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SECTION 09960:

GUIDELINE

SPECIFICATION

FOR

HIGH-PERFORMANCE

COATINGS

0

30/04/05

I Issued for Use

REV

DATE

DESCRIPTION

KINGDOMOFSAUDIARABIA

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SECTION 09960 HIGH-PERFORMANCE COATINGS

TABLE OF CONTENTS

Item No

Title

Page No

PART 1

GENERAL

1

1.01

DESCRIPTION OF WORK

1

1.02

SECTION INCLUDES

2

1.03

RELATED SECTIONS

2

1.04

REFERENCES

3

1.05

DEFINITIONS

11

1.06

SUBMITTALS

13

1.07

QUALITY CONTROL

15

1.08

HEALTH AND SAFETY CONSIDERATIONS

17

1.09

DESIGN CRITERIA

18

1.10

JOB CONDITIONS

18

1.11

DELIVERY, HANDLING AND STORAGE

20

PART 2

PRODUCTS

22

2.01

GENERAL

22

2.02

ACCEPTABLE MANUFACTURERS

24

2.03

COLORS AND FINISHES

24

2.04

COATING SYSTEMS/SELECTION GUIDE

25

PART 3

EXECUTION

31

3.01

GENERAL

31

3.02

BANDS, LETTERING SCHEDULE AND COLOR FOR EXTERIOR COATING 31

3.03

SURFACE PREPARATION

32

3.04

APPLICATION OF COATINGS

36

3.05

FIELD QUALITY CONTROL

41

SECTION 09960 HIGH-PERFORMANCE COATINGS

TABLE OF CONTENTS (Contd.)

Item No

Title

Page No

3.06

REMEDIAL WORK

43

3.07

PROTECTION

44

3.08

CLEAN-UP

44

SECTION 09960 HIGH-PERFORMANCE COATINGS

PART 1

GENERAL

1.01 DESCRIPTION OF WORK

A. The extent of painting and coating work is shown on the Contract Drawings and Schedules, and as herein specified.

B. This Specification covers the total removal of existing paint and coating, surface preparation, supply and application of materials, and inspection requirements for painting and/or coating the interior and exterior surfaces of steel and concrete structures, tanks, pipes etc. for high-performance coating.

C. Painting and Coating Work Included

1. Surface preparation of new work, including priming and coats of paint specified in addition to shop priming required under other Sections of the specifications.

2. Surface preparation of existing work, including priming and coats of paint specified in this Section.

3. Field painting and coating of all bare and covered tanks, pipes etc. including color coding specified under the applicable Division 15 Sections and of hangers, exposed steel and iron work, and primed metal surfaces of equipment installed under the mechanical and electrical work, except as otherwise indicated.

4. Where unfinished items or surfaces are not specifically mentioned, these shall be painted the same as adjacent similar materials or areas.

5. In general, the surfaces to be field coated shall consist of, but not be limited to exterior steel and iron surfaces.

6. Shop Primed Work

a) Final field painting or touch-up of manufacturer's shop primed or shop painted work shall not be done until operational testing has been completed and certified.

D. Painting and Coating Work not Included

1. The following categories of work do not require painting or coating and are not included as part of the field-applied finish work, or included in other Sections of these Specifications:

a) Shop Priming

1) Unless otherwise specified, shop priming of new ferrous metal items are included under the various sections for structural steel, miscellaneous metal, hollow metal work, and similar items.

b) Pre-Finished Items

1)

Unless otherwise indicated, do not include painting when factory- finish or installer-finishing is specified for such new items as:

SECTION 09960 HIGH-PERFORMANCE COATINGS

(a)

Stainless steel, aluminum, copper, lead, chromed steel, brass or bronze, and other finish metal items.

(b)

Architectural aluminum.

(c)

Insulated surfaces.

(d)

Surfaces of steel members with concrete cast against them or steel members which will be fully embedded in concrete.

c) Concealed Surfaces

1) Unless otherwise indicated, painting is not required on wall or ceiling surfaces in concealed areas and generally inaccessible areas, such as foundation spaces, furred areas, spaces above suspended ceilings, utility tunnels, pipe spaces, duct shafts, and elevator hoist ways, as applicable to this Project. Painting of piping, equipment, and other such items within these areas is required.

d) Operating Parts and Labels

1)

Moving parts of operating units, mechanical and electrical parts, such as valve and damper operators, linkages, sensing devices, motors and fan shafts will not require finish painting unless otherwise indicated.

2)

Do not paint over any code-required labels, such as Underwriters' Laboratories and Factory Mutual, or any equipment identification, performance rating, name, or nomenclature plates where such painting shall obscure legibility of such labels.

1.02 SECTION INCLUDES

A. High-Performance Coatings for Lining Systems

B. High-Performance Coatings for Tanks

C. Corrosion Resistant Coatings

D. Galvanized Steel Painting

E. Abrasion Resistant Coatings

1.03 RELATED SECTIONS

A. Section 01320

B. Section 01330

C. Section 01410

D. Section 01450

Construction Progress Documentation

Submittal Procedures

Regulatory Requirements

Quality Control

SECTION 09960 HIGH-PERFORMANCE COATINGS

E. Section 01650

Product Delivery Requirements

F. Section 01660

Product Storage and Handling Requirements

G. Section 03310

Structural Concrete

H. Section 05120

Structural Steel

I. Section 07925

Joint Sealants

J. Section 09910

Paints

K. Section 09970

Coatings for Steel

L. Section 09980

Coatings for Concrete and Masonry

1.04

REFERENCES

A. The referred codes and standards are intended to provide an acceptable level of quality for materials and products. In case of conflict between these standards and the text of this Specification, the Specification text shall govern.

