shall be drained
off or cleaned daily.

7.14 The Contractor shall be responsible for protecting all rotating equipment, painted
surfaces, electrical equipment, gauge faces, identification tags, etc. from damage
caused by abrasive blast cleaning or painting. Removal of items and subsequent
reinstallation after completion of painting works shall be carried out by tradesman
competent in the relevant activity.

7.15 Only filtered air shall be used to blow off spent abrasive from the prepared surfaces. All
abrasive blasting residue shall be collected, removed from site and disposed of by the
Contractor in accordance with the appropriate statutory requirements.

7.16 Areas which cannot be properly prepared by abrasive blasting, such as gaps, voids
and inaccessible areas, shall be brought to the attention of CBH.

7.17 New Concrete Surfaces e.g. Bund Walls, Tanks etc.

New concrete must be well cured and dry prior to coating. Allow all concrete to cure a
minimum of 28 days prior to any coating application works. All concrete shall be
suitably prepared prior to coating application to ensure a suitable surface that will
provide sound adhesion between the applied coating and the concrete substrate.

All surfaces shall be abrasive blast cleaned to remove loose material, laitance, curing
compounds and release agents. Care must be taken to only sweep blast the surface,
and the use of a lower nozzle pressure is recommended.

The Contractor may nominate alternative preparation methodologies such as high-

pressure water washing or acid etching but must provide performance parameters for
the nominated surface preparation technique and confirmation from the coating
manufacturer of suitability of the surface preparation for the selected coating system.

The Contractor shall request from the Principal all information relating to curing
compounds, bond breakers, form release oils and the like applied to the concrete
surface to be coated in order to provide a suitable surface preparation methodology.

The section 7.17 New Concrete Surfaces above is intended as a guide only and
additional information (Inspection Test Plans, Other Specifications and
Methodology etc.) is to be sourced and approved by CBH before commencement
of any related new or remedial works.

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8. Application of Coatings
8.1 Standard of Workmanship
Competent and experienced personnel shall perform all coating preparation and
application.

8.2 Storage of Coatings

Coatings shall be delivered to site in the original and unopened containers.
Batch numbers and shelf life expiry dates shall be clearly visible.
Coatings which have settled excessively or gelled shall not be used.
Coatings shall be stored in dry and cool environments at a temperature not
o
exceeding 30 C or as specified by the manufacturer.

8.3 Mixing of Coatings

Coating manufacturers mixing and thinning directions shall be strictly observed.
Two pack epoxy coatings shall be allowed the Coating manufacturers specified
induction period before application.
Use air driven power stirrers to mix liquid coating.
Caution: Electric power tools can be an ignition source for solvent vapours.

8.4 Ambient and Surface Conditions

Coating shall not be applied when the relative humidity exceeds 85% steel surface
o o
temperature at or lower than 10 C and/or not falls below 3 C above dew point; the
o
steel surface temperature exceeds 50 C or exceeds the product Coating
manufacturers maximum allowable steel surface temperature.

Steel surfaces to be coated shall be clean and dry. Grain dust fallout, spent abrasive
and dust shall be removed with clean, dry compressed air prior to application of
coating material.

8.5 Sealing of crevices

Inaccessible areas such as crevices and bolted member joints which cannot be
coated in accordance with this specification shall be sealed with a flexible sealant
material that is compatible with the substrate and applied coating system. All such
locations shall be approved by CBH prior to application.

8.6 Application of Coating

Airless spray is the preferred application methods. Conventional Spray, rolling or
brush application shall only be used with the approval of CBH.

8.7 The Contractor is responsible for all damage caused by over-spray. Precautions
such as stopping spray application in adverse conditions, planning work areas and
schedules around the prevailing wind strength and directions, erecting tarpaulins or
barrier screens around work areas, and masking shall be taken.

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8.8 Stripe Coating Before Each Coat.

All edges, deeply pitted steel, studding materials and welds shall be coated
by brush in an even and consistent film with each coat in the coating system
prior to spray application of the same coating. Solvent-Borne Inorganic Zinc
Silicate coatings are exempted from this requirement.

Care shall be exercised to ensure that coating materials are not unduly
brushed out as this will reduce the dry film thickness, nor shall the coating
material be applied in excessive quantities. Care must also be taken to
ensure the correct type and size of brush is used for the shape and size of
the structure and or area to be stripe coated.

Failure to adequately stripe coat will cause premature failure of the coating
in the areas that are required to be stripe coated. Natural surface tension
forces causes the coating to retreat from any edge type formation.

