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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
Construction

Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)




JO Document Number:
JO-AM-MGC-SP-203


Document Title:









MGC Revamp Project

(JO/HC125/MP12)


SPECIFICATION FOR PAINTING AND COATING
OF METAL SURFACES NEW CONSTRUCTION











A1 ISSUED FOR TENDER
ISSUE
REV
ISSUE OR REVISION
DESCRIPTION
ORIGIN BY DATE
CHECKED BY
DATE
DATE APPROVED BY DATE
Joint Operations
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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
Construction

Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)



Revision Change Details

Revision Change Description Change Location
A1 Issued for tender



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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


Contents

1 SCOPE 7
2 APPLICATION 7
3 TERMINOLOGY 7
3.1 Definitions 7
3.1.1 Abrasive 7
3.1.2 Grit 7
3.1.3 Shot 7
3.1.4 Comparator 7
3.1.5 Coat 8
3.1.6 Cure 8
3.1.7 Discontinuity (Holiday) 8
3.1.8 Dry Film Thickness 8
3.1.9 Pot-life 8
3.1.10 Rust grade (Degree of Rusting) 8
3.1.11 Atmospheric Zone 8
3.1.12 Surface Profile 8
3.2 Abbreviations 8
4 REFERENCE CODES AND STANDARDS 8
4.1 Conflicts 8
4.2 List of Standards, Codes and Specifications 9
4.2.1 National/International Standards 9
4.2.2 Painting/Coating - General 9
4.2.3 Surface Preparation 9
4.2.4 Inspection/Testing 9
4.2.5 Health and Safety 10
4.2.6 J Standards 10
5 ENVIRONMENTAL CONDITION 10
6 HEALTH, SAFETY AND ENVIRONMENT 11
6.1 General 11
6.2 Storage, Handling and Mixing Safety Precautions 11
6.2.1 Safe Storage 11
6.2.2 Manufacturer's Health/Safety Precautions 11
6.3 Safety Precautions for Blasting/Painting Equipment 11
6.4 Safety Precautions in Flammable Atmospheres 12
6.5 Safety Precautions in Confined Space 12
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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


6.6 Site Clearance & Environmental Protection 12
7 PAINTS/COATING MATERIALS 13
7.1 General 13
7.2 Approvals 13
7.3 Zinc-Rich Epoxy Primer 13
7.4 Inorganic Zinc Silicate Primer 13
7.5 Zinc Phosphate Primer 13
7.6 Mordent Solution (T-wash) Pre-treatment Primer 13
7.7 High Build Epoxy Intermediate 13
7.8 Coal Tar Epoxy Primer/lntermediate/Finish 14
7.9 Two -Pack Polyurethane Finish 14
7.10 Amine Adduct Epoxy Paint 14
7.11 "Solvent Free" High Build Epoxy Paint 14
7.12 "Zinc Free" Inorganic Silicate Finish 14
7.13 High Temperature Aluminium Silicone Finish 14
7.14 Metal Spray Coatings 14
7.15 Restriction on Using Aluminium Pigments and Metal Spray 15
8 SURFACE PREPARATION 15
8.1 General 15
8.2 Working Restrictions 15
8.2.1 Weather Conditions 15
8.2.2 Work Conditions 15
8.3 Surface Imperfections Removal 16
8.4 Surface Contaminants Removal 16
8.5 Dry Abrasive Blast Cleaning Practice 16
8.6 Blast Cleaning Standard 17
8.7 Restrictions on Alternative Techniques to Blast Cleaning 18
8.8 Power Tool Cleaning 18
8.9 Hand Tool Cleaning 18
8.10 Acid Pickling (Etching) Preparation 18
8.11 Preparation of Stainless Steels 18
8.12 Preparation of Galvanized Surfaces 19
9 PAINT/COATING APPLICATION 19
9.1 General Requirements 19
9.2 Selection of Painting/Coating System 20
9.3 Paint Mixing and Thinning 20
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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


9.4 Restrictions on Painting 20
9.4.1 Weather Conditions 20
9.4.2 Work Conditions 20
9.5 Paint Application Practice 21
9.5.1 General 21
9.5.2 Airless Spray Application 21
9.5.3 Brush Application 21
9.5.4 Roller Application 22
9.6 Priming 22
9.7 Shop Painting 22
9.7.1 Completely Fabricated Items 22
9.7.2 Partially Fabricated or Non-Fabricated ltems 22
9.8 Repair of Damages/Defects 23
10 INSPECTION AND TESTING 23
10.1 General Requirements 23
10.2 Materials and Equipment Inspection 24
10.3 Inspection/Testing Equipment 24
10.4 Environmental Conditions Testing 24
10.5 Blasted Surface Inspection Resting 24
10.5.1 Visual Inspection 24
10.5.2 Surface Profile Testing 24
10.5.3 Contaminants Free Testing 24
10.6 Painted Surface Inspection/Testing 25
10.6.1 Visual Inspection 25
10.6.2 Curing of Inorganic Zinc Silicate Primer Test 25
10.6.3 Paint Film Thickness Test 25
10.6.4 Paint Adhesion 25
10.6.5 Holiday Detection (Porosity Check) 26
11 QUALITY ASSURANCE 26
12 DOCUMENTATION 26
12.1 General 26
12.2 Work Proposal 26
12.3 Work Records/Reports 27
12.4 Final Report 27
13 PAINTING/COATING SCHEDULES 27
14 COLOUR SCHEDULE 27
15 Appendices 28
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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


Appendix 1 PAINTING RECORD/DATA SHEET 29
Appendix 2A COLOUR SCHEDULE 31
Appendix 2B COLOUR IDENTIFICATION FOR HAZARDS AND FIRE/SAFETY 32
Appendix 2C Deleted 32

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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
Construction

Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


1 SCOPE
This document is derived from KOC Standard For Painting And Coating Of Metal Surfaces
New Construction Doc. No. KOC-P-001
This Standard specifies the minimum basic requirements for surface preparation, coating
materials, method of application and inspection/testing for -protective external and where
applicable, internal painting/coating of metallic surfaces for above ground oil, gas and sea
water facilities and related utilities.
This Standard covers the painting/coating for both newly constructed onshore facilities. It
also covers the repair of defects or damages to the new painted items.
This Standard is not applicable to buried pipelines and subsea lines, decorative paints for
non-metal surfaces areas (concrete, masonry, wood, etc.), field trial of newly developed
painting/coating systems.
The internal coating of piping, pressure vessels and tanks is specified in document JOS-02-
05 Internal Coatings.
2 APPLICATION
The materials and equipment for surface preparation, paint and coating application and
inspection/testing, shall conform to the requirements of this Standard and the referenced
standards/codes mentioned herein.
Any exceptions or deviations from this Standard, along with their merits & justification, shall
be brought to the attention of JOs Controlling Department for their review, consideration
and amendment by Standards Division (if required).
Compliance with this Standard does not of itself confer immunity from legal or statutory
obligations.
3 TERMINOLOGY
3.1 Definitions
For the purposes of this Standard, the following definitions apply:-
3.1.1 Abrasive
Natural or synthetic solid material used as a medium in abrasive blast-cleaning.
3.1.2 Grit
A term used to describe the angular or irregularly shaped particles of abrasives used.
3.1.3 Shot
A term used to describe the spherically shaped panicles of abrasive used for blast cleaning.
3.1.4 Comparator
A specimen surface, or surfaces, of known average profile, representing a particular
abrasive blast-cleaning process.
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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


