STANDARD TECHNICAL SPECIFICATIONS FOR ELECTRIC WORKS

CORROSION PROTECTION

( SPECIFICATION )

411837908.doc Page 1 of 23
 CORROSION PROTECTION

ADDC/AADC STANDARD : 411837908.DOC

411837908.doc Page 2 of 23
 CORROSION PROTECTION

CONTENTS

STANDARD TECHNICAL SPECIFICATIONS FOR ELECTRIC WORKS.............................1

1 GENERAL......................................................................................................................3
1.1 Site Conditions.................................................................................................................3
2 APPLICABLE CODES AND STANDARDS................................................................4
2.1 Abbreviations and Definitions..........................................................................................4
2.2 ADDC/AADC Codes........................................................................................................4
2.3 Applicable Standards........................................................................................................4
3 RESPONSIBILITIES AND GUARANTEES...............................................................5
4 SAFETY PRECAUTIONS.............................................................................................6
5 MATERIALS..................................................................................................................7
6 GALVANISED STEEL SURFACES..............................................................................8
7 PAINTING AT MANUFACTURER‘S PREMISES.....................................................9
8 REPAIR PROCEDURES.............................................................................................10
8.1 Immersion Conditions.....................................................................................................10
8.2 Exposure Conditions.......................................................................................................10
9 PERFORMANCE AND APPLICATION OF PAINTS..............................................10
9.1 General Requirements.....................................................................................................10
9.2 Inspection During Guarantee..........................................................................................11
10 SURFACE PREPARATION AND PAINTING...........................................................12
10.1 Cleaning and Surface Preparation of Ferrous and Non Ferrous Surfaces........................12
10.2 Application - Brush or Roller..........................................................................................12
10.3 Application Airless Spray...............................................................................................12
10.4 Painting on Metal Surfaces (other than galvanized)........................................................12
10.4.1 General...........................................................................................................................12
10.4.2 Paint System...................................................................................................................13
10.5 Painting of Transformer and Reactor Tanks, other Tanks, etc........................................14
10.5.1 External Surfaces of Transformer/Reactor Tank, Covers, OLTC Head, Control Cabinets,
Cooling Equipment, Access Ladders, etc.)......................................................................14
10.5.2 Internal Surfaces of Transformer/Reactor Tank, Cover, Core Steel Plates, etc.).............15
10.6 Painting of Oil Chamber of Oil Separators.....................................................................16
10.7 Painting of Dry-Type Distribution Transformers and their Housings, Pre-Fabricated
MV Switchgear Housing, Cubicles, Panel, etc................................................................16
10.8 Painting of Fuel Tank for Diesel Generator.....................................................................16
10.8.1 Outside Surface...............................................................................................................16
10.8.2 Inner Surface...................................................................................................................17
10.9 Painting on Galvanized Steel Surfaces............................................................................17
10.10 Painting of Galvanized Towers and Galvanized Outdoor Steel Structures......................18
10.11 Painting of Stub Angles and Pile Caps............................................................................18

411837908.doc Page 3 of 23
 CORROSION PROTECTION

411837908.doc Page 4 of 23
 CORROSION PROTECTION

CORROSION PROTECTION

1 GENERAL
This specification generally covers surface protections against corrosion and defines the
minimum requirements for surface preparation/treatment, protective coatings and painting for
structural steel, iron works, metal and other non-metallic surfaces.
The following shall be applicable and shall be considered:
a) All metallic parts (except stainless steel parts) used inside closed rooms shall be painted or
galvanised.
b) All metallic parts used outdoor shall be galvanized and painted.
c) Zink and paints and related protection material shall be in accordance with the latest
international standards as a minimum requirement, and shall comply with the requirements of
proper health, safety, and environmental conditions.
d) Equipment to be used for performing the required galvanizing or painting, should be
equivalent to the equipment recommended by the paint manufacturer and should be suitable
to apply the coating as specified.
e) Painting materials shall be delivered to locations where painting is to be carried out, in
unopened original containers, which shall bear a legible product designation, batch number,
date of manufacture and expiry date. The date of manufacture must not be before the date of
paint system approval.
f) Only complete paint kits shall be mixed. No partial kits will be accepted. Surplus Paint in
Pots of expired mixed material must not be used after the expiry date of these materials.
g) The painting material shall be handled and stored in accordance with the paint
manufacturer’s latest published instructions and shall be protected against damage, moisture,
direct sunlight and temperatures.
h) Storage temperature of paint shall range between 5oC and 35oC.
i) Compressed air used for cleaning, surface preparation (abrasive blasting) and application
shall be free of oil and moisture.
j) Blasting material shall be clean and free from oil or contaminants. The particle size shall be
capable of achieving specified surface profile.