B. The latest revision of the referred codes and standards shall be used wherever applicable. In case of conflict, the Contractor shall propose equipment conforming to one group of codes and standards.

C. RCBC

D. ACI

Royal Commission Building Codes

American Concrete Institute

1.

ACI 308

Standard Practice for Curing Concrete

2.

ACI 503R

Use of Epoxy Compounds with Concrete

E. ASTM

American Society for Testing and Materials

1.

ASTM A780

Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

2.

ASTM C672M

Standard Test Method for Scaling Resistance of Concrete Surfaces Exposed to Deicing Chemicals

3.

ASTM C811

Standard Practice for Surface Preparation of Concrete for Application of Chemical-Resistant Resin Monolithic Surfacings

4.

ASTM D117

Standard Guide for Sampling, Test Methods, and Specifications for Electrical Insulating Oils of Petroleum Origin

5.

ASTM D512

Standard Test Methods for Chloride Ion in Water

6. ASTM D516

7. ASTM D522

8. ASTM D570

9. ASTM D609

10. ASTM D740

11. ASTM D823

12. ASTM D1002

13. ASTM D1005

14. ASTM D1044

15. ASTM D1186

16. ASTM D1193

17. ASTM D1248

18. ASTM D1400

19. ASTM D1475

20. ASTM D1535

21. ASTM D1653

22. ASTM D1730

SECTION 09960 HIGH-PERFORMANCE COATINGS

Standard Test Method for Sulfate Ion in Water

Standard Test Methods for Mandrel Bend Test of Attached Organic Coatings

Standard

Plastics

Test

Method

for

Water

Absorption

of

Standard Practice for Preparation of Cold-Rolled Steel Panels for Testing Paint, Varnish, Conversion Coatings, and Related Coating Products

Standard Specification for Methyl Ethyl Ketone

Standard Practices for Producing Films of Uniform Thickness of Paint, Varnish, and Related Products on Test Panels

Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal)

Standard Test Method for Measurement of Dry-Film Thickness of Organic Coatings Using Micrometers

Standard Test Method for Resistance of Transparent Plastics to Surface Abrasion

Standard Test Methods for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to a Ferrous Base

Standard Specification for Reagent Water

Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and Cable

for Nondestructive

of

Nonconductive Coatings Applied to a Nonferrous Metal Base

Standard Test Measurement of

Method

Dry

Film

Thickness

Standard Test Methods for Density of Liquid Coatings, Inks and Related Products

Standard

Munsell System

Practice

for

Specifying

Color

by

the

Standard Test Methods for Water Vapor Transmission of Organic Coating Films

Standard Practices for Preparation of Aluminum and Aluminum-Alloy Surfaces for Painting

23. ASTM D1763

24. ASTM D2092

SECTION 09960 HIGH-PERFORMANCE COATINGS

Standard Specification for Epoxy Resins

Standard Guide for Preparation of Zinc-Coated (Galvanized) Steel Surfaces for Painting

25. ASTM D2240

Standard

Test

Method

for

Rubber

Property

-

Durometer Hardness

 

26. ASTM D2370

Standard

Test

Method

for

Tensile

Properties

of

27. ASTM D2583

28. ASTM D2794

29. ASTM D3278

30. ASTM D4060

31. ASTM D4138

32. ASTM D4212

33. ASTM D4227

34. ASTM D4258

35. ASTM D4259

36. ASTM D4260

37. ASTM D4261

38. ASTM D4262

39. ASTM D4263

40. ASTM D4285

Organic Coatings

Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor

Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact)

Standard Test Methods for Flash Point of Liquids by Small Scale Closed-Cup Apparatus

Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber Abraser

Standard Test Methods for Measurement of Dry Film Thickness of Protective Coating Systems by Destructive Means

Standard Test Method for Viscosity by Dip-Type Viscosity Cups

Standard Practice for Qualification of Coating Applicators for Application of Coatings to Concrete Surfaces

Standard Practice for Surface Cleaning Concrete for Coating

Standard Practice for Abrading Concrete

Standard Practice for Acid Etching Concrete

Standard Practice for Surface Cleaning Concrete Unit Masonry for Coating

Standard Test Method for pH of Chemically Cleaned or Etched Concrete Surfaces

Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method

Standard Test Method for Indicating Oil or Water in Compressed Air

41. ASTM D4414

42. ASTM D4417

43. ASTM D4541

44. ASTM D4708

45. ASTM D4752

46. ASTM D4787

47. ASTM D5064

48. ASTM D5137

49. ASTM D5402

50. ASTM D6132

51. ASTM D6237

52. ASTM E104

53. ASTM E337

54. ASTM G8

55. ASTM G11

56. ASTM G14

57. ASTM G19

SECTION 09960 HIGH-PERFORMANCE COATINGS

Standard Practice for Measurement of Wet Film Thickness by Notch Gages

Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel

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

Standard Practice for Preparation of Uniform Free Films of Organic Coatings

Standard Test Method for Measuring MEK Resistance of Ethyl Silicate (Inorganic) Zinc-Rich Primers by Solvent Rub

Standard Practice for Continuity Verification of Liquid or Sheet Linings Applied to Concrete Substrates

Standard Practice for Conducting a Patch Test to Assess Coating Compatibility

Standard Specification for Hexyl Acetate

Standard Practice for Assessing the Solvent Resistance of Organic Coatings Using Solvent Rubs

Standard Test Method for Nondestructive Measurement of Dry Film Thickness of Applied Organic Coatings over Concrete Using an Ultrasonic Gage

Standard Guide for Painting Inspectors (Concrete and Masonry Substrates)