3.1.5 Coat
A continuous layer of a coating material that results from a single application.
3.1.6 Cure
The chemical reaction resulting in the final polymerized product in the paint/coating system.
3.1.7 Discontinuity (Holiday)
A void, crack, thin spot, foreign inclusion or contamination in the coating film that
significantly lowers the dielectric strength of the coating.
3.1.8 Dry Film Thickness
The dry film thickness of paint is the thickness of paint without solvent and is measured by
film thickness gauge & expressed in micron (1000 microns equivalent to 1mm).
3.1.9 Pot-life
The elapsed time within which a coating can be effectively applied after all components of
coating system have been thoroughly mixed.
3.1.10 Rust grade (Degree of Rusting)
Classification describing the degree of rust formation on a steel surface prior to cleaning.
3.1.11 Atmospheric Zone
The part of an offshore structure above the splash tone.
3.1.12 Surface Profile
The micro-roughness of a surface, generally expressed as the average height of the major
peaks relative to the major valleys.
3.2 Abbreviations
JO Joint Operations Wafra
CS Carbon Steel
DFT Dry Film Thickness (of Paint)
WFT Wet Film Thickness (of Paint)
MIO Micaceous Iron Oxide
RH Relative Humidity
4 REFERENCE CODES AND STANDARDS
4.1 Conflicts
In the event of conflict between this Standard and the standards/codes referenced herein,
or other contractual or purchase requirements, the most stringent requirement shall apply,
unless otherwise specified.
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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


4.2 List of Standards, Codes and Specifications
The latest edition of the following standards, codes and specifications shall apply:
4.2.1 National/International Standards
4.2.2 Painting/Coating - General
BS349 Identification of the Contents of Industrial Gas Containers
BS381C Specification for Colour for Identification, Coding and Special Purposes.
BS729 Specification for Hot-dip Galvanized Coatings on Iron and Steel Articles
BS1710 Specification for Identification of Pipelines and Services.
BS3416 Specification for Bitumen-based Coatings for Cold Application Suitable for
Use in Contact with Potable Water.
BS4800 Schedule of Paint Colours for Building Purposes.
BS5493 Code of Practice for Protective Coating on Iron and Steel Structures
against Corrosion.
BSEN 22063 Metallic and Other Inorganic Coatings. Thermal Spraying, Zinc, Aluminium
and their Alloys.
4.2.3 Surface Preparation
ASTM D2092 Guide for Treatment of Zinc-Coated (Galvanised) Steel Surfaces for
Painting.
ES 7079-A1 Specification for Rust Grades and Preparation Grades of Uncoated Steel
(ISO 8501-1) Substrate and of Steel Substrate After Overall Removal of Previous
Coatings -Visual Assessment of Surface Cleanliness.
BS 7079-D2 Preparation of Steel Substrate Before Application of Paints and Related
(IS0 8504-2) Products. Abrasive Blast Cleaning.
SIS 05 59 00 Pictorial Surface Preparation Standards for Painting Steel Surfaces.
SSPC-SP Steel Structures Painting Council Surface Preparation Specifications.
4.2.4 Inspection/Testing
ASTM Dl186 Test Method for Non-destructive Measurement of Dry Film Thickness of
Nonmagnetic Coatings Applied to a Ferrous Base.
ASTM Dl212 Test Methods for Measurement of Wet Film Thickness of Organic
Coatings.
ASTM D2697 Test Method for Volume of Non-volatile Matter in Clear or Pigmented
Coatings.
ASTM D3276 Guide for Painting Inspectors (Metal Substrates).
ASTM D3359 Test Methods for Measuring Adhesion by Tape Test
ASTM 4417 Test Methods for Field Measurements of Surface Profile of Blast Cleaned
Steel
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Doc. Title :
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


ASTM D4541 Test Method for Pull-Off Strength of Coatings Using Portable Adhesion-
Testers
BS 3900-H3 Designation of Degree of Rusting
IS0 9000 Model of Quality Assurance in Design, Development, Production,
Installation and Servicing
NACE RP01BB Discontinuity (Holiday) Testing of Protective Coatings
NACE RP0287 Surface Profile Measurements of Abrasive Blast Cleaned Steel Surface
Using a Replica Tape
SSPC-PA2 Measurement of Dry Paint Thickness with Magnetic Gauges
4.2.5 Health and Safety
API 2217 Guidelines for Confined Space Work in the Petroleum Industry
BS 5378 Safety Signs and Colours
NFPA 231 Standard for General Storage
OSHA 29 CFR 1910 Regulation, Pertaining Work in Confined Areas
4.2.6 JO Standards
-JO/AM-MGC-SP-001 Plant Design data
JOS-02-01 Piping Selection and Design
JOS-02-04 Insert Sleeves for Internally Coated Carbon Steel Pipes
JOS-02-05 Internal Coatings
4.2.7 KOC Standards
KOC-P-002 Internal Lining of Steel Tanks and Vessels Part 2. Rigid Reinforced
Fibreglass Lining
KOC P-017 Colour Coding Arrangement and Application for Piping

5 ENVIRONMENTAL CONDITION
The environment of Kuwait is severe on all plant and equipment and must be considered
carefully before selection/approval of paints and coating materials.
The ambient temperature range is -3C to + 55C. The exposed black body metal
temperature due to solar radiation is 85 C.
Humidity can pose a serious problem with long periods of relative humidity (RH) level of
100% being part of the normal weather pattern.
For other environmental conditions in Kuwait, refer to JOS-00-001 Plant Design data, which
provides the detailed design information regarding the environmental, site and utility supply
conditions prevailing throughout the JO facilities.
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Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


6 HEALTH, SAFETY AND ENVIRONMENT
6.1 General
The contractor shall employ all necessary health and safety procedures to protect
personnel and surrounding environment during on-site field works.
All relevant safety requirements of the JO Fire and Safety Regulations shall be conformed,
in particular the requirements for blasting and power tool cleaning, for scaffolding and
access platforms, for compressors and compressed air equipment for ventilation and
ventilation equipment in confined areas and for personnel protection, protective equipment
and clothing.
The contractor shall comply with the JO Fire & Safety Regulations and the Health &
Hygiene Procedures while performing the works within JO areas.
Where there is a risk of flammable atmosphere being present in a particular work area JO
may, with relevant safety authority, impose restrictions on methods of surface preparation.
Flame heating equipment shall not be used in hazardous areas.
For internal painting/coating of drinking water facilities (tanks, vessels, etc.), the contractor
shall submit evidence (Kuwait heath authority approval) that the paint system will not in any
way contaminate the water and will not affect the drinking quality of the water.
6.2 Storage, Handling and Mixing Safety Precautions
6.2.1 Safe Storage
a) All paints, coatings and thinners shall be stored in enclosed storage areas or
structures that are well-ventilated and protected from temperatures exceeding
manufacturer's recommendations, open flames, electrical discharge and direct
sunlight. Air conditioned storage areas shall be considered where excessive ambient
temperatures are expected.
b) The storage area shall be secluded and no other materials shall be stored in the
enclosed place. The enclosure shall be demarcated as NO SMOKING area strictly.
c) All paints, coatings, solvents, oil and equipment cleaners shall be stored in closed
labelled original containers.
d) Portable fire extinguishers of suitable quality and appropriate quantity shall be
provided at the storage areas and such extinguishers shall be inspected and
approved by Fire & Safety Department.
6.2.2 Manufacturer's Health/Safety Precautions
Manufacturer's health/safety precautions and procedures for mixing, handling, storage and
application of paints and coating materials shall be strictly adhered to. Safety precautions
shall be clearly described on the technical data sheet of paint and coating materials
supplied as well as on the containers.
6.3 Safety Precautions for Blasting/Painting Equipment
Blast cleaning and spray painting guns shall be earthed (spark proofing) to prevent building
up of an electrostatic charge, especially when the application is in confined work places.
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Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