1.1 Site Conditions

For site requirements, reference shall be made to the Standard Technical Specification, Part:
 S-AA-GEN-GDF - General Conditions

411837908.doc Page 5 of 23
 CORROSION PROTECTION

411837908.doc Page 6 of 23
 CORROSION PROTECTION

2 APPLICABLE CODES AND STANDARDS

2.1 Abbreviations and Definitions

 ASTM - American Society for Testing and Materials
 BS - British Standards
 DIN - German Industrial Standards
 EIA/TIA - Electronic Industries Association/Telecommunication Industries
Association
 EN - European Standard
 IEEE - Institute of Electrical & Electronic Engineers
 IEC - International Electrotechnical Commission
 ISO - International Standard Organisation
 ITU-T - International Telecommunication Union Telecommunication Standardisation
Sector of ITU
 RAL - German Institute for Quality Assurance and Certification e.V.
 SIS - Swedish Standards
 VDE - German Association of Electrical, Electronic & Information Technologies

2.2 ADDC/AADC Codes

The following national codes shall be obligatory binding for design and operation of any
auxiliary equipment as applicable:
 The Electricity Distribution Code (Abu Dhabi Distribution Company, Al Ain Distribution
Company)
 The safety rules are specified in the following part of the Standard Technical Specification.
 S-AA-GEN-SQA - Safety and Quality

2.3 Applicable Standards

The corrosion protection components to be provided under this Specification shall, in general, be
manufactured under quality assurance system conforming to the latest issues of ISO or its
equivalent National Standard.
The latest Revisions or Editions of the following Standards as well as their direct and subsequent
‘Normative References shall be applicable.

411837908.doc Page 7 of 23
 CORROSION PROTECTION

ASTM 123 Zinc (hot-dip galvanised) coating on Iron & steel products
ASTM A165 Specifications for Electrodeposited Coatings of Cadmium on Steel
ASTM A386 Specifications for Zinc Coating (Hot Dip) on Assembled Steel Products
ASTM A525 Specifications for General Requirements, Steel Sheet, Zinc Coated
(Galvanised) by the Hot Dip process
ASTM 8633 Specifications for Electrodeposited coatings of Zinc on Iron and Steel
ISO 4578 Adhesives – Determination of peel resistance of high strength adhesive bonds
>Floating-Roller method<
ISO 4624 Paints and varnishes >Pull-Off test for adhesion<
ISO 4628-1 Paints and varnishes – Evaluation of degradation of coatings – Designation of
quantity and size of defects, and of intensity of uniform changes in
appearance >Part 1: General introduction and designation system<
ISO 4628-2 Paints and varnishes – Evaluation of degradation of coatings – Designation of
quantity and size of defects, and of intensity of uniform changes in
appearance >Part 2: Assessment of degree of blistering<
DIN 55928 Protective painting of steel structures – instructions
DIN 55945 Painting materials
DIN 18363 Paint work – buildings
DIN 18364 Surface protection work for steel
DIN 53210 Determination of rust degree
DIN 55151 Determination of adhesion
SIS 05 5900 Surface cleaning
BS EN 1461

3 RESPONSIBILITIES AND GUARANTEES

ADDC/AADC shall have the right to access at all times for inspection of the work and all
pertinent materials during preparation and progress of the work. Should any work or material be
found to be defective or not in compliance with the Specification, replacements by the
Bidder/Contractor at his own cost must be carried out.
Inspection of coatings by ADDC/AADC shall neither relieve the paint manufacturer from his
responsibility of providing good quality products nor the Bidder/Contractor from his
responsibility of acquiring the specified quality of material or the correct performance of the
work. This is also applicable to shop-primed structural steel or other components.

411837908.doc Page 8 of 23
 CORROSION PROTECTION

All materials shall be protected against corrosion and damage due to the influence of the
prevailing climatic conditions including the incidence of dust, sandstorms and seawater spray.
The Bidder/Contractor shall bear the responsibility for all losses and damages, which may, occur
through inadequate measures against such influences and shall replace the damaged parts at his
cost.
The Bidder/Contractor shall bear the full responsibility for galvanizing and paint applied by him
or by others.
The complete painting and corrosion protection system is guaranteed for a period of not less than
5 years after the Final Acceptance Certificate.
The Bidder/Contractor shall provide a Guarantee Performance Bond to assure the performance
of extended guarantee obligations for corrosion protection. The Bidder/Contractor (after FAC)
shall carry out during the extended guarantee period any repair or replacement on the corrosion
protection executed under this specification at no additional cost after being intimated by
ADDC/AADC.
If the repairs are not carried out to the satisfaction of ADDC/AADC, these repairs shall be
performed by others, who will be assigned by ADDC/AADC, and the costs thereof shall be
borne by activating the Performance Bond valid for the extended guarantee obligations.