Standard Practice for Maintaining Constant Relative Humidity by Means of Aqueous Solutions

Standard Test Method for Measuring Humidity with a Psychrometer (The Measurement of Wet- and Dry- Bulb Temperatures)

Standard Test Methods for Cathodic Disbonding of Pipeline Coatings

Standard Test Method for Effects of Outdoor Weathering on Pipeline Coatings

Standard Test Method for Impact Resistance of Pipeline Coatings (Falling Weight Test)

Standard Test Method for Disbonding Characteristics of Pipeline Coatings by Direct Soil Burial

SECTION 09960 HIGH-PERFORMANCE COATINGS

F. ANSI

American National Standards Institute

1. ANSI A21.52

Ductile Iron Pipe, Centrifugally Cast, Gas

G. AWWA

American Water Works Association

1. AWWA D102

Coating Steel Water-Storage Tanks

H. BSI

British Standards Institution

1. BS 3900: PART F17

Methods of Test for Paints - Determination of Wet- Scrub Resistance and Cleanability of Coatings

2.

BS 3900-H1

Methods of Test for Paints - Evaluation of Degradation of Coatings - Designation of Quantity and Size of Defects and of Intensity of Changes - General Principles and Designation System

3.

BS 3900-H4

Methods of Test for Paints - Evaluation of Degradation of Coatings - Designation of Quantity and Size of Defects and of Intensity of Changes - Assessment of Degree of Cracking

4.

BS 3900-H5

Methods of Test for Paints - Evaluation of Degradation of Coatings - Designation of Quantity and Size of Defects and of Intensity of Changes - Assessment of Degree of Flaking

5.

BS 1062-1

Paints and Varnishes - Coating Materials and

 

Coating Systems for Exterior Masonry and Concrete

 

-

Part 1: Classification

 

6.

BS 1062-3

Paints and Varnishes - Coating Materials and Coating Systems for Exterior Masonry and Concrete - Determination and Classification of Liquid-Water Transmission Rate (Permeability)

7.

BS 1062-6

Paints and Varnishes - Coating Materials and Coating Systems for Exterior Masonry and Concrete - Part 6: Determination of Carbon Dioxide Permeability

8.

BS 1062-7

Paints and Varnishes - Coating Materials and Coating Systems for Exterior Masonry and Concrete

 

-

Part 7: Determination of Crack Bridging Properties

9.

BS 1062-11

Paints and Varnishes - Coating Materials and

 

Coating Systems for Exterior Masonry and Concrete

 

-

Part 11: Methods of Conditioning Before Testing

10.

BS 5493

Protective

Coating

of

Iron

and

Steel

Structures

 

Against Corrosion

11.

BS 7079-A1

Preparation of Steel Substrates Before Application of

SECTION 09960 HIGH-PERFORMANCE COATINGS

Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 1: Specification for Rust Grades and Preparations Grades of Uncoated Steel Substrates and of Steel Substrates after Overall Removal of Previous Coatings

I. International Protective Coating Standards

J. ISO

International Organization for Standardization

1.

ISO 1461

Metallic Coatings - Hot Dip Galvanized Coatings on Fabricated Ferrous Products - Requirements

2.

ISO 2063

Metallic and other Inorganic Coatings - Thermal Spraying - Zinc, Aluminum and their Alloys

3.

ISO 2409

Paints and Varnishes - Cross-Cut Test

 

4.

ISO 2808

Paints

and

Varnishes

-

Determination

of

Film

 

Thickness

 

5.

ISO 8501-1

Preparation of Steel Substrates before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 1: Rust Grades and Preparation Grades of Uncoated Steel Substrates and of Steel Substrates after Overall Removal of Previous Coatings

6.

ISO 8501-2

Preparation of Steel Substrates before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 2: Preparation Grades of Previously Coated Steel Substrates after Localized Removal of Previous Coatings

7.

ISO 8502-3

Preparation of Steel Substrates before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 3:

 

Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure-Sensitive Tape Method)

8.

ISO 8502-6

Preparation of Steel Substrates before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 6:

 

Extraction of Soluble Contaminants for Analysis - The Bresle Method

9.

ISO 8502-9

Preparation of Steel Substrates before Application of Paints and Related Products - Group B: Methods for the Assessment of Surface Cleanliness - Part B9:

 

Field Method for the Conductometric Determination of Water-Soluble Salts

10.

ISO 8503-1

Preparation of Steel Surfaces before Application of Paints and Related Products - Surface Roughness

SECTION 09960 HIGH-PERFORMANCE COATINGS

Characteristics of Blast Cleaned Steel Substrates - Specification for Surface Profile Comparators for the Assessment of Abrasive Blast-Cleaned Products

 

11.

ISO 8503-2

Preparation of Steel Substrates before Application of Paints and Related Products - Method for the Grading of Surface Profile of Abrasively Blast Cleaned Steel using a Comparator

12.

ISO 12944-1

General Introduction

 

13.

ISO 12944-2

Classification of Environments

 

14.

ISO 12944-3

Design Considerations

 

15.

ISO 12944-4

Types of Surface and Surface Preparation

 

16.

ISO 12944-5

Protective Paint Systems

 

17.

ISO 12944-6

Laboratory Performance Test Methods

 

18.

ISO 12944-7

Execution and Supervision of Paint Work

19.

ISO 12944-8

Development of Specifications for New Work and Maintenance

20.

ISO 20567-1

Paints and Varnishes - Determination of Stone Chip Resistance of Coatings - Part 1: Multi Impact Test

21.

ISO 20567-2

Paints and Varnishes - Determination of Stone Chip Resistance of Coatings - Part 2: Single Impact Test

K.