All blasting equipment shall be inspected and certified by an authorised competent third
party. Pressurised hoses shall be tested and certified for maximum safe working pressure.
Hoses and other pressure items shall be checked periodically to make sure that any
damage or loss of electrical conductivity will not lead to a safety hazard.
Pressurised hose and blasting gun shall compulsorily be equipped with 'Deadman Switch'.
Suitable fire extinguishers shall be provided near the air compressor.
Enclosures shall be provided all around the area, where shot / grit blasting will be carried
out.
Clean air-mask PPE shall be worn by the technicians while blasting or spray painting.
6.4 Safety Precautions in Flammable Atmospheres
JO will advise on the area classification for both plant design and construction/
maintenance projects. Certain paint compositions shall not be used in some plant design
area classification (e.g. zone I), as it can ignite with explosive force at certain conditions
(see clause 7.15 of this Standard).
The contractor shall provide JO with all necessary material safety data sheet for the
proposed paint systems, solvents and painting procedure In order to determine area
classification for the duration of painting work.
6.5 Safety Precautions in Confined Space
All tank/vessel interiors shall be gas-free. Approval under entry permit procedure is required
before the tank/vessel can be entered.
A!I electrical equipment used including lighting equipment, ventilation equipment, high
voltage holiday testing equipment, etc., shall be grounded and suitable for the hazardous
area classification of the working areas as advised by JO. All other equipment including
ladders, tools, etc., shall be spark- proof.
The procedures for performing safe work in confined spaces shall be in accordance OSHA
29 CFR 1910 or API 2217.
6.6 Site Clearance & Environmental Protection
On completion of painting works, facilities shall be arranged by contractor for effective and
safe removal of spillage collection and disposal of paints/coating materials, brushes,
scaffolding, waste, equipment, etc. All necessary precautions shall be taken to safeguard
the surrounding environment.
For all new equipment, piping and structures, blasting and the application of primer shall be
carried out in the shop. No blasting work shall be carried out inside the operating plant.
When this is unavoidable and blasting and painting must be performed on site then
CONTRACTOR shall arrange adequate protection around the equipment to be painted so
as to not affect the adjacent facilities and shall be subjected toprior approval from JO.
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Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


7 PAINTS/COATING MATERIALS
7.1 General
All paints/coating materials shall be chemically pure, and free from foreign contaminants.
The age of coating material components shall not exceed the recommended pot-life as
limited by the manufacturers.
All paints/coating materials shall be delivered to the site in original sealed manufacturer's
containers with batch/code numbers and date of manufacture clearly marked thereon.
7.2 Approvals
All paints and coating materials, including thinners and equipment cleaners, in any one
system shall originate from one manufacturer.
The JO approved schemes are only those used in the painting/coating schedules A-C
(Appendix 3) end as defined in clauses 7.3-7.14 of this Standard. The use of alternative
schemes shall be approved in writing by JO
The contractor's submittal for painting/coating materials shall include details of generalized
composition, service temperature and technical specifications of the products to be used for
JO review and approval.
The selected composition of painting / coating materials shall comply with the relevant
clauses pertaining to the materials given below.
Paint manufacturers shall be from a KOC/SAC approved vendor list.
7.3 Zinc-Rich Epoxy Primer
This primer based on polyamide cured 2 pack epoxy. Minimum volume of solids shall be
63% as per ASTM D2697.
7.4 Inorganic Zinc Silicate Primer
Based on ethyl silicate media. Minimum volume of solids shall be at least 58% as per
ASTM D2697. Capable of withstanding continuous high temperature (up to 400
o
C) and
have excellent abrasion and chemical resistance.
7.5 Zinc Phosphate Primer
Based on long oil alkyd and urethane alkyd media. Minimum volume of solids shall be 48%
as per ASTM D2697.
7.6 Mordent Solution (T-wash) Pre-treatment Primer
Used for preparation of galvanized surfaces. It is a two component etch primer, based on
phosphoric acid solution incorporating copper salts and corrosion inhibitive pigments in a
solvent/water solution.
7.7 High Build Epoxy Intermediate
Based on polyamide cured two pack high build epoxy binder pigmented with Micaceous
Iron Oxide (MIO).Minimum volume solids shall be 55% per ASTM D2697.
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Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


7.8 Coal Tar Epoxy Primer/intermediate/Finish
The formulation of the two pack incorporate:
Pack 1. Epoxy resin and suitable pigments.
Pack 2. Polyamide or amine curing agent and coal tar.
The Epoxy resin shall comprise at (east 35% by weight in the resin/coal tar blend as per
ASTM 02697.
For contrasting of intermediate coats, aluminium or red oxide may be used.
7.9 Two -Pack Polyurethane Finish
Based on acrylic modified two pack aliphatic polyurethane with titanium dioxide or MIO
pigment. Minimum volume of solids shall be 45% per ASTM D2697.
A semi-gloss and colour retention finish is required.
7.10 Amine Adduct Epoxy Paint
A two pack epoxy amine adduct cured paint which cures to a coating with excellent
resistance to chemicals.
Minimum volume of solids shall be 48% as per ASTM D2697.
It shall be approved by the NWC (National Water Council) and Kuwait health authority.
7.11 "Solvent Free" High Build Epoxy Paint
Based on polyamide cured two pack epoxy with a coating with good resistance to fresh
water and to abrasion.
Minimum volume of solids shall be 100%per ASTM D2697 (solvent free).
It shall be approved by the NWC (National Water Council) and health authority.
7.12 "Zinc Free" Inorganic Silicate Finish
Air curing zinc free inorganic silicate based on ethyl silicate media; capable of withstanding
continuous high temperature (up to 400'C) and have excellent abrasion and chemical
resistance.
7.13 High Temperature Aluminium Silicone Finish
Based on silicone alkyd or modified silicone alkyd media (e.g. acrylic silicone). Minimum
volume of solids shall be 49% as per ASTM D2697.
Pigmented with leafing aluminium pigment.
Heat resistant, capable to withstand continuous high temperature up to 400C. Must be
capable of "curing" to handle at ambient temperature.
7.14 Metal Spray Coatings
a) Based on molten Aluminium metal sprayed on surfaces prepared in accordance with
BS EN 22063.
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


b) Aluminium metal spray coating is suitable for high temperature (up to 550C) surfaces
with restriction (see clause 7.15). The sprayed aluminium may be silicon sealed and
for temperatures up to 250'C silicon sealed sprayed aluminium can provide more
protection and longer Iife.
7.15 Restriction on Using Aluminium Pigments and Metal Spray
Due to the susceptibility of metallic aluminium to ignite with explosive force, Aluminium
metallic pigments and Aluminium metal spray shall not be used on any surface operating
above 120
o
C in area zone 1 as specified in JO Hazardous Area drawings.
8 SURFACE PREPARATION
8.1 General
All fabrication works including cutting and drilling of holes shall be completed prior to
surface preparation. In special areas, however, preparation and priming of structured steel
members and piping maybe approved by JO prior to final assembly.
Surface preparation shall preferably, for optimum coating performance, be ' carried out by
dry abrasive blast cleaning. Alternative techniques shall only be applied in some
circumstances as described in clause 8.7.
The surface preparation requirements for painting systems are indicated in the painting
schedules A-C Appendix 3) and detailed in the clauses as follows:
8.2 Working Restrictions
8.2.1 Weather Conditions
All surface preparation shall not be conducted in the following conditions:
a) When the steel surface temperature is less than 3% above dew point.
b) When the air temperature is below 5C
c) When the relative humidity (RH) is 85% or higher.
d) Under adverse weather conditions, e.g. rain, fog, sandstorm, high wind velocity (56
Km/hr. or higher), high wave tide or when such conditions are likely prior to
completion of the work (i.e. abrasive blast cleaning).
8.2.2 Work Conditions
Field surface preparation shall not be conducted in the following conditions:
a) Outside daylight hours on exterior locations, unless permitted by JO Approved special
lighting shall be arranged for night blast cleaning.
b) When the initial primer coat cannot be completed within 4 hours of preparation.
Surfaces which remain uncoated for longer than this period shall be re-blasted prior
to priming.
c) When adjacent areas or equipment are insufficiently protected from damage or
contamination by abrasive dust or debris.
d) In areas close to painting operations, to prevent damage or contamination of wet
paint films by abrasive material.
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