8.9 All known field weld areas shall be given the specified abrasive blast
preparation but left uncoated for a distance of 50mm from the weld line.
Such areas shall be given the appropriate touch-up treatment after site
erection.

8.10 The Coating manufacturers pot life and re-coat intervals (min and max)
shall be strictly observed. The Contractor shall reference the Coating
manufacturers coating cure information detailing the pot life, touch dry,
minimum re-coat and maximum re-coat intervals.

8.11 Prior to the application of any coat of material, any damage or defects to
previous coats shall be touched up with the specified coating before further
coats are applied within a specified system.

8.12 No thinner shall be added unless necessary for proper application. Thinning
shall not exceed limitations established with the coating manufacturers
product data sheet. When the use of thinner is permissible, it shall be added
during the initial mixing process. It is not permissible to add additional
thinner after the coatings have been thinned to the proper consistency.

8.13 Coatings shall be applied in an even and consistent finish, free of defects
such as, but not limited to, runs, blistering, amine blush/bloom, holidays,
inadequate cure, loss of adhesion/cohesion, overspray, sags, pinholes, mud
cracks, blooming, entrapped air or solvent, spent abrasive and foreign
matter.

Any repairs to the finished coatings for any of the above defects (or any
defects not listed) that may be detrimental to the design life (minimum 10
years to first maintenance) shall be repaired at no extra cost to the principal.

Each coat within a system shall be of a contrasting colour to the subsequent

coats.

8.14 Where possible, each coating within a multi-coat coating system shall be top
coated within 24 hours of application to avoid contamination, unless
otherwise stated on the coating manufacturers product data sheet.

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8.15 Contaminated coating surfaces shall be cleaned using a suitable solvent or

non-ionic detergent and High Pressure Fresh Water.

8.16 Rollers shall not be used for applying inorganic zinc primer coating. Use of
rollers for other coatings, refer coating manufacturers PDS.

8.17 Protection of Existing Finishes

All cleaning, surface preparation and coating works shall be scheduled so
that dust, contaminates and overspray will not be deposited onto previously
painted surfaces, surfaces that are to be left unpainted or surfaces painted
by a different material or product.

8.18 Hot Dip Galvanising

All galvanising shall be carried out by the hot dipping process and conform
to the requirements of AS/NZS 4680 Hot Dipped Galvanised (Zinc)
Coating on Fabricated Ferrous Articles.

The finished galvanised coating must be adherent, continuous, smooth and

totally free of any defects which could be detrimental to the intended end
use. Zinc coatings must be free of spikes, runs and lumps. Particular
attention must be paid to the removal of excess zinc in and around bolt
holes. Dross and flux must not be adhered to or be an inclusion in the
galvanised coating.

Any repair of the galvanising must be strictly in accordance with AS/NZS

4680 - Hot Dipped Galvanised (Zinc) Coating on Fabricated Ferrous
Articles. Particular attention must be paid to the removal of excess zinc in
and around bolt holes.

All Galvanising vent relief holes on rectangular hollow sections, circular

hollow sections, square hollow sections or box beam members are to be
plugged (with an approved metal composite putty) and sealed unless noted
otherwise on the drawings or approved in writing by the principal or its
representative. Once vent holes have been plugged all vent holes must be
sanded flush and coated as per AS/NZS 4680.

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9. Acceptance Criteria & Treatment of Defective Work

9.1 General

The field testing/inspection procedures detailed in this section shall be used by the
Contractor to establish compliance with this Specification. Other tests as determined
by CBH may be performed as required. Surface treatment found to be defective shall
be re-instated in accordance with this Specification at no cost to CBH.

9.2 Surface Contaminants

The presence of soluble salts on the surface of freshly blasted steel shall be
determined in accordance with the procedure(s) detailed in AS/NZS 3894.6. A
2
chloride result higher than 50mg/m (or figure determined by the applicable paint
manufacturer) shall have further high pressure fresh water washing (with potable
2
water) of the affected surface and re-blasting until the result is less than 50mg/m , to
remove flash rusting corrosion products prior to coating.

Coating to be over coated shall be tested for dust and spent abrasive as determined
in accordance with the procedure detailed in AS/NZS 3894.6, by pressing a wide,
clear adhesive 1580 tape onto the upper surfaces of suspect areas. Contaminants
shall be clearly seen when the tape is removed and placed against a dark/light
background. Affected surfaces with a rating of above 0 - 1, shall be blown down
using filtered compressed air and retested using the tape. If contamination is still
present, the surfaces shall be high pressure fresh water washed until clean.