4 SAFETY PRECAUTIONS
All painting and corrosion protection works shall be performed under strict safety conditions,
primarily adequate ventilation and protection from open flames, spark and excessive heat.
The Bidder/Contractor shall take all necessary precautions to protect personnel and property
from hazards due to falls, injuries, toxic fumes, fires, explosions or other dangers.
All paint and thinners shall be stored in areas, which are well ventilated and protected. The
Bidder/Contractor shall consider air-conditioned storage facilities due to the limited store-ability
of the paints required.
Temporary constructions, ladders scaffolding, runways, etc. required for safe execution of the
painting work shall be rigidly built so as to safely support four times the weight of all materials,
apparatus, equipment and workers thereon.
Test Instruments
The surface preparations for steel iron works shall be compared with the relevant pictures of SIS
05 5900. The surface profile shall be measured by using a Profilometer, i.e. Tester Tape.
If required by ADDC/AADC/ENGINEER copper sulfate test shall be carried out to check for
residual mill scales.

411837908.doc Page 9 of 23
 CORROSION PROTECTION

The dry film thickness or galvanization thickness on steel shall be measured by means of a
magnetic or electrical thickness gauge such as "Microtester" or "Elcometer", and recorded in a
tabulated form, indicating each layer of coat and the total dry film thickness.
In case of fluid retaining structures, pinhole detection shall be carried out by means of low-
voltage, non-destructive flow detector, whereas, in the case of rubber lining or wrapping,
damages shall be checked by means of a spark tester.
During application of paint the wet film thickness shall be checked continuously by means of an
approved wet film thickness gauge. Also, the dew point has to be monitored continuously by
through an approved instrument and methods of measurements/ recording.
A pull-off adhesion test must be used in case of paint on concrete and steel surfaces.
An approved type of multi-cross cutter for adhesion tests depending on the thickness of the
coating is also required.
For the above mentioned tests which shall be performed in the presence of ADDC/AADC, all
respective instruments shall be provided by the Bidder/Contractor, and shall be kept in good
working condition and valid/certified calibration.

5 MATERIALS
The materials of successive coats shall be from the same manufacturer and subject to
ADDC/AADC’s approval before relevant orders are placed.
Materials shall be used from a manufacturer who has good experience with his products with
regard to corrosion protection in such special areas. Further reference for supply of samples is
made hereafter.
Materials, which are to be supplied and used for the surface protection work (e.g. paints, filling
cements, metallic coating etc.,) must comply with quality regulations and standards, as well as
with the following provisions and any special permit conditions and official regulations. Should
a certain material, stipulated in the Specification, not possible to get during the design/execution
of the paint system, it shall be possible subject to an approval by ADDC/AADC, to use an
alternative material that can be proven to be at least equal in quality and suitability.
The Bidder/Contractor shall obtain the paint manufacturer's specific recommendations,
directions and specific provisions for application. These recommendations and directions shall be
strictly adhered to. The use of any amount of thinners is restricted to the permission of
ADDC/AADC and paint manufacturer.
All paints shall be delivered in their original undamaged sealed containers and shall remain
unopened until required for use. Paint, which has gelled or otherwise deteriorated over the
storage period, shall not be used.
The quality of the paints should be such that they do not form solid sediment but, at most, a
slight skin in unopened original containers over a period of not less than six months calculated

411837908.doc Page 10 of 23
 CORROSION PROTECTION

from the manufactures delivery date. A paint which has formed a solid sediment or more than
just a slight skin in the unopened original containers by the time of use or which cannot be
processed satisfactorily shall not be used. A sediment shall be regarded as solid if it cannot be
dispelled again quickly and completely by stirring with an adequate electric driven mixer
(maximum speed 350 to 400 rpm).
Paint that does not have to be prepared by mixing several constituents should be delivered to the
site, just prior to use, in such a state of readiness that they need only be adjusted to brushing or
spraying consistency. This is to meet the relevant working conditions, such as temperature, by
adding the particular thinners as per the manufacturer instructions, which shall be subject to
ADDC/AADC approval.
In the case of paints, which are only prepared for use immediately before application by mixing
several constituents (e.g. multi-constituent types), the various constituents should be of such a
kind that mixing at site is restricted to the necessary extent.
Paints and filling cements selected for the protection of steel or aluminium alloys against
corrosion, for which no regulations, permit conditions or technical conditions of delivery exist,
may be used if proven suitable, by the Bidder/Contractor, for the necessary degree of protection
against corrosion, and after approval of ADDC/AADC.