8.3 Surface Imperfections Removal
Surface imperfections or irregularities shall be removed completely (made flush or smooth)
prior to blast cleaning. Imperfections shall be considered as follows:
a) Weld spatter and slivers shall be removed. Sharp or rough welds shall be rounded
and contoured. Any other observed defects in welds and material should be referred
to JO for disposition.
b) Porosity (weld voids) shall be cleaned and filled with acceptable filler material or
closed over by a suitable mechanical method approved by JO
c) Sharp or rough edges shall be rounded, chamfered or broken.
d) Such imperfections that appear after blast cleaning or acid pickling shall be similarly
removed. If grinding is needed, checking of the remaining wall thickness and JOs
approval are required.
8.4 Surface Contaminants Removal
The metal surface shall be cleaned to remove any oil, grease, din, etc. using solvent and/or
suitable emulsifying alkaline cleaners followed by washing with clean water or wet steam
rinsing. SSPC-SP7 outlines these methods.
Degreasing by wiping the surface with solvent only is not recommended in heavily
oil/grease surface contamination, because this invariably leads to the spreading of a thin
film of oil over wide area. The solvent/emulsifying agent cleaned surface shall be allowed to
dry before proceeding with further preparation or painting.
Soluble salts on steel surface exposed to a salt laden atmosphere shall be removed by
washing or by any other suitable technique. See clause 10.5.3 for iron salts contaminant
free testing.
8.5 Dry Abrasive Blast Cleaning Practice
Dry abrasive blast cleaning shall be used to remove all rust and mill scale and to achieve
the required visual standard and surface profile defined in the approved painting/coating
schedules (Appendix 3).
Abrasive material shall satisfy the following requirements:-
a) Abrasive material for mild / carbon steel preparation shall be industrial grade metal
angular grit or shot (generally iron or steel). Contaminated or re-cycled grit or shot
shall not be used. Abrasives for stainless steel substrate shall be non-metallic
materials. New less-dust generating abrasive media such as "Garnet" plastic
granulates and alike, capable of producing the required surface profile may be used
for blast cleaning.
b) Sand may be used as abrasive material for field blast cleaning, subjected to JOs
approval. Sand material shall be graded (30-60 mesh), hard, version, silica or olivine
sand with less than a 10 percent breakdown. No sand shall be used more than once.
c) The selected abrasive material shall be in accordance with SSPC-SP-COM or BS
7079 R.D2 (IS0 8504-2).
d) Abrasive material shall be dry and free from oil, grease, dust, salts and any other
impurities or contaminants.
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