NACE

National Association of Corrosion Engineers

 

1.

NACE RP0172

Surface Preparation

of

Steel

and

other Hard

 

Materials by

Water

Blasting

Prior

to Coating

or

Recoating

 

2.

NACE RP0184

Repair of Lining Systems

 

3.

NACE RP0188

Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

4.

NACE RP0287

Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel Surfaces Using a Replica Tape

5.

NACE RP0288

Inspection of Linings on Steel and Concrete

 

6.

NACE RP0591

Coatings for Concrete Surfaces in Non-Immersion and Atmospheric Service

7.

NACE RP0892

Coatings and Linings over Concrete for Chemical Immersion and Containment Service

SECTION 09960 HIGH-PERFORMANCE COATINGS

L. SIS

Swedish Standard Institution

1.

SIS 055900

Surface Pictorial Preparations Standard for Painting Steel Surfaces

M. SSPC

The Society for Protective Coatings

 

1.

SSPC-SP1

(Surface Preparation Standards) - Solvent Cleaning

2.

SSPC-SP2

(Surface

Preparations

Standards)

-

Hand

Tool

 

Cleaning

3.

SSPC-SP3

(Surface

Preparation

Standards)

-

Power

Tool

 

Cleaning

4.

SSPC-SP5

(Surface Preparation Standards) - White Metal Blast Cleaning

5.

SSPC-SP6

(Surface Preparation Standards) - Commercial Blast Cleaning

6.

SSPC-SP7

(Surface Preparation Standards) - Brush-Off Blast Cleaning

7.

SSPC-SP8

(Surface Preparation Standards) - Pickling

 

8.

SSPC-SP11

(Surface Preparation Standards) - Power Tool Cleaning to Bare Metal

9.

SSPC-SP12

(Surface Preparation Standards) - Surface Preparation and Cleaning of Metals by Waterjetting Prior to Recoating

10.

SSPC-SP13

(Surface Preparation Standards) - Surface Preparation of Concrete

11.

SSPC-SP14

(Surface Preparation Standards) - Industrial Blast Cleaning

12.

SSPC-SP15

(Surface Preparation Standards) - Commercial Grade Power Tool Cleaning

13.

SSPC-PA1

(Paint Application Standards) - Shop, Field and Maintenance Painting of Steel

14.

SSPC-PA2

(Paint Application Standards) - Measurement of Dry Coating Thickness with Magnetic Gages

15. SSPC-PA Guide 3

16. SSPC-PA6

(Paint Application Standards) - A Guide to Safety in Paint Application

(Paint Application Standards) - Fiberglass- Reinforced Plastic (FRP) Linings Applied to Bottoms of Carbon Steel Aboveground Storage

1.05

17. SSPC- PA7

DEFINITIONS

SECTION 09960 HIGH-PERFORMANCE COATINGS

Tanks

(Paint Application Standards) - Applying Thin Film Coatings to Concrete

A. acrylic: A synthetic resin used in high-performance water-based coatings. A coating

in which the binder contains acrylic resins.

B. adhesion: The ability of dry paint to attach to and remain fixed on the surface without blistering, flaking, cracking or being removed by tape.

C. air cure: One method by which liquid coatings cure to a dry film. Oxygen from the air enters the film and cross-links the resin molecules. Also called “Air Dry” and “Oxidizing.”

D. alkyd: Synthetic resin modified with oil. Coating that contains alkyd resins in the binder.

E. amide: A functional group which can act as an epoxy resin curing agent.

F. butadiene: A gas which is chemically combined with styrene to create a resin used in latex binders, styrene-butadiene.

G. catalyst: Substance whose presence increases the rate of a chemical reaction, e.g., acid catalyst added to an epoxy resin system to accelerate drying time.

H. chroma: A measurement of color. The degree of saturation of a hue. A color at its full intensity has maximum chroma.

I. coat: A continuous layer of metal material or a continuous film of paint, resulting from

a single application.

J. corrosion inhibitive: A type of metal paint or primer that prevents rust by preventing moisture from reaching the metal. Zinc phosphate, barium metaborate and strontium chromate (all pigments) are common ingredients in corrosion-inhibitive coatings. These pigments absorb any moisture that enters the paint film.

K. DFT: Dry Film Thickness.

L.

durability:

maintenance painting.

The expected

life

of a protective

paint system to the

first major

M. emulsion paint: Coating in which resins are suspended in water, then flow together with the aid of an emulsifier. Example: latex paint.

N. enamel: Broad classification of paints that dry to a hard, usually glossy finish. Most equipment-coating enamels require baking. Enamels for walls do not.

O. epoxy: Extremely tough durable synthetic resin used in some coatings. Epoxy coatings are extremely tough, durable and highly resistant to chemicals, abrasion, moisture and alcohol.

SECTION 09960 HIGH-PERFORMANCE COATINGS

P.

film thickness: Depth or thickness of the dry coating in millimeters.

Q.

galvanizing: Process in which a thin coating of zinc is applied to iron or steel to prevent rust.

R.

lining: A Protective coating on the inner surface of a tank or similar.

S.

material safety data sheet (MSDS): Information sheet that lists any hazardous substance that comprises 1% or more of the product’s total volume. Also lists procedures to follow in the event of fire, explosion, leak or exposure to hazardous substance by inhalation, ingestion, or contact with skin or eyes. Coating manufactures are required to provide retailers with an MSDS for every product they sell to the retailer. Sales clerks should make MSDSs available to retail customers.

T.

mineral spirits: Paint thinner. Solvent distilled from petroleum.