6 GALVANISED STEEL SURFACES

This article defines the minimum requirements for galvanizing as well as for surface cleaning
and preparation of galvanized steel surfaces prior to application of protective coating.
All galvanizing is to be done by the hot-dip process with spelter, not less then 98% of which
must be pure Zinc. No alternative process to be used without the approval of ADDC/AADC. No
components are to be galvanized which are likely to come into subsequent contact with oil. Bolts
are to be completely hot-dip galvanized including the threads.
The zinc coating is to be uniform, clean, smooth and as free from sponge as possible. All
galvanized items are to be protected from injury to the Zinc coating due to abrasion damage
during periods of transit, storage and erection. Damaged areas at the coating are to be repaired
with the Zinc rich paint or hot Zinc-spray or other approved flake metallic compounds according
to relevant Standards.
The galvanizing procedure shall be started only after having finished all chipping, trimming,
fitting and bending. Also, all drilling, punching, cutting and welding shall have been completed
and all burns removed.
All steel, including bolts, nuts and washers, shall be galvanized at the manufacturer’s premises
by means of hot dipping in accordance with internationally recognized standards such as ASTM
A 239, or equivalent. The Zinc coat applied shall conform to ASTM A-123, minimum thickness
grade 85 and higher (see table 2, ASTM A 123-89a).

411837908.doc Page 11 of 23
 CORROSION PROTECTION

Adhesion tests outlined in Article 7.4.2, ASTM A 123-84, shall be performed, at the discretion of
ADDC/AADC.
Where members are of such length that they cannot be dipped in one operation, great care shall
be exercised to prevent wrapping. All holes in material shall be free of excess spelter after
galvanizing. All material shall be safeguarded against embrittlement during galvanizing. The
Zinc coating shall be uniform in thickness and so applied that it will adhere to the surface of the
steel.
Major damage to galvanizing shall be cause for rejection. Material on which galvanizing has
been damaged shall be re-dipped unless the damage is minor and local then it can be repaired by,
simply, applying galvanizing repair paint or hot zinc spray to the satisfaction of ADDC/AADC.
For protection during transport and erection, all galvanized steel members shall be coated with a
suitable pre-primer with minimum thickness of 40 micron and matching the primer to be applied
after erection. The primer shall be subject to ADDC/AADC’s approval.
If not otherwise specified, galvanized steel surfaces shall be chromated with approximately 4-
micron thickness and shall be removed by suitable means prior to painting.
Single items such as cable trays, fences, etc. shall be galvanized, and PVC covered if so
approved by ADDC/AADC.

7 PAINTING AT MANUFACTURER‘S PREMISES

The painting at works is for the purpose of applying priming coat systems under favorable
conditions and with rational methods and to protect the surface against corrosion with suitable
painting protective coating system.
Painting Systems are chosen according to the required resistance to aggressive agents and are
applicable to all surfaces under the prevailing conditions. Exceptions determined by
technological conditions or by the specifications of the manufacturers of equipment shall be
subject to ADDC/AADC's approval.
All metal surfaces such as for switch-gear, cubicles and panels, structures and supports, casings,
enclosures, frames and sub-frames, etc. i.e. all equipment or parts thereof incorporated in the
work, shall be chemically pre-treated and shall be free from Zinc-Oxide. This suggests the
following treatment to be carried out:
 Steel treated by : Zinc-Phosphate
 Aluminium treated by : Chromating
 Other materials treated adequately : Treated
which shall be followed by a coating system (preferably powder coating) with good resistance to
impact/abrasion and adhesion to the substrate.
The applied dry film shall be of an approved quality of corrosion paint.

411837908.doc Page 12 of 23
 CORROSION PROTECTION

Extra amounts of paint sufficient for all repairs shall be made available and shall be applied to all
surfaces after erection and before commissioning of equipment, if so required.
The final coat shall preferably comply with code RAL 7032 "Grey" or as directed or otherwise
approved by ADDC/AADC.
In any case, at an early stage the Bidder/Contractor shall explain, in great detail, all corrosion
protection measures he intends to take, indicate the relevant standards for testing the applied
measures, and apply for ADDC/AADC's approval of the above mentioned steps.
The workshop priming coats are to be tested and faults repaired according to the specifications
before applying further coats of paint.
Steel parts, which are to be welded at site, shall be free from workshop coats along the welding
seams, the width of the free strip being approximately 5 cm.
Workshop priming coats applied shall be of rust preventing material, which depends on the
intended use and on the length of time until the final protection is applied. Should the protection
coat show signs of damage, repairs should be made in good time. Shop primers applied for
transportation/storage purposes shall be removed at site by shot blasting and the full coating
system shall then be applied.