e) Abrasive materials shall be capable of achieving the required surface profile without
contamination of the substrate. To produce the required surface profile, abrasive
particle size shall follow the surface preparation commentary of SSPC manual as
necessary to comply with visual blast cleaning standards mentioned in clause 8.6 of
this Standard.
f) All abrasive materials shall be kept dry, and covered when not used.
g) Abrasive sample shall be provided by the contractor for JOs testing and approval
before work commencement.
The blasting equipment and technique shall comply with the following requirements:
a) The contractor's abrasive blast cleaning equipment shall satisfy JOs safety
requirements (See clause 6.3).
b) For field and shop blast cleaning, abrasive shall be carried by a jet of compressed air
through a hand-held nozzle. The compressed air supply and volume shall meet work
requirement and shall be substantially free from oil and water contamination. Traps
and filters shall be cleaned regularly.
c) For blast cleaning of large horizontal surface areas, like tank roofs, bottoms etc., a
self contained vacuum blast unit can be used. Such machines are usually operated
by remote compressed air or hydraulically actuated for traction.
d) 'Deadman handles' shall be fixed to the blast line as close as practicable to the blast
nozzle and shall be held by the blast operator alone.
e) Nozzles used shall have a maximum orifice size of 9 mm and shall be of venturi
design.
Openings in vessels, piping, access fittings, nozzles, etc. shall be properly protected
against entry of abrasive material. All previously painted or galvanised surfaces shall be
adequately protected prior to commencing any blasting operation.
Blast cleaned rusty surface (due to rain or condensation) and surfaces with temporary
holding primer, shall be re-blasted to the specified surface profile.
Surface blast cleaning to the specified surface profile shall extend a minimum of 150 mm
beyond the area to be coated during the same day.
Surface blasting to the specified surface profile shall continue a minimum of 25 mm into
adjoining previously coated surface. The edges of the previous coating shall be feathered.
All prepared surfaces shall be cleaned from any dust/abrasive material preferably by dry
brushing and/or vacuuming with industrial vacuum cleaner. Pressure air blowing is not
permitted. Any surface showing signs of contamination, after blast cleaning, shall be solvent
cleaned and re-blasted.
8.6 Blast Cleaning Standard
The surface profile height shall be in accordance with the requirement of painting system.
The measurement techniques of surface profile testing are specified in ASTM D4417.
Blast cleaning shall be carried out to a visual standard in accordance with SIS 05 59 00,
either as Sa 2, Sa 2 or Sa 3. (identical to BS 7079 Part A1 or IS0 8501-1) subjected to the
requirements of paint manufacturer's data sheet. Reference shall be made to these
standards for photographs of equivalents to the mentioned qualities.
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8.7 Restrictions on Alternative Techniques to Blast Cleaning
In some circumstances, blast cleaning shall not be done and alternative surface .reparation
techniques (like manual/power tool cleaning) shall be applied. These alternative techniques
are subject to JOs approval and restricted as follows:
a) When dry abrasive blast cleaning is unsafe or any of JOs safety precautions/
requirements cannot be met.
b) When there is a risk of damage to instrumentation, equipment (e.g., electrical,
rotating, etc.) within the proximity of blasting operations.
c) Where there is a flammable atmosphere or similar condition present, restrictions may
be applied by JO.
d) Where blast cleaning is not practical, e.g. for welds, edges, bolts, nuts, corners,
crevices etc. and for paint defects/damages repair.
8.8 Power Tool Cleaning
Power tool cleaning shall be to a visual standard in accordance with SIS 05 59 00 St 3 or
BS 7079 Part A1 St 3 (equivalent to U.S. Standard SSPC-Sp3).
Where power tool cleaning is carried out, 100% of the surface shall be covered using
abrasive or wire type power discs. In some locations which can not accommodate a power
disk, e.g. welds, power impact tools shall be applied (vibratory and rotary, needle guns,
scrapers) followed up by wire brush cleaning.
Power tool cleaning shall extend a minimum of 25 mm distance into adjoining coated
surfaces.
8.9 Hand Tool Cleaning
Hand tool cleaning may be used for cleaning rusted surfaces in some circumstances as
specified in clause 8.7 and for paint defects/damages repair.
Hand tool cleaning shall be to visual standard in accordance with SIS 05 59 00 St2
(BS7079 St2) which is equivalent to SSPC-SP2.
8.10 Acid Pickling (Etching) Preparation
This method may be used by contractors, in some circumstances and locations as an
alternative to blasting provided that it is compatible with paint system and approved by JO
When using this method, the surface shall be etched to a degree suitable for the specified
coating system. Details on this method are specified in SSPC- SP8.
JO Fire and Safety Regulations shall be adhered to when using this method
8.11 Preparation of Stainless Steels
Stainless steels shall not be painted unless specified by the relevant equipment data sheet.
The surface specified to be painted shall be:
a) thoroughly degreased using solvent cleaning or suitable emulsifying agent and
washed with fresh water to remove any contamination.
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b) blast cleaned to a surface profile of 25-50micron using chloride free abrasive such as
alumina. Copper slag abrasives shall not be used. Hand or power tools using P60
grade paper may be used for surface preparation, when grit blast cleaning is
impractical. (see clause 8.7).
c) protected from any further contamination by debris produced during grit blasting of
adjacent carbon steel because embedded panicles could promote corrosion. Any
observed contamination should be referred to JO for disposition.
Blast/Power tool cleaning equipment used for carbon steel shall not be subsequently used
on stainless steel.
8.12 Preparation of Galvanized Surfaces
Painting of new galvanized surfaces shall be only for top coating purposes in conformity
with systems B1, Dl-10, Dl-11 of Appendix 3 of this Standard. The surface preparation
method shall be carried out as follows:
a) The greasy film on the new galvanized steel surface and any other oil or grease
contamination shall be removed using emulsifying agent:
b) The surface shall be chemically etched (primed) by using proprietary T-wash solution.
(see clause 7.6 )
c) Weathered surfaces shall be cleaned using wire brushing or sweep blasted to remove
all corrosion products or deposits and degreased with emulsifying agent.
Other surface preparation methods may be used in accordance with ASTM D 2092 for
painting new galvanized surfaces subject to Os approval.
9 PAINT/COATING APPLICATION
9.1 General Requirements
Painting/coating works shall be in accordance with the requirements established by this
Standard and the recommendations of the paint/coating manufacturer. Any area not
specifically covered, shall be in accordance with the principles and guidelines set forth in
the SSPC Manual.
The contractor shall provide all materials, tools, equipment and manpower required for
carrying out the works.
Surfaces, to be painted/coated, shall be inspected and approved by JO before any painting
coating is applied. This shall be after surface preparation and between each subsequent
coating. No primer or paint shall be applied without JOs approval.
All surfaces, to be painted / coated, shall be dry and dust/contaminants free before
application of the first coat.
Precautions shall be taken to prevent painting from being applied to name plates,
couplings, shafts, valve stems, vent openings, gauge glasses, pressure gauges, etc.
Masking tape, plastic film or any other suitable material shall be used, and all shall be
removed after completion and acceptance of the painting application.
All areas prepared for field welds shall be kept free from paint over a distance of at least
100 mm from the weld centre, except welding / shop primer of 25 microns.
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A minimum of 100 mm around edges of abrasive blasting shall be left unless adjoining a
recently prepared and coated other surface.
Crevices created by two surfaces in close contact which cannot be protected by painting
should be mastic sealed on both sides.
9.2 Selection of Painting/Coating System
The selection of painting/coating system for particular applications and required surface
preparation shall be as given in the approved painting Schedules A, B, C, (Appendix 3) of
this Standard.
9.3 Paint Mixing and Thinning
Mixing of paint to an even consistency, manufacturer's mixing instructions, environmental
conditions and maximum pot life shall be strictly adhered to, especially for two -pack paints.
Mixing, by high speed mechanical agitators or rotary mixers, with flat blade and speed
control, shall be used for containers larger than 5 litres. Hand mixing is permitted only for
containers up to 5 litres.
For painting systems where pigment separation readily occur e.g. zinc silicate primers,
continuous mixing shall be carried out during application.
After thorough mixing, the correct viscosity of the paint shall be proved by measuring with
an approved flow cup.
Thinners shall not be added to paint without JO approval, only the thinners recommended
by the paint manufacturer may be used, even for cleaning.
When thinning is permitted by JO paint manufacturer's instructions shall be strictly adhered
and the accepted procedures mentioned in clause 7.3 of ASTM D3276 shall be followed.
9.4 Restrictions on Painting
9.4.1 Weather Conditions
Painting shall not be conducted in the similar weather conditions of abrasive blast cleaning
as specified in clause 8.2.1 of this Standard and also under the following conditions:
a) When the metal surface temperature above 50C.
b) Under adverse weather conditions, e.g. rain, fog, sandstorm, high wind velocity (56
Km/hr. or higher), high wave tide or when such conditions are likely before the
paint/coating has become dry.
9.4.2 Work Conditions
Painting/Coating shall not be conducted in the following work conditions:
a) Where the specified surface finish is not existed at the time of applying the first coat.
b) When adjacent areas or equipment are not sufficiently protected from paint
application.
c) Outside daylight hours on exterior locations unless permitted by JO Approved special
lighting shall be arranged for night painting.
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9.5 Paint Application Practice
9.5.1 General
a) The specified surface finish, of all areas to be painted, shall be prepared before
applying the first coat if required surfaces shall be re-prepared to the specified finish.
b) The paint shall be applied in a uniform manner and to the prescribed number of coats
and dry film thickness (DFT) given in Painting Schedules without any .runs, sags,
marks or other blemishes. Finished application shall be uniform in colour, texture and
appearance.
c) Intermediate and finish paintings shall be applied following final assembly of
component pans. For surfaces inaccessible for proper painting and/or inspection,
painting shall be applied prior to final assembly. The contractor and JO will designate
inaccessible areas.
d) Where a multi-coat paint system is specified to be used, all intermediate coats shall
be of contrasting colour to differentiate between coats. Colours for intermediate coats
shall refer to the paint manufacturer's recommendations.
e) Time intervals between coats shall be kept to the minimum recommended by paint
manufacturer in order to prevent contamination between coats. In case contamination
does occur, it shall be removed by washing with suitable detergent solution and
rinsing with clean fresh water.
9.5.2 Airless Spray Application
a) Paint application by airless spraying shall be the preferred paint application process.
The use of air spray method shall conform to the requirement of coating system and
shall be subject to JOs approval.
b) Spraying equipment, guns, nozzle sizes, orifice sizes & shapes and pressure ranges
shall meet the work requirements and the paint manufacturer's recommendations and
shall be free from oil and water contamination.
c) All paint spraying lines and pots shall be cleaned and flushed before the addition of
new material.
d) Large surfaces shall be painted with passes in two directions at right angles. Spray
overlap of the previous pass shall be by 50%. .
9.5.3 Brush Application
a) Brush application shall be done on areas which cannot be properly sprayed e.g. for
welds, edges, bolts, nuts, corners, crevices etc., and for touch-up maintenance where
spray application is not practical.
b) Stripe coating of sharp edges, corners and welds can be done before application of
finish paint to ensure that these areas receive the minimum specified film thickness.
c) Brushes shall be of a type, size and shape which permits proper application of paint
and meets manufacturers recommendations.
d) Brush application shall be done such that a uniform coat, with no deep or detrimental
brush marks is obtained. Runs and sags shall be avoided.
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9.5.4 Roller Application
This method of application can be used subject to JOs approval for painting large areas of
relatively flat steel surfaces and where high film build is generally not to be attained. Roller
application will ride over high spots and miss edges and shall not be used for painting
corners, bolt heads, etc. Care must be taken to choose the correct roller pile length,
depending on the type of paint and degree of roughness of the surface.
9.6 Priming