U.

paint: A pigmented coating material, in liquid or in paste or powder form, which, when applied to a substrate, forms an opaque film having protective, decorative or other specific properties. "Paint" as used herein means all coating systems which include primers, emulsions, enamels, stains, sealers, fillers, and other applied coating materials whether used as prime, intermediate, or finish coats.

V.

primer: First complete coat of paint of a painting system applied to a surface. Such paints are designed to provide adequate adhesion to new surfaces or are formulated to meet the special requirements of the surfaces.

W.

protective coating system: The sum total of the coats of metal materials and/or paints or related products which are to be applied or which have been applied to a substrate to provide corrosion protection.

X.

protective paint system: The total sum of the coats of paints or related products which are to be applied or which have been applied to a substrate to provide corrosion protection.

Y.

resin: Synthetic or natural material used as the binder in coatings. Can be translucent or transparent, solid or semi-solid. Examples: acrylic, alkyd, copal ester, epoxy, polyurethane, polyvinyl chloride, silicone.

Z.

solids: The part of the coating that remains on a surface after the vehicle has evaporated. The dried paint film. Also called Nonvolatile.

AA.

solvent: Any liquid which can dissolve a resin. Generally refers to the liquid portion of paints and coatings that evaporates as the coating dries.

BB.

spontaneous combustion: Oils used in many paints can generate heat as they react with air. A fire can occur when materials soaked with these oils are improperly handled or disposed of. Follow all label instructions to avoid the risk of spontaneous combustion.

CC.

substrate: The surface to which the coating material is applied or is to be applied.

DD.

urethane: An important resin in the coatings industry. A true urethane coating is a two-component product that cures when an isocyanate (the catalyst) prompts a chemical reaction that unites the components.

SECTION 09960 HIGH-PERFORMANCE COATINGS

EE.

vehicle: Portion of a coating that includes all liquids and the binder. The vehicle and the pigment are the two basic components of paint.

FF.

volatile organic compound (VOC): Organic chemicals and petrochemicals that emit vapors while evaporating. VOC generally refers to the solvent portion of the paint which, when it evaporates, results in the formation of paint film on the substrate to which it was applied.

GG.

volume solids: Solid ingredients as a percentage of total ingredients. The volume of pigment plus binder divided by the total volume, expressed in percent. High-volume solids mean a thicker dry film with improved durability.

HH.

WFT: Wet Film Thickness.

1.06

SUBMITTALS

A. The Contractor shall submit to the Royal Commission, under the provisions of SECTION 01330, the following items for review and approval before commencing Work:

1. Manufacturer's technical information including paint label analysis and application instructions for each material proposed for use.

2. In addition to the requirements for submitting color samples, the Contractor shall, prior to proceeding with paint and/or coating application, provide mock- ups or field samples, of each substrate to be painted and/or coated. The mock- ups or field samples shall be painted and/or coated to demonstrate method of application, finish texture, color, smoothness, general appearance of the coating and quality of workmanship. The size and location of the mock-ups or field samples shall be determined by the Royal Commission.

3. In case of maintenance coatings, a condition survey report shall be prepared by Contractor based on findings from field inspections. The report shall describe in detail condition of structures to be coated and shall include the procedures for execution of the work.

4. Specifications for each material and cross-reference to the specific paint and finish system and application. Identify by manufacturer's catalog number and general classification.

5. The type and characteristics of the specific materials and items proposed to be used for the work and the sources or facilities for the supply and/or production of such materials and items.

6. The document submittal for each type of coating system material which shall include the manufacturer's complete product specification, technical/performance data and preparation and installation instructions and recommendations.

7. A manufacturer's Certificate of Compliance on the suitability of each type of coating material proposed with specific references to the climatic and environmental conditions under consideration.

SECTION 09960 HIGH-PERFORMANCE COATINGS

8. An outline of procedures proposed for execution of the work, and of testing not covered by Standards and Codes specified herein.

9. The number, type and capacity of all equipment intended for carrying out the work and associated testing.

10. Product Data

a) The following information on composition of organic coatings shall be submitted:

1)

Surface preparation to achieve a surface and profile depth suitable for coating.

2)

Name and manufacture of proposed coating to be used.

 

3)

Composition of coating material. Contents of organic binder, filler and solvent.

4)

Type, grade and class of epoxy in accordance with ASTM D1763.

5)

Results of mechanical, physical and chemical tests according to the following general list:

(a)

Impact, ASTM G14 or D2794.

 

(b)

Abrasion resistance with CS 17 Wheel of 1 kg weight, 5000 cycles, ASTM D1044.

(c)

Adhesion shear, ASTM D1002.

 

(d)

Hardness Shore D, ASTM D2240.

(e)

Hardness Barcol, ASTM D2583.

(f)

Elongation, ASTM D522.

 

(g)

Salt spray for 2000 hours, ASTM D117.

 

(h)

Weatherometer for 5000 hours, ASTM G11 and/or G23.

 

(i)

Resistance to different chemicals.

 

(j)

Resistance to microbiological degradation.

 

(k)

Temperature resistance in dry and wet conditions.

 

(l)

Water absorbance, ASTM D570.

 

(m)

Water vapor permeability, ASTM D1653.

 

(n)

Permeability

of

oxygen,

nitrogen,

carbon

dioxide

and

 

hydrogen sulfide.

 
 

(o)

Cathodic disbanding, ASTM G8 or G19.

 

6)

Method for application of coating.

 

7)

Method for field repair of coating.

8)

Precautions for shipping, handling and storage.

 

11. On 300 x 300 mm hardboard, provide samples of each color and material, with texture to simulate actual conditions. Resubmit each sample as requested until acceptable sheen, color, and texture is achieved.