9.3 Surface Profile

Surface profile shall be within the range of 35-65 microns (average 50 microns).
Blasted steel with non-conforming profile values shall be re-blasted with suitably
graded abrasive to ensure compliance with this Specification (surface profiles within
the coating manufacturers data sheets recommendations may also be accepted at
the discretion of the Principal or its representative).

The Contractor shall take records of typical daily surface profile values using replica
tape such as Testex Press-O-Film Replication Tape in accordance with the
procedure detailed in AS/NZS 3894.5 Method A. Replica tape records shall be affixed
to the Daily Inspection Report form as detailed in AS/NZS 3894.10.

9.4 Wet Film Thickness (WFT) Measurements

Contractors shall be capable of calculating the % volume solids reduction for different
thinning ratios. Frequent monitoring of the WFT shall be done by the contractor to
achieve the specified DFT.

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9.5 Dry Film Thickness (DFT) Measurements

DFT readings shall be taken according to AS3894.3

High DFT readings (above 150% of maximum specified DFT per coat) shall
require complete removal at the discretion of CBH. The minimum thickness
stated in this specification is the absolute minimum. Any readings found to
be below the specified minimum are to be repaired at no cost to CBH.

9.6 Cure State

Solvent Borne Inorganic Zinc Silicate and appropriate Organic coatings shall
be tested for cure in accordance with procedures detailed in AS/NZS 3894.4
Method C Rub Test. Discolouration of the test rag shall be considered
evidence of insufficient cure. Coating which does not exhibit a cure trend
consistent with the Coating manufacturers cure information, (allow for
temperature differences) shall be removed and re-instated in accordance
with this Specification at no cost to CBH.

9.7 Adhesion Testing

Each coat within a System may be tested for adhesion at CBHs discretion
and by the Contractors Quality Control representative. The areas tested
shall be representative of the total coated section.

The adhesive test described in AS1580 Method 408.2 shall be used for field
testing within the coating process (i.e. daily or before the application of
subsequent coats) at the discretion of CBH or its nominated representative.
For coatings 125 microns and above, this simple test requires an X (with
the intersecting cut at approximately 30o) to be cut using a sharp Stanley
blade through to the substrate.

For coatings 50-125 microns, the cross hatch method is required. 6 cuts,
2mm apart.

Coatings less than 50 microns, the cross hatch is 11 cuts 1mm apart.

The adhesive test results shall be graded and recorded as detailed in

AS1580.408.2 Table 1.

Coatings with unacceptable adhesion test results shall be removed and

reinstated at no cost to CBH.

All completed coatings or disputed results, shall have adhesion testing

conducted with an Elcometer 106 or similar approved adhesion device in
accordance with AS1580 Method 408.5. Minimum acceptable adhesion
values shall be:
System of - SB-IZS Primer and Topcoats (one pack) 2MPa (290PSI)
System of - HB Epoxy Primers, HB Epoxy and Topcoats 3MPa
(435PSI)
System of - HB/HS Epoxy 4 MPa (580 PSI)
The Contractor shall spot repair all areas subject to adhesion testing at no
cost to CBH.

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9.8 Holiday Testing

All coatings exposed to immersion, buried or marine conditions (definitions

of a marine environment are a category D or E as described in AS 2312)
shall be tested using an Elcometer High/Low Voltage Holiday Detector
device or approved similar. Test voltages and procedures shall be in
accordance with AS/NZS 3894.1/ AS/NZS 3894.2. Defects such as
pinholes, cracks, blisters, voids, foreign inclusions and rogue profile peaks
shall be marked for repair and retested upon full cure of the repair coating.

Any discontinuitys identified, shall be repaired and retested allowing

sufficient cure periods between testing. Any repairs/areas that fail a retest
shall be removed and reinstated (at the discretion of the Principal or its
representative) in accordance with section 10.0 of this specification.

Coatings with 5 or more defects per 5m2 section, or where the defective
area is equal to 20% or more of the total coated surface, shall be rejected
outright. Defective coating shall be removed and be reinstated in
accordance with this Specification at no cost to CBH.

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10. Maintenance Coating Repair Procedure

10.1 All paint delivered to site for touch-up works shall be in the original sealed containers,
properly labelled with the name of the manufacturer and the description of the
contents. Paint shall be stored in accordance with the coating manufacturers
instructions.