Priming shall be done on prepared surfaces before rusting occurs or within 4 hours of blast
cleaning, whichever is sooner. The only relaxation allowable to this requirement is where
the following three (3) conditions exist.
a) The work to be primed is fully enclosed
b) The ambient temperature is above 11
o
C
c) The relative humidity is below 75%
All acid de-scaled steel surfaces shall be primed as soon as the surface is dry and while it
is still warm.
In order to facilitate shop or site handling procedure, holding (shop) primer of 25 microns
may be applied on steel surface. If applied, however, this shall not replace the function or
pan of the film thickness specified for the priming coat. Shop or welding primers shall be
compatible with the specified painting system.
Zinc silicate primers shall be applied to abrasive blasted surfaces only. In order to protect
the porous primer film from salt or chemical contamination, it shall be sealed with a tie coat
as soon as practicable after complete curing has occurred. The tie coat shall achieve sound
adhesion to the zinc silicate primer and be compatible with the finishing coat.
9.7 Shop Painting
Shop painting of items may be carried out by the contractor as below, subject to JOs
approval.
a) The contractor shall be responsible for paint condition on arrival of such items 'on-site'
and shall carry out any paint damage repair needed.
b) The contractor shall comply with all aspects of this Standard and related aspects of
JOs safety regulations.
9.7.1 Completely Fabricated Items
a) Full surface preparation and painting works shall be done prior to transportation to
site.
b) All painted items shall be protected/packed to avoid any coating damage during
transportation. Care shall be taken in handling and installation to minimize coating
damage.
9.7.2 Partially Fabricated or Non-Fabricated ltems
a) These items may be prepared/primed and further coated before transportation to site
with the approval of JO.
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b) The painting used shall have enough durability to withstand the 'on-site' construction
period before further painting occurs.
9.8 Repair of Damages/Defects
New painted surfaces are likely to require repair and maintenance in the following cases:
a) for painted areas which have been damaged by other adjacent field activities or
during handling/transportation of off-site painted items.
b) For areas which suffer paint defects e.g. disbonding, insufficient film thickness,
blistering etc.
The type of coating materials used for repair and maintenance shall be identical to, or
compatible with the original material.
The selection of suitable surface preparation shall depend on the size of areas to be
painted, the type of repair painting materials to be used and the Safety regulations involved.
The following order of preference shall be adopted.
a) Dry blast cleaning to the required visual standard (Sa 2-1/2 or Sa 3) and surface
profile.
b) Power tool cleaning to standard St3 (only where blast cleaning is not practical or
permitted).
c) Hand tool cleaning to standard St2 (only for minor touch up/repair work)
Surface preparation of defective or damaged areas shall be extended over the surrounding
sound coating for a minimum of 25 mm on all sides and a further 25 mm of sound paint
work shall be lightly blasted to etch the surface.
Surfaces to be painted that become contaminated with oil, grease, salts, etc. shall be
cleaned with a proprietary solvent/detergent solution and rinsed with fresh clean water.
Repair works shall be in accordance with the specified painting system to restore the film
thickness and shall cover the prepared surface and the etched pant work. For colour coding
and/or cosmetic reasons it may be necessary to extend the finish coat over a large
surrounding area.
It is mandatory that all defective work be corrected to the satisfaction of JOs
representative. Work shall not be deemed complete until the foregoing bas been achieved.
10 INSPECTION AND TESTING
10.1 General Requirements
Inspection and testing at all stages of surface preparation and painting/coating application
shall be conducted by the contractor. The contractor shall provide all necessary inspection
equipment and perform such inspections as necessary to assure that the painting/coating
complies with the requirements of this Standard.
Surface preparation and painting/coating application may be subjected to inspection and
approval at any stage by JO.
JO inspector shall have the right to inspect at all times any tools, materials or equipment
used in the performance of surface preparation and paint application to ensure the
compliance with the requirements of this Standard.
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10.2 Materials and Equipment Inspection
Abrasive material shall be inspected to ensure compliance with the requirements of this
Standard. (see clause 8.5.2)
Painting/coating materials shall be inspected to ensure compliance with the requirements of
clause 7.0 and the specified painting schedules (Appendix 3) of this Standard.
Equipment for blast cleaning and paint application shall be inspected to ensure the
compliance with the requirements of this Standard (see clauses 6.3, 8.5.3 and 9.5) and
paint manufacturer's recommendations.
10.3 Inspection/Testing Equipment
The contractor shall have the necessary equipment and tools for inspection and testing of
environmental conditions, surface preparation and painted/coated surfaces. All this
equipment shall be approved by JO prior to starting any work. The contractor shall provide
calibration certificates for all measurement and test equipment for JOs review.
10.4 Environmental Conditions Testing
Prior to commencing any blast cleaning/paint application work, ambient temperature, metal
surface temperature and relative humidity (RH) shall be measured. Readings shall comply
with clauses 8.2.1 and 9.4.1. For works in confined areas, the oxygen deficiency and gas
testing shall be performed.
Other environmental conditions, e.g. wind speed, sandy or rainy weather, shall be checked
before the commencement of any work.
10.5 Blasted Surface Inspection Resting
10.5.1 Visual Inspection
a) Metal substrate shall be checked to ensure spatter / protrusions removal, cleanliness
etc. prior to blast cleaning.
b) Blast cleaned surfaces shall be visually inspected (surface magnifier may be used) to
ensure the absence of all types of imperfections and contaminants and for the
conformance with the specified visual standard mentioned in the painting / coating
schedules (Appendix 3).
10.5.2 Surface Profile Testing
On dry blast cleaned surfaces the profile height shall be spot checked by means of surface
profile comparator or by replica tape and a calibrated micrometer in accordance with ASTM
D4417 or NACE RP0287 to ensure the compliance with painting schedule requirements.
10.5.3 Contaminants Free Testing
When requested by JO, a Potassium Ferro-cyanide paper test shall be carried out to
confirm the absence of contamination of the blast cleaned surface by soluble iron salts.
This shall be done in accordance with BS 5493 Appendix G.
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10.6 Painted Surface Inspection/Testing
10.6.1 Visual Inspection
All painted surfaces shall be visually inspected to ensure the absence of skips, overspray,
sags, foreign panicles contamination, air pockets, drips, holidays and any other paint
defects. The repair of damaged/defected coating shall be done In accordance with clause
9.8 of this Standard.
10.6.2 Curing of Inorganic Zinc Silicate Primer Test
a) Zinc silicate primed substrate shall be tested for adequate curing prior to over coating
(see clause 9.6.4).The test shall be performed as follows:-
Rub the applied coating with a clean tissue or piece of cloth. There should be no
trace of paint on the cloth. The cloth should then be soaked in cleaners as
recommended by the paint manufacturer; and again rubbed on the coating. After
about thirty seconds there should be no trace of zinc on the cloth. If there is any
greyness, then the zinc silicate is not fully cured and shall not be over coated.
b) The manufacturer's recommendations/instructions shall be fully adhered when
performing this test.
10.6.3 Paint Film Thickness Test
a) The paint shall conform to the system and to the minimum film thickness as specified
in the painting schedules.
b) The wet film thickness (WFT) shall be spot measured as an initial indication of the
expected dry film thickness (DFT). The measurement shall be in accordance with
ASTM D1212.
c) The DFT of individual coats and of the total painting system shall be measured in
accordance with ASTM Dl186 or SSPC-PA2. There shall be at least one area each
for horizontal, vertical and curved surfaces. For internal painting in storage tanks, the
film thickness shall be measured at ten (10) randomly selected areas.
d) A minimum of five (5) readings shall be taken in each area. Additional readings shall
be taken, if there is any change in personnel, application equipment, spray nozzle
size, thinning of the paint, etc.
e) The (DFT) shall be measured by using an approved coating thickness gauge suitable
for the given type of painting system and thickness range.
f) The gauge shall be calibrated prior any measurement. The calibration shall be
repeated at least once an hour if working on the same surface, and before measuring
film thickness on the insides of angles and at points nearer than 15 mm from an
edge.
10.6.4 Paint Adhesion
When requested by JO, a spot adhesion test may be carried out using a suitable Adhesion
Tester. The paint adhesion recorded must be at least equal to the specified adhesion by the
paint manufacturer for the type of paint and or system. The paint adhesion testing shall be
in accordance with ASTM D3359 or ASTM D4541.
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10.6.5 Holiday Detection (Porosity Check)
All coated metal surfaces shall be subjected to visual inspection for holidays, pinholes and
overspray. For special coatings where pinholes cannot be allowed, a full scan holiday test
shall be done, using suitable equipment for each type of coating as high voltage can cause
damage to coatings. The acceptable level of pinhole shall be subjected to JOs approval.
Holiday detection test shall be carried out in accordance with NACE RP0188.
11 QUALITY ASSURANCE
The Contractor / Manufacturer shall operate quality systems to ensure that the
requirements of this Standard are achieved. The quality systems shall be preferably based
on IS0 9000 series of standards and the contractor / manufacturer shall demonstrate
compliance by providing a copy of the accredited certificate or the quality manual.
Verification of a contractor's / manufacturer's quality system is normally part of the pre-
qualification procedure and is, therefore, not detailed in the core text of this Standard."
12 DOCUMENTATION
12.1 General
All correspondence, drawings, instructions, data sheets, design calculations, or any other
written information shall be in English language. In case of dual languages, one language
shall be English.
All dimensions, units of measurement, physical constants, etc. shall be in SI units, unless
otherwise specified.
All documents (texts, specifications, data sheets, etc.) shall be provided with electronic files
in the approved software/MSWord, Excel, AutoCAD, etc.).
Any design calculations shall be submitted in the approved and widely used software
agreed by JO.
12.2 Work Proposal
The contractor shall submit his proposal for all aspects of work, for the approval of JO prior
to the commencement of any work. This will include the following:
a) Information on work location, materials selection, equipment to be used, items to be
coated, surface preparation, painting schedule to be used, etc.
b) Manufacturer's technical data sheet, material performance certificates and test
approvals shall be provided for each paint/coating product.
c) Material safety data sheets and safety precautions to be taken
d) Inspection and test plans and procedures, and the equipment to be used.
e) Specific repair proposals to satisfy the requirements of clause 9.8 for both extensive
and minor repair.
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12.3 Work Records/Reports
The contractor shall operate a comprehensive recording/reporting system on all aspects of
the painting work including inspection/testing work. The data shall be set out on painting
work record/data sheet within 24 hours of carrying out a specific work. Appendix 1 shows a
sample of this record/data sheet.
12.4 Final Report
A report shall be submitted on completion of the painting works. The final report shall
include a summary on all aspects covered e.g., surface preparation, painting systems used
and inspection and testing records performed.
13 PAINTING/COATING SCHEDULES
The painting/coating schedules (A-C) are attached to this Standard in Appendix 3. The
requirements for surface preparation and painting/coating systems are listed for categories
of onshore structure, equipment and other facilities.
The painting/coating schedules explained in Appendix 3 are:
Schedule A External Painting/Coating Systems for Onshore Storage & Processing
Equipment.
Schedule B Painting Systems for Onshore Structural Steel works.
Schedule C - Painting Systems for Mechanical, Electrical and Instrumentation
Equipment
Schedule D - Deleted
Schedule E - Deleted
N.B. For details of Internal Coatings of piping, pressure vessels and storage tanks, see
document JOS-02-05 Internal Coatings.
For the coating of the base of storage tanks see KOC-P-002 part 2. Internal Lining of Steel
Tanks and Vessels part 2. Rigid Reinforced Fibreglass Lining.
14 COLOUR SCHEDULE
The finishing colours to be applied to various equipment and facilities shall be in
accordance with colours mentioned in colour schedule of Appendix 2. Selecting different
colours are subject to JOs approval.