SECTION 09960 HIGH-PERFORMANCE COATINGS

12. On actual surfaces to be painted, duplicate paint finishes of the accepted samples, on at least 12 m 2 of surface as directed. Provide full-coat finish mock- up samples having required sheen, color, and texture as approved. Simulate finished lighting conditions for review of in-place work. Sample mock-ups shall serve as standard for finish work throughout the Project.

13. An area of the Project will be selected by the Royal Commission to represent typical job surfaces and conditions. Paint and finish the area in accordance with the schedule and as specified. After finishes are accepted, the area will be used for comparison in evaluation of other painting and finishing of other related areas.

14. A complete schedule of materials including substitutes. This schedule, in triplicate, shall list materials by manufacturer, brand name, and type for each surface to be finished.

15. Three copies of Suppliers factory Quality Control Program containing details of suppliers program for testing, monitoring and reporting to the Royal Commission, for review on the quality of materials being supplied for use in the work.

16. Three copies of the Contractors on-site Quality Control Program outlining the procedures proposed to be used for the execution and testing of the work as required by the Specifications.

B. The Contractor shall submit to the Royal Commission by completion of work:

1. Detailed coating schedules describing as-built systems applied to each facility. This schedule shall include surface dryness, surface roughness, methods used for cleaning contaminants and surface preparation. It shall also include information such as batch numbers of all components of the coating system.

1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of Work and shall develop and propose programs and methods of construction and testing to achieve the specified quality to the approval of the Royal Commission in accordance with SECTION 01450.

B. The Contractor shall develop, as part of his Quality Control Program coating operation inspection forms as needed to record the relevant inspection and testing data.

C. The Royal Commission or their authorized representative shall be provided with a detailed schedule and shall be notified 24 hours in advance of all required hold and witness points requiring inspection prior to the scheduled time for coating activities. Failure to provide the required notification may result in the requirement for re- inspection or rework.

D. Hold points for inspection shall occur after the following operations, and at any other points requested by the Royal Commission:

1. Initial surface condition prior to start of work.

SECTION 09960 HIGH-PERFORMANCE COATINGS

2. After surface preparation.

3. Stripe coating of difficult areas.

4. Application of each coat of the coating system.

5. Completion of the full system prior to putting back into service, i.e. final inspection.

E. The Contractor shall maintain a qualified supervisor on site during all coating application operations in accordance with SECTION 01450.

F. The Contractor shall conduct the following test to ensure conformance with the requirements of this Specification:

1. Surface profile.

2. Surface chloride content.

3. Measurement of WFT and DFT.

4. Adhesion of coating.

5. Moisture content in concrete.

6. Holiday detection as agreed with the Royal Commission.

G. Source Quality Control

1. Pipes, fittings, valves and other equipment of iron or steel shall be tested at the place of manufacture in accordance with the relevant standard specifications unless otherwise stated.

H. Paint Compatibility

1. Provide finish coats which are compatible with the prime paints used.

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

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

c) Notify the Royal Commission in writing of any anticipated problems using the coating systems specified on substrates pre-primed.

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

a) Verify existing paint coating materials by site examination and testing, if required. Notify the Royal Commission for direction as to obtaining

SECTION 09960 HIGH-PERFORMANCE COATINGS

access and samples.

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

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

4. Painting Steel and Concrete

a) Comply with SSPC specifications as referenced in par. 1.04.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full accordance with the respective health and safety requirements established by the following:

1. Kingdom of Saudi Arabia

a) Legislation, Regulation, Standards and Codes.

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor

a) Health and Safety Standards and Systems as accepted by the Royal Commission.

B. In the absence of any of the above, best accepted industry practice shall be employed throughout.

C. Sufficient mechanical forced ventilation shall be provided for the duration of blasting, coating and curing operations inside tanks or other confined areas.

D. Proper lighting, without creating shadows or glare, shall be provided during coating application. The lighting fixtures shall be explosion proof, safety type system.

E. Positive pressure helmets and goggles shall be worn by workmen during blasting operation inside tanks or other confined areas.

F. Spraying equipment shall be grounded and all precautions shall be taken to prevent buildup of static electricity.

G. All sources of ignition and persons smoking shall be kept at least 50 m away during mixing, coating and curing operations.

H. When blasting in confined areas or inside tanks, all blasting nozzles shall be equipped with "dead man" or remote controls for automatic shutoff.

SECTION 09960 HIGH-PERFORMANCE COATINGS

1.09 DESIGN CRITERIA

A. The paint and coating systems shall be suitable for the intended service conditions and environments. Special importance is given to its durability under exposure to oil, gasoline, diesel, chemicals, acids, waste water, potable water, sun, abrasive sand and dust storms, and high humidity seacoast air.

B. The Contractor shall be aware of the above mentioned requirements and assure that all materials, preparation and methods of application shall ensure full performance of all coating systems. Full performance shall mean to provide full protection to the material coated and maintain an acceptable appearance for a period of 10 years with no abrasions, which occurs as a result of operations. Failure of coating system due to preparation, application, materials, natural or service environment shall not be considered full performance.

C. The Contractor shall provide a 10 years guarantee for the coatings applied under the work of this Contract. During this period, the Contractor shall repair or replace, as directed by the Royal Commission, all coatings which fail to perform as specified. Failure shall include any lessening of protection to the material coated, degradation of integrity of the coating material or deterioration of surface condition beyond normal wear and weathering due to any cause other than damage to the coating during normal operations, such as nicks or abrasion.

1.10 JOB CONDITIONS

A. General

1. The Contractor shall not apply exterior paint or coating during sand storms, rain, or fog.

2. The Contractor shall not apply paint or coating when the relative humidity exceeds 85%, or to damp or wet surfaces, unless permitted by the paint manufacturer's printed instructions.