10.2 As a general rule, coating repairs shall be performed using the specified surface
preparation and coating system. The coating manufacturers specific repair
procedures shall be adopted where the maximum re-coat period has expired. SB
Inorganic Zinc Rich Ethyl Silicate coatings shall be repaired as per manufacturers
recommendations. Epoxy Zinc Rich may only be used for small areas with CBH
approval.

10.3 Unless approved by CBH, power wire brushing, grinding, sanding or needle gun shall
2
not be acceptable for the spot repair of defective surfaces exceeding 0.5m .

10.4 Surface preparation on site shall not be carried out in wet or excessively hot, humid
(85%) or windy conditions or in the presence of water spray or any other potential
contaminants.

All areas to be repaired shall be taken back to bare metal using abrasive blast or
hand tool preparation to a standard required by the coating manufacturer of the
coating being applied.

Surface preparation shall extend 50 mm over each coat in the coating system to
feather and expose the sub-coating.

All existing sound coatings shall be lightly abraded to remove any surface
contamination and to provide adequate anchor for the new coating to sufficiently
adhere too.

All surfaces in the repair area (base metal exposed, feathered areas or lightly
abraded/whip blasted) shall be high pressure cleaned with potable water to remove
any deposited or entrapped contaminants. The surface shall be tested to the
manufactures requirements for the new coating. Should the threshold values be
exceeded, then high pressure washing will continue until the concentrations of
containments fall below the required threshold.

The new coating shall be applied according to the manufacturers specification. No

hard line shall be present where the new coating meets existing coating.

10.5 The required coating DFTs shall be achieved according to the manufacturers
specification. The final DFTs shall be included in the Contractors Daily Paint Reports.

All repaired areas and repair procedures shall be clearly detailed in the Contractors
Daily Paint Reports.

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11. Handling & Transport

11.1 All steelwork and equipment that has been finished coated shall be handled with care
so as to preserve the coating in the best possible condition. Steelwork shall not be
handled until the coating has completely cured and dried hard.

11.2 All steelwork and equipment shall be adequately protected and prepared for
transport, including loading, protected from securing methods and protected while
unloading. Material such as soft slings and soft protective wrapping is to be used.

12. Safe Work Practices on site

12.1 All Contractor personnel performing work on Site are required to satisfactorily attend
the CBH Site Safety Course and shall observe all Site safety rules while on Site (refer
CBH General Safety Rules Handbook). When directed by CBH the Contractor shall
provide a Job Safety Analysis (JSA) to be approved by CBH before the
commencement of any work.

12.2 All safety, lost time or near miss incidents shall be reported to CBH. Failure to report
safety incidents may, at the discretion of CBH, result in the termination of the
Contract.

12.3 Contractor and Sub-Contractor supplied equipment or services such as, but not
limited to, scaffolding, access equipment, cranage, pressure vessels, electric and
pneumatic equipment shall conform to all the appropriate statutory regulations. All
equipment used on Site shall be maintained in good working order in strict
accordance with the Coating manufacturers guidelines and be fit for purpose.

12.4 Personal Protective Equipment such as protective clothing, safety helmets, safety
glasses, safety boots, hearing protection, respiratory equipment and skin protection
shall be supplied by the Contractor. Eye wash solution must be available at the work
site.

12.5 Material Safety Data Sheets for all materials used shall be readily available at the
work Site for quick reference. Personal safety equipment guidelines shall be strictly
observed.

12.6 Abrasive blast cleaning shall be performed in accordance with the current statutory
regulations and requirements. Dead-man devices shall be correctly fitted and
operational on all abrasive blasting equipment used on site.

12.7 Work areas shall be suitably roped off or isolated and clearly marked Abrasive
Blasting in Progress or Painting in Progress, as appropriate.
o
12.8 All coatings and thinners shall be stored below 30 C in a well ventilated and safe
storage container appropriately signed and away from any ignition source.

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12.9 Abrasive blast hoses and airless spray lines shall be capable of conducting static
electricity to earth. Airless spray pump motors shall be fitted with an effective
earthing cable.

12.10 Safety harnesses and appropriate height safety equipment shall be utilised at all
elevated work sites not scaffolded to statutory regulation standards. Personnel
working on elevated work platforms (EWP) or using height safety equipment shall
be appropriately trained and certified.

12.11 Effective exhaust fans shall be used when applying coatings in confined spaces.
The exhausting equipment shall be of sufficient capacity to ensure the solvent
vapour/air concentration does not reach the Lower Explosive Limit value.

When applying coatings in confined areas, the Contractor shall provide and
understand the use of equipment used to monitor air quality. Sentries are required
for all Confined Space Entry and all personnel are to be certified in Confined Space.

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