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15 APPENDICES
Appendix 1 PAINTING RECORD/DATA SHEET
Appendix 2A COLOUR SCHEDULE
Appendix 2B COLOUR IDENTIFICATION FOR HAZARDS AND FIRE/SAFETY
Appendix 2C DELETED
Appendix 2D DELETED
Appendix 3A EXTERNAL PAINTING/COATING SYSTEMS FOR CONSHORE
STORAGE AND PROCESSING EQUIPMENT
Appendix 3A EXTERNAL PAINTING/COATING SYSTEMS FOR CONSHORE
STORAGE AND PROCESSING EQUIPMENT
Appendix 3B SCHEDULE B PAINTING SYSTEMS FOR ONSHORE STRUCTURAL
STEELWORKS
Appendix 3C SCHEDULE C: PAINTING SYUSTEMS FOR MECHANICAL,
ELECTRICAL AND INSTRUMENTATION EQUIPMENT
Appendix 3D DELETED
Appendix 3E DELETED


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APPENDIX 1 PAINTING RECORD/DATA SHEET
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Appendix 1 - PAINTING RECORD/DATA SHEET (Continued)
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APPENDIX 2A COLOUR SCHEDULE
Table 1
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APPENDIX 2B COLOUR IDENTIFICATION FOR HAZARDS AND FIRE/SAFETY
Table2











APPENDIX 2C DELETED
APPENDIX 2D - DELETED




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Table 4Appendix 3A EXTERNAL PAINTING/COATING SYSTEMS FOR ONSHORE STORAGE AND PROCESSING EQUIPMENT
A1 Tanks, Vessels, Exchangers, Heaters, Columns, Saddles and Others

SYSTEM SCOPE SPECIFICATION MIN THICKNESS DFT
(MICRON)
REMARKS
A1.1 CS Uninsulated
Non fire proof vessel skirts
Tank roof
Outer run of floating roof
Up to 120
o
C

Preparation
Visual standard Sa 2
Surface profile 25 35 micron
Priming
Zinc rich Epoxy
Intermediate
Two pack High build MIO Epoxy
Finish
Acrylic modified 2 pack
Polyurethane




50

125

70
Total 245
Where preparation is carried out in shop, it is mandatory
that the first coat be carried out at the same location.
A1.2 Underside Of all Tanks
Severe exposure
Up to 120
o
C


Preparation
Visual standard Sa2
Surface profile 75 microns
Priming/Intermediate/Finish
Three coats Coal Tar Epoxy


3 x 150
Total 450

A strip of 25mm wide at plate edge shall be left bare to
avoid welding contamination.
Project : MGC Revamp Project (JO/HC125/MP12) Page 34 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


Alternative
Primer
Modified urethane alkyd
Finish
Alkyd enamel
75
40
2 x 40
Total 195


Appendix 3A; Schedule A (Continued)

SYSTEM

SCOPE

SPECIFICATION

MIN THICKNESS DFT
(MICRON)

REMARKS
A1.3 CS Uninsulated
121
o
C to 175
o
C


Preparation
Visual standard Sa3
Surface profile 25 35 micron
Priming
Inorganic zinc silicate
Finish
High temperature
Acrylic





75
50
Total 125
Primed surfaces to be free of zinc, salt prior to finish
coating
Second coat to be applied as a mist prior to full coating
Inorganic zinc Silicate primed surface shall be tested for
degree of cure prior to over coating (see clause 10.6.2)
A1.4 CS Uninsulated
176
o
C to 400
o
C (Specially for
Columns, Vessels, Exchangers/
Heaters)


Preparation
Visual standard Sa3
Surface profile 25 35 micron
Priming
Inorganic zinc silicate
Finish
High temperature modified




75
25
Total 100
As above A1.3 remarks
Alternative pigments to A1 shall be used in zone 1 area
Silicon Aluminium finish coat may not fully cure until
equipment is in service
Second coat to be applied as a mist prior to full coating
Project : MGC Revamp Project (JO/HC125/MP12) Page 35 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


Al silicone
A1.5 CS/Low alloy steel
Uninsulated
Up to 550
o
C


Preparation
Visual standard Sa3
Priming
Al metal spray
Finish
High temperature
Al silicone



150
20
Total 170
This type of coating shall not be used on any service
operating in hazardous area zone 1
Aluminium Silicone which fills the metal pores for
smooth and long life coating shall be applied
immediately after metal spray. It must generally be
exposed to 175
o
C or higher to cure.


Appendix 3A; Schedule A (Continued)

SYSTEM

SCOPE

SPECIFICATION

MIN THICKNESS DFT
(MICRON)

REMARKS
A1.6 CS Uninsulated
Up to 120
o
C
Standard Exposure


Preparation
Visual standard Sa 2
Surface profile 25 35 micron
Priming
Zinc rich Epoxy
Finish
High temperature
Two pack high buils MIO Epoxy





75
125
Total 175
Where preparation is carried out in shop, it is mandatory
that the first coat be carried out at the same location
A1.7 CS Uninsulated
Up to 120
o
C
Standard Exposure
Preparation
Visual standard Sa 2
Surface profile 25 35 micron



As above A1-6 remarks

Project : MGC Revamp Project (JO/HC125/MP12) Page 36 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)




Priming
Zinc rich Epoxy
Finish
Two pack high build MIO Epoxy


50
2 x 100

Total 250
A1.8 CS insulated
To be insulated/Fire proofed
Up to 400
o
C


Preparation
Visual standard Sa 2
Surface profile 25 35 micron
Priming
Zinc rich Epoxy
Finish
Zinc free inorganic silicate high temperature
curing