8 REPAIR PROCEDURES

8.1 Immersion Conditions

The necessary touch-up shall be performed by sand blasting (Vacuum blasting preferable) the
defective area to SA2.5 of SIS 05 5900. The edge of the paint sound shall be feathered by
grinding, or use of emery paper, and allowance for overlapping shall be taken in consideration.
Painting will then proceed in accordance with the original paint specified.

8.2 Exposure Conditions

Depending on the extent of damage, either blasting or grinding or brushing the defective area
may be allowed. Feather down the sound paint allowing for overlapping and then proceed in
accordance with the original paints specified.

9 PERFORMANCE AND APPLICATION OF PAINTS

9.1 General Requirements

For better adhesion and corrosion protection, priming coats shall be applied by brush or by
airless spray only. The other coats of paint are to be applied in accordance with the paint
manufacturers' recommendations.
All surfaces to be painted must be moisture-free and painting shall not take place when:

411837908.doc Page 13 of 23
 CORROSION PROTECTION

 The surface temperature is above 50oC

 The relative humidity is above 85 % or the surface temperature is closer than 3oC or below
the dew point
 It is raining
 Sandstorms occur to such extend that the wet paint might be affected.
If during the painting work, low temperatures, excessive humidity, mist or rain occur, the paint
shall first be allowed to dry, and areas, which have been damaged due to the above conditions
must then be removed and renewed.
Great care must be taken to ensure that paint is applied to all surfaces including unused bolt
holes and back-to-back members (where possible). This includes surfaces at joints, plates, etc.
Application shall be performed only by use of approved "strike-brushes" or as directed by
ADDC/AADC or by the manufacturer's recommendation.
Paints shall only be applied on clean dry surfaces after the approval of ADDC/AADC and shall
commence within four hours after cleaning, if not otherwise approved. All material shall be
evenly applied so as to be free from runs, sags, laps, skips, tears, blisters or other defects. All
finishes shall be clean and in good sound condition. Each coat shall completely and uniformly
cover the coat underneath it.
Excessive coat thickness shall not exceed the maximum specified by the paint manufacturer.
There must be no delay between the application of successive coats but each coat must be
thoroughly dry or as directed in the paint instructions before the next coat is applied.
Before additional coats are applied to painted surfaces, the existing paint shall be cleaned from
all foreign matters and then suitably sanded, if necessary, according to directions given by the
paint manufacturer and subject to approval of ADDC/AADC.
The individual layers of paint are to be shaded down in such a way that it can easily be seen if
the underlaying surface is completely covered with paint and which paint layer of the whole
system is involved. If coats of paint are interrupted, (e.g. for welding, test marks, etc.) a margin
of approximately 5 cm is to be left untouched in order to obtain a satisfactory sequence and
overlapping of layers.
Before every coat of paint the surface is to be cleaned and damages in previously applied coats
are to be corrected in accordance with the relevant paint specifications.
Every coat of paint shall have a thickness as even as possible. It must not be, in any place, lower
than the specified minimum thickness. Too big thickness is not recommended, and adherence to
the manufacturers maximum coat thickness shall be observed.
All finishes shall be in clean, good and sound condition and kept clean and dry until the paint has
reached a hard setting. Completed surfaces, which do not meet the levels, as set forth in these
Specifications, shall be re-coated at the cost of the Bidder/Contractor.

411837908.doc Page 14 of 23
 CORROSION PROTECTION

To ensure the suitability of paints the Bidder/Contractor shall execute sample tests at site. Such
panels must be approved and shall be used as reference for quality control.
These tests shall be carried out at a very early stage of the contract period and no paint shall be
ordered beforehand. Final selection of the paint is subject to the approval of ADDC/AADC,
depending on the results of the above mentioned site tests.

9.2 Inspection During Guarantee

The entire work of painting and corrosion protection is to be inspected by ADDC/AADC at the
following periods:
 Before the Final Acceptance Certificate is issued
 The second Inspection two years later
 The third Inspection four years after the date of Final Acceptance Certificate
 The final inspection at the end of the five years guarantee period.
Limits of Failure
During guarantee all coatings on surfaces in direct contact with fluids shall be free from defects
such as pinholes, blisters, loss of adhesion, peeling, etc. They shall have during the guarantee
period a degree of rust within the range R-O to R-1 according to DIN 53 210 or its equivalent.
Surfaces under atmospheric corrosion shall be repaired and /or painted if their rust degree falls
within the range R-2 and R-3 according to DIN 53 210 or its equivalent.