3. The Contractor shall not apply any coating when the substrate surface temperature is below 3 ° C above the dew point (condensation level).

B. The Contractor shall not apply coating when the surfaces to be painted and the surrounding air conditions are outside the limits following below:

1. Zinc Ethyl Silicate

a) Surface and Air Temperature

1)

Below 10°C and above 32°C, unless otherwise permitted by the paint manufacturer's printed instructions.

b) Relative Air Humidity

1)

Below 50% and above 90%, unless otherwise permitted by the paint manufacturer's printed instructions.

SECTION 09960 HIGH-PERFORMANCE COATINGS

2. Other Coatings

a) Surface and Air Temperature

1)

Below 10°C and above 32°C, unless otherwise permitted by the paint manufacturer's printed instructions.

b) Relative Air Humidity

1)

Above 85%, unless otherwise permitted by the paint manufacturer's printed instructions.

C. Paint may be applied during inclement weather if the areas and surfaces to be painted are enclosed and heated or air conditioned within the temperature and relative air humidity limits specified.

D. The Contractor shall measure moisture content of surfaces using an electronic moisture meter.

E. The Contractor shall not apply finishes unless the moisture content of surfaces is below the following maximum:

1. Plaster: 5%.

2. Concrete and Concrete Blocks: 5%.

F. Thermally Sprayed Metallic Coatings

1. The materials and conditions for metal spraying shall be in accordance with ISO 2063.

G. The Contractor shall read and follow carefully the label instructions on each container in regards to minimum and maximum allowable surface temperature for each specific product prior to application.

H. Provide adequate and continuous ventilation during interior applications. Interior enclosures such as tanks shall be properly vented to ensure forced ventilation until protective coatings have reached total cure.

I. High intensity flood or spot lights are required for visibility. All lighting equipment shall be low voltage and explosion-proof.

J. All personnel entering tanks after abrasive blasting shall wear rubber soled shoes with clean disposable shoe covers sweat bands and lint-free gloves.

K. If required, stand-by equipment shall be at the jobsite to avoid any shutdowns or delays in production.

L. When coating existing tanks and/or when work location is in restricted areas, the schedule of work shall be coordinated with the O & M Contractor and the Royal Commission to obtain access to the work areas.

M. The manufacturers' instructions shall be followed with regard to minimum and maximum allowable surface temperature for each specific product.

SECTION 09960 HIGH-PERFORMANCE COATINGS

1. Adequate and continuous ventilation shall be provided during application of coatings. The tanks shall be properly vented until coatings have reached total cure. Unless otherwise directed, at least 7 days curing under ventilation shall be provided.

2. Adequate lighting at work areas shall be provided during coating application.

1.11 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store equipment and material units in accordance with SECTIONS 01650 and 01660, as well as the following requirements:

1. Name or title of material.

2. Manufacturer's stock number and date of manufacture.

3. Manufacturer's name.

4. Manufacturing standard.

5. Contents by volume for major pigment and vehicle constituents.

6. Thinning instructions.

7. Application instructions.

8. Color name and number.

9. Product data sheets.

10. Quality control certificates.

B. Store materials and equipment in a designated storage space on the site. Keep storage space neat, clean, and accessible at all times. Protect floors from paint spillage. Comply with fire safety requirements for flammable materials.

C. Provide adequate, enclosed and well ventilated storage facilities separate from storage of other building materials. Store paint material at a minimum ambient temperature of 7°C.

D. Containers of paint or components shall not be opened except for immediate use. Materials older than the manufacturers recommended shelf life shall not be used and shall be removed from the site.

E. All necessary precautions to prevent fire hazards and spontaneous combustions have to be taken.

F. At the end of daily work, all containers in use shall be closed tightly and removed from site.

SECTION 09960 HIGH-PERFORMANCE COATINGS

G. The Contractor shall not dispose solid and liquid wastes from its work down to any sanitary fitting, sink and drains. All waste materials shall be removed from the site in airtight containers and disposed as directed by the Royal Commission.

SECTION 09960 HIGH-PERFORMANCE COATINGS

PART 2

PRODUCTS

2.01

GENERAL

A. All goods and products covered by these Specifications shall be procured, when available, from an in-Kingdom manufacturer. Procurement of all goods and products manufactured out-of-Kingdom must be approved by the Royal Commission.

B. Proprietary names used to designate colors or materials are not intended to imply that products of the named manufacturers are required to the exclusion of equivalent products of other Saudi Arabian manufacturers.

C. Coatings shall be premixed and formulated, except for the 2-component on-site catalyzed coatings. Pigments shall be capable of being readily and uniformly dispersed to provide a homogenous mixture for the selected method of application, i.e. brush, roller, conventional air assisted spray or airless spray methods, as recommended in the manufacturer's application data sheets. Coatings shall not be thinned except as indicated in the manufacturer's product data sheets and then only using the manufacturers recommended thinner.

D. Provide only absolutely pure linseed oil, turpentine, shellac, and other like material that are of the highest quality with identifying labels intact and seals unbroken.

E. Use only primers and under coaters that are suitable for each surface to be covered and that are compatible with the finish coat required.

F. If ferrous metals are shop primed, the Contractor shall make every effort to determine the type of primer used. If this is not possible or the primer is not compatible with the proposed finish coat, a barrier coat as recommended by the coating manufacturer may be required prior to application of finish coat.