75
75
Total 150
Primed surfaces to be free of zinc salts prior to finish
coating
Second coat to be applied as a mist prior to full coating
Inorganic Zinc Silicate primed surface shall be tested for
degree of cure prior to over coating. (see clause 10.6.2)

Appendix 3A; Schedule A (Continued)

SYSTEM

SCOPE

SPECIFICATION

MIN THICKNESS DFT
(MICRON)

REMARKS
A1.9 CS to be fire Proofed up to 120
o
C



Preparation
Visual standard Sa 3
Surface profile 50 micron
Priming
Inorganic zinc silicate
Finish
Two pack Epoxy tie coat




60
25
Total 85
As above A1.8 remarks
Project : MGC Revamp Project (JO/HC125/MP12) Page 37 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
Construction

Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


A1.10 Stainless steels A1S1 300 and 400
series and duplex types
Up to 120
o
C


Preparation
Visual standard Sa 2
Surface profile 25 35 micron
Priming
High build epoxy for stainless steels
Finish
Recoatable acrylic polyurethane





120

40

Total 160
Stainless steels shall not be painted except where
specified by the relevant data sheet.
Under no circumstances shall Zinc containing paints be
used on stainless surfaces.
This system may be applied for temporary protection of
austenitic stainless steels during sea transportation

A1.11 Austenitic stainless steels
>120
o
C


Preparation
Visual standard Sa 2
Surface profile 25 35 micron
Coating
2 coats foster atlas heat resistance 57-73 or
approved equivalent



2 x 80

Total 160
Same as A1 10 above
Project : MGC Revamp Project (JO/HC125/MP12) Page 38 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


Appendix 3A EXTERNAL PAINTING/COATING SYSTEMS FOR ONSHORE STORAGE AND PROCESSING EQUIPMENT
A2 Above Ground Piping, Pipelines, Valves and Fittings

SYSTEM

SCOPE

SPECIFICATION

MIN THICKNESS DFT
(MICRON)

REMARKS
A2.1 CS Uninsulated
Up to 400
o
C

Preparation
Visual standard Sa 3
Surface profile 50 micron
Priming
Inorganic zinc silicate
Finish
Zinc free inorganic silicate high temperature air
curing




75
75
Total 150
Same as A1-8 above
The coating system for off the shell valves could be
manufacturers standard subject to the Companys
approval.
A2.2 CS / Low alloy steel
Uninsulated
Up to 550
o
C


Preparation
Visual standard Sa 3
First coat
Al metal spray
Finish
High temperature Al Silicone



150
20
Total 170
Same as A1 6 above remarks

A2.3 Stainless steels AISI 300 and 400
series and duplex types
Up to 120
o
C


Preparation
Visual standard Sa 2
In accordance with clause 8.11
Priming
High build epoxy for stainless steel
Finish
Recoatable acrylic polyurethane



120
40
Total 160
Stainless steels shall not be painted/coated except
where specified by the relevant data sheet
Under no circumstances shall Zinc containing paints be
used on stainless steel surfaces
Project : MGC Revamp Project (JO/HC125/MP12) Page 39 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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A2.4 Austenitic Stainless steels
> 120
o
C

Preparation
Visual standard Sa 2
In accordance with clause 8.11
Coating
Two coats of Foster Atlas heat resistance 57-73
or approved equivalent



2 x 80

Total 160
Same as A2 3 above

Project : MGC Revamp Project (JO/HC125/MP12) Page 40 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
Construction

Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


Appendix 3B SCHEDULE B PAINTING SYSTEMS FOR ONSHORE STRUCTURAL STEELWORKS
Items: 1. Grating, Ladders, Handrail, Fencing, Stairways, Walkway, Stair treads, Cable trays, Ducting and Platforms.
2. General Concrete / Not Concrete Encased Structure Steel Work


SYSTEM

SCOPE

SPECIFICATION

MIN THICKNESS DFT
(MICRON)

REMARKS
B1 Ladders, platforms, handrails, stair
treads, open grid flooring steel
grating.



Hot dip galvanizing and top coating
Hot dip galvanizing preparation:
Visual standard Sa 2
BS 729 requirements
Coating
Hot dip galvanize shall be carried out in
accordance with BS 729. The minimum coating
weight shall be 610 grams/m
2
surface
Top coating of galvanized surface maybe required
for coding or for maintenance of several
weathered items.
Preparation
In accordance with clause 8.12 of this standard
Intermediate
Two pack High build Epoxy
Finish
Recoatable Acrylic Polyurethane in the
requirement colour














120
40
Total 160
When not galvanized, use system B2 for all except
handrails which shall be A1.1
Project : MGC Revamp Project (JO/HC125/MP12) Page 41 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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B2 Stairs treads, open grid flooring steel
gratings
Preparation
Visual Standard Sa 2
Painting Systems
Three coats, 40 micron each of Bituminous Paints
to BS 3416 type 1 applied by dipping



3 x 40
Total 120


The system may only be used with specific approval of
the Company.
Generally use system B1
B3 General not concrete encased
structural steel work
Preparation
Visual standard Sa 2
Surface profile 50 micron
Primer
Inorganic Zinc Silicate
Intermediate
Two pack high build MIO Epoxy
Finish
Acrylic Modified Polyurethane




75

125

70
Total 270

Primed surface shall be free from zinc salts prior to
finish painting
Intermediate coat to be applied as mist prior to finish
painting
Inorganic Zinc Silicate primed surface shall be tested for
degree of cure before over-coating.
B4 General concrete encased structural
steel work
Preparation
Visual standard Sa 3
Surface profile 50 micron
Primer
Inorganic Zinc Silicate
Finish
Zinc free Inorganic Silicate high temperature air
coating





75

75
Total 150
Primed surface to be free of salts prior to further
painting.
Where concrete is applied off-side, the finish coat shall
be applied to suit.
Inorganic Zinc Silicate primed surface shall be tested for
degree of cure before over-coating

Project : MGC Revamp Project (JO/HC125/MP12) Page 42 of 43
Doc. Title :
Specification for Painting and Coating of Metal Surfaces New
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


ITEMS: ROTATING EQUIPMENT(PUMPS, COMPRESSOR, MOTORS, ETC) ELECTRICAL EQUIPMENTS SUPPORTS


SYSTEM

SCOPE

SPECIFICATION

MIN THICKNESS
DFT(MICRON)

REMARKS
C1 Pumps, compressors, Motors, Fans
etc



As for A1.1, A1.3, A1.4 and A1.8 systems
Machinery and drivers, instruments & associated
valves may be finish coated in accordance with
manufacturers standard coating systems
Manufacturers should provide details of the
proposed PAINTING systems for future
maintenance and repair
The paint system must be capable of withstanding
the environmental conditions for period of 5 years
to Ri3 per BS 3900 H3 scale of degree of rusting










Total painting system to be shop applied
C2 Moving Parts
Flywheel Shafts, Couplings etc.
Preparation
Visual Standard Sa 3
Surface profile 25 35 micron
Coating System
Shall be as for system A1.1




Total painting system to be shop applied
C3 Electrical Equipment
Motors, Switchgears, Standard
Equipment, Transformers/Rectiliers
This type of equipment shall be prepared, primed
and finished in accordance with the
manufacturers standard
The system must be capable of withstanding the
environmental conditions for period of 5 years to
Ri3, per BS 3900 H3 scale of degree of rusting


Manufacturers standard shall be subject to JO
approval.
Project : MGC Revamp Project (JO/HC125/MP12) Page 43 of 43
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Doc. No. (Rev) : JO-KOC-P-001 (Rev. A1)


C4 Housings and Equipment Supports Preparation
Visual standard Sa 2
Surface profile 25 - 35 micron
Priming
Zinc rich Epoxy
Intermediate
Two pack High build MI0 Epoxy
Finish
Acrylic Modified Polyurethane





50

150

70

Total 245
Housings to be finish coated in sellers works
Shop fabricated supports shall be painted in workshop
C5 Control Panels As for C3 System

All panels must display a smooth finish appearance.
Hammered of stippled etc are not acceptable.