10 SURFACE PREPARATION AND PAINTING

10.1 Cleaning and Surface Preparation of Ferrous and Non Ferrous Surfaces
Surfaces shall be cleaned and prepared for painting in accordance with the following regulations
and specifications:
 Chemical cleaning and surface preparation/etching
 Mechanical hand cleaning according to SIS 05 5900
 Blast cleaning of steel surfaces with abrasive as approved by ADDC/AADC and according
to SIS 05 5900 SA2.5 or SA3 or equivalent.
Aluminum and other light metals shall have their surfaces cleaned and degreased by a detergent
such as trichloroethylene prior to painting. A one coat of a wash-primer shall be applied before
proceeding with the specified coating system. Wash-primer shall be applied in a very thin film (5
- 10 microns) direct on pre-treated surfaces.

411837908.doc Page 15 of 23
 CORROSION PROTECTION

10.2 Application - Brush or Roller

Round or oval brushes are the most suitable for irregular surfaces as well as for rough steel. In
gaps or areas difficult to reach, smaller and specially shaped brushes or spraying shall be used.
The paint shall be applied with an even thickness. All kinds of brush trace, runs, and other
defects are to be avoided and if necessary reconditioned.
Rollers are suitable for large surfaces. The applied film must be as smooth as possible and of a
uniform dry film thickness. Sprinkling of the paint and subsequent spreading out by means of the
roller is prohibited.

10.3 Application Airless Spray

The equipment for this system must enable a satisfactory application of paint material. With the
airless system it must be taken into consideration that the equipment is laid out in such a way as
to obtain the required spraying pressure, that the nozzle size corresponds to the recommendation
of the paint manufacturer, and that the spray angle is adjusted to the requirements of the surfaces
to be painted.
The paint must be continuously mixed, and sprayed on evenly cross process (in two directions at
90° angle) whereby the individual layers shall overlap. The spray gun shall always be held
perpendicular to the surface to be sprayed, at such a distance that the paint reaches the surface
when still moist.

10.4 Painting on Metal Surfaces (other than galvanized)

10.4.1 General
This article covers, besides the painting of work fabricated at site, also repair painting of
damaged surfaces originally corrosion protected at the manufacturer's premises.
For general performance and application under local climate conditions, reference is made to
Standard Technical Specification, Part:
 S-AA-GEN-GDF - General Conditions

All surfaces shall be carefully dried and cleaned prior to painting; in particular, removal of all
foreign matters such as salt, grease, dust, sand, dirt, and rust (if applicable) is of utmost
importance. Sand blasting to SA2.5.

10.4.2 Paint System

10.4.2.1 Steel Surfaces (inside buildings) Subject to Approval of ADDC/AADC

Zinc rich epoxy primer m 40 - 60

411837908.doc Page 16 of 23
 CORROSION PROTECTION

Epoxy intermediate (MIO) m 80 - 100

Epoxy final m 40 - 60
Total m 160 - 220

10.4.2.2 Externally located away from Coast Line

Zinc rich epoxy primer m 40 - 60
Epoxy intermediate (MIO) m 60 - 100
Final aliphatic polyurethane or acrylic epoxy m 40 - 60
Total m 140 - 220

10.4.2.3 Externally Located Near Coast Line

Zinc rich primer with 92% or more Zn content in m 60 - 80
the dry film
Epoxy intermediate (MIO) m 60 - 80
Final aliphatic polyurethane m 60 - 80
Total m 180 - 240

10.4.2.4 Aluminium Surfaces

If anodized Aluminium, care must be taken not to damage the anodized layer and a suitable pre-
treatment must be used.
For unanodized Aluminium, one of the two below mentioned methods are acceptable prior to the
paint application:
1. Method
Using of t-wash or wash primer.
2. Method
Sweep blasting using a chloride free abrasive material.
Abrade for:
Polyamide Epoxy primer m 50 - 60
Aliphatic Polyurethane m 40 - 60
Total m 90 - 120

411837908.doc Page 17 of 23
 CORROSION PROTECTION

10.5 Painting of Transformer and Reactor Tanks, other Tanks, etc.

10.5.1 External Surfaces of Transformer/Reactor Tank, Covers, OLTC Head,

Control Cabinets, Cooling Equipment, Access Ladders, etc.)
All steel surfaces of solid type transformer tanks, conservators, cable boxes, etc. shall be
sand-blasted in accordance with DIN 55928, Part 4 (equivalent to SIS 055900), and all surfaces of
radiators and corrugated tank walls shall be thoroughly cleaned of rust, scale, grease and dirt and
other foreign matter and all imperfections shall be removed by means of approved methods.

Then the following painting systems shall be applied complying with the requirements as specified
below.

Solid type transformer tanks, conservators, cable boxes etc.:

One (1) primer coat

Two component epoxy zinc-phosphate or
Two-component epoxy zinc-dust m 80
One (1) intermediate coat
Two-component epoxy micaceous iron oxide m 100
One (1) top coat
Two-component polyurethane m 40
Minimum total coating thickness (dry-film, incl. tolerances) m 220

411837908.doc Page 18 of 23
 CORROSION PROTECTION

Corrugated sheet steel tanks, radiators:

One (1) primer coat

Two-component epoxy zinc-phosphate or
Two-component epoxy zinc-flake m 80
One (1) intermediate coat
Two-component epoxy micaceous iron oxide m 100
One (1) top coat
Two-component polyurethane m 40
Minimum total coating thickness (dry-film, incl. tolerances) m 220

If any hot-dip galvanised steel parts will be provided, e.g. for access ladders etc., the same
painting methods as above shall be applied. However, instead of a primer coat as specified above
one adhesive base coat shall be applied. In this case, the minimum thickness of galvanising shall
be 55 m. However, a two-component epoxy zinc-dust coat instead of hot dip galvanising is
preferred.

In case of any kind of aluminium and/or ordinary stainless steel (Cr-Ni alloyed only) the primer
coat as above may be omitted, and the minimum thickness of the “intermediate” coat and of the
top coat as specified above shall be at least 50 m each (total min.100 m).

The final coat of painting shall be non-porous and of homogeneous quality and shall be of a
uniform shade of colour code RAL 7032 (pebble-grey). For OLTC equipment and sub-supplier’s
accessories only, the colour code as per manufacturer’s standard may also be accepted, on condition
that a two-component epoxy based undercoat (minimum thickness 80 m) and a two-component
polyurethane based top coat (minimum thickness 80 m) will be applied. The total dry-film
thickness shall not be less than 160 m.

Mechanical damage of painting shall be repaired at site with the same original type of painting as
above.

10.5.2 Internal Surfaces of Transformer/Reactor Tank, Cover, Core Steel Plates, etc.)
Inside the transformer and rector vessel, sand-blasting shall be performed in accordance with
DIN 55928 Part 4 (equivalent to SIS 055900). After that, an oil-resistant insulating coating shall
be applied to all steel surfaces in contact with the oil (e.g. tank, cover, core steel plates, etc.).

411837908.doc Page 19 of 23
 CORROSION PROTECTION

The minimum dry-film thickness shall be 35 m. The applicable colour code shall be RAL 9010
(white) or equivalent.

10.6 Painting of Oil Chamber of Oil Separators

Primer Coat – Phenolic resin base coating (brushing or spraying) dry-film thickness 80 micron.
Final Coat - Phenolic resin base coating (brushing or spraying) dry-film thickness 40 micron.
A chemical resistant system based on Phenolic resin or Amine adduct hardener. (Excellent
resistance to oil and solvent) - color: white.

10.7 Painting of Dry-Type Distribution Transformers and their Housings, Pre-

Fabricated MV Switchgear Housing, Cubicles, Panel, etc.
Upon making the surfaces chemically passive, by Iron Phosphate, electrostatic coating of paint
shall be applied as follows:
External paint thickness: 70 m +/- 10 m
Interior paint thickness: 40 m +/- 10 m
The painting of the outer housings for dry type distribution transformers shall be of colour code
RAL 7032 (pebble-grey), and that for the windings dry type transformers and their structure may
be in accordance with the manufacturer’s standard. The colour codes for other housings, panels,
etc. shall be in accordance with the relevant Articles below.

10.8 Painting of Fuel Tank for Diesel Generator

The coatings specified below shall be applied for the fuel oil tanks.

10.8.1 Outside Surface

Carbon steel surfaces, not insulated, indoors, such as structural steel, cranes, air ducts, pipes,
condensers, tanks and vessels' exterior surfaces, valves and fittings, where temperatures may
reach up to 100°C.
At Works
Surface preparation : Blasting according to SIS 055900
Grade : SA 2 1/2
Primer-optional : Depending on production flow, a single-pack inorganic Ethyl, Zinc
Silicate shop-primer, which shall be possible to weld, may be used
Dry film thickness : 15-25 m
Solids by volume : min. 37%

411837908.doc Page 20 of 23
 CORROSION PROTECTION

Prime coat : Inorganic ethyl Zinc Silicate. Dry film thickness 75 microns. Solids
by volume min. 65%.
At Site
Pre-treatment : Thorough cleaning to remove oil, grease, dirt and any other
contaminants. De-rusting of all mechanical damages according to
SIS 055900
Grade : ST3
Touch-up : with 2-pack self priming aluminium containing high build epoxy
with solids by volume content of not less than 85%
Dry film thickness : 75-100 m
Finish coat : 2-pack epoxy polyamide. Dry film thickness 100 microns. Solids
by vol. min. 70%.
Minimum Total System
Dry film thickness : 175 m
Note:
When airless spray application is not possible, 2 coats of 2-pack epoxy Polyamide cured finish
may be applied by roller or brush to achieve specified thickness.

10.8.2 Inner Surface

Surface Blast-cleaning with suitable blasting-material up to SA 2 1/2 in accordance with
preparation the SVENSK STANDARD SIS 05 59 00 or DIN 55928, part 4.
Dry film
Treatment Color Compound thickness
micron
Primer binder: epoxide-/Polyamide resin
pigments: Zinc Phosphate, filler 100 *
min. Vol. Solid: 70%
Intermediate Redbrown binder: epoxide-/Polyamide Resin
Coat pigments: Zinc Phosphate, filler 100 *
min. Vol. Solid: 70%
Finish Coat Grey binder: epoxide-/Polyamide resin
pigments: Zinc Phosphate, filler 100 *
min. Vol. Solid: 70%
Total: 300
Remark: * airless application

411837908.doc Page 21 of 23
 CORROSION PROTECTION

10.9 Painting on Galvanized Steel Surfaces

Surface preparation of galvanized Steel surfaces shall be carried out in the following manner.
Prior to chemical treatment/surface preparation, the galvanized surfaces shall be carefully
cleaned by brushing with fresh water to remove all foreign matters such as salt, white rust, Zinc
Oxide and Zinc corrosion products, dust, sand and dirt. The following surface preparations shall
be performed.
Hot-dipped galvanized Steel surfaces shall be very lightly sand swept, taking in consideration
not to drastically reduce the galvanization - or chemical treatment, subject to the approval of
ADDC/AADC/ and the location of them within the plant.
Electrolytically Zinc coated Steel surfaces shall be either mechanically roughened or chemically
etched by T-wash, wash primer, etc, subject to approval of ADDC/AADC.
Prior to painting, the galvanized surfaces shall be carefully checked for damages, defects and
impurities. In case of stubborn white rust, and corrosion products it is necessary to remove these
by sweep-blasting or mechanical brushes. However, tarnishing of surfaces must be avoided.
Furthermore, in case of rusted areas, and welded seams, such areas shall be blasted to SA 2.5 and
painted with Zinc rich primer or hot Zinc spray. In specific cases where damages are severe re-
galvanizing shall be required.
Such prepared surfaces must be approved by ADDC/AADC prior to paint application.

10.10 Painting of Galvanized Towers and Galvanized Outdoor Steel Structures

Galvanised tower member parts in between bolted connections shall not be painted. The paint
might resist the short circuit current flowing from the earth wire through the tower steel structure
to the ground connection.
The following steps shall be followed after tower erection/stringing has been completed:
Degreasing and washing with fresh water
Light abrasive uniform sweep blasting or (T-wash) by phosphoric acid based primer
1 coat Epoxy (MIO) m 75
1 coat alphatic Polyurethane m 50
1 coat alphatic Polyurethane m 50
Total m 175

Inaccessible surface e.g. back to back members shall be painted prior to site erection.
In highly restricted areas, all towers and structures above specified height, application of the red
and white bands shall be in accordance with Annex 14, Aerodromes, Chapter 6, paragraph 6.2.5

411837908.doc Page 22 of 23
 CORROSION PROTECTION

of the International Standards and Recommended Practices issued by the International Civil
Aviation Organization, and shall be subject to ADDC/AADC's approval.
Galvanized structures, such as towers, supporting structures and gantries located 70 km away
from the coastal line need not to be painted unless else specified.

10.11 Painting of Stub Angles and Pile Caps

The stub angles shall be galvanized. Prior to galvanizing, all stub angles shall be sandblasted in
accordance with SA 3 (SIS 055900).
Painting should be applied in the zone 20 cm above and 50 cm below concrete level.
 1 coat of primer to be applied
 3 coats of 125 m, each to be applied, 2 pack coal tar epoxy paint
 2 coats of 2-pack coal tar epoxy paint 125 m each covering approximately 10 cm above
the concrete level and coating the foundation cap in total (including approximately 50 cm
of the vertical surfaces of the foundation) shall be applied
 After erection the intermediate and final coat as for the galvanized steel painting shall be
applied as described above up to the joint of the stub angle.
Surfaces of Steel piling caps:
 The Steel piling cases shall be sand-blasted (SA2) and treated by coal tar epoxy or any
suitable coating, etc. down to 50 cm below ground level
 The Bidder/Contractor may propose other measures to protect the stub angles from
corrosion, e.g. proposing special type of steel.

411837908.doc Page 23 of 23