G. If nothing else is mentioned in this Section, penetrants shall have 10 mm minimum penetration capability and 95% minimum water repelling rating. They shall also be highly resistant to chloride ion penetration and shall show a minimum of 90% reduction on chloride ions at depth of 25 mm as compared to untreated concrete.

H. Abrasive Blasting Media

1. If nothing else is mentioned in this Section:

a) The Contractor shall propose the abrasive blasting media to be employed for approval by the Royal Commission. Only clean, sharp and angular grit from an approved source shall be used for abrasive blast cleaning. The grit shall be free from excessive fines and shall not contain more than 50 ppm of chlorides, sulfates or other water-soluble salts. The grit may be steel grit, chilled iron grit, aluminum oxide grit, silica or crushed garnet grit. Other abrasive blasting media and methods of surface preparation may be proposed by the Contractor for approval by the Royal Commission.

b) The use of sand for surface preparation is not permissible unless the sandblasting takes place in a totally enclosed area equipped with particulate emission control measures.

SECTION 09960 HIGH-PERFORMANCE COATINGS

I. Use products of the same manufacturer for succeeding coats with the possible exception of the following:

1. Where shop primed materials are to be finish painted or prime coat materials are by a different manufacturer than finish coat materials, confirm compatibility of the primers with the manufacturer of the finish coat paints.

2. Where existing previously painted surfaces are to be finish painted, confirm compatibility of existing painted surfaces with the manufacturer of the succeeding new paints.

J. Provide paints of durable and cleanable quality. Use paint materials which will withstand normal washing as required removing pencil marks, ink, ordinary soiling, and related conditions without showing discoloration, loss of gloss, staining, or other damage.

K. Organic Coatings

1. The type and quality of the coating must be chosen with regard to the corrosive properties of the media to be transported or stored, and to the extreme climatic conditions. The coating shall have a high abrasion resistance, excellent adhesion and a low water and gas permeability.

2. The materials used for the coating must be free from low temperature volatile solvents or other constituents which can cause evaporation and peeling during storage.

3. The organic coatings used for internal and external insulation shall have a softening point (by the ring and ball method) higher than 110°C.

4. The coating shall have a dry film thickness of not less than specified.

5. Primer materials shall be rust inhibitive and fully compatible with finish coat materials.

6. Shop applied finish coatings on steel shall consist of zinc galvanize, alkyd enamel or epoxy paint systems.

7. Paint applied over primed or previously painted surfaces shall cause no wrinkling, lifting or damage to under laying paint.

8. Epoxy system coatings shall be applied without primer unless indicated otherwise in this Section.

9. The materials used for the coating of (steel) pipes used for transporting of drinking water or equipment located in drinking water must be sufficiently free from low temperature volatile solvents or other constituents which can cause evaporation and peeling during storage or can cause taste or odor in the drinking water.

10. Unless stated otherwise in this Section, on Contract Drawings or Technical Specifications, minimum total paint film thickness including prime coat (if any), intermediate coats, and finish coat shall be no less than:

SECTION 09960 HIGH-PERFORMANCE COATINGS

a) Alkyd Enamel:

125 micron.

b) Coal Tar Epoxy:

500 micron.

c) Epoxy Enamel:

500 micron.

d) Polyurethane:

500 micron.

e) Organic Coatings:

300 micron.

f) Zinc Layer Thickness

1)

Hot Dip Galvanized Steel:

80 micron.

2)

Bolts and Nuts:

80 micron.

3)

Metallic fittings and valves for underground piping including connecting parts, bolts and nuts:

120 micron.

11. The coatings shall be free from voids, missed spots and pinholes.

12. The type and quality of the coating must be chosen with regard to the corrosive properties of the fluid to be transported and/or stored, and to the extreme climatic conditions. In view of the presence of abrasive particles and conditions producing high water velocities, varying media pressures and the prevailing wind and sand conditions, the coating shall have a high abrasion resistance, excellent adhesion and a low water and gas permeability.

2.02 ACCEPTABLE MANUFACTURERS

A. All coating materials (paints) shall be furnished by a manufacturer, regularly engaged in the manufacture of coatings for industrial application. All coatings shall be per manufacturers designated product line.

2.03 COLORS AND FINISHES

A. Prior to beginning the work, the Contractor shall submit to the Royal Commission for approval sample color chips and a Color Schedule for all surfaces to be painted and finished. Colors may not necessarily be the manufacturers’ standard colors. Special colors shall be provided as required.

B. Use representative colors when preparing samples for the Royal Commission’s review. Final acceptance of colors will be from sample mock-ups applied on the job.

C. Color Pigments

1. Pure, non-fading types to suit the substrates and service indicated. Lead content in pigment, if any, shall not exceed more than 0.5% lead, based on the total non-volatile, dry-film, of the paint by weight. This limitation shall extend to all interior surfaces and those exterior surfaces, such as stairs, decks, porches, railing, windows, and doors which are readily accessible to children under 7 years of age.

SECTION 09960 HIGH-PERFORMANCE COATINGS

2.04 COATING SYSTEMS/SELECTION GUIDE

A. Coating materials are given herein by generic type for application on ferrous and concrete substrates. However, when performing isolated patch repairs on small areas, the Contractor may propose to use other coatings, which shall be consistent with environment and compatible with the original coatings. The generic coating systems are given as guidance when no specific requirements are given to the Contractor.

B. For potable water storage tanks, the coating materials shall be approved for potable water usage.

C. All material and systems proposed will be subject to review and acceptance by the Royal Commission.

D. Generic coating systems for steel and concrete surfaces. The coating systems are sectioned into field of application:

1. Tanks for Leaded and Unleaded Gasoline and Diesel

a) Phenol Modified Epoxy, in 2 to 3 Layers:

OR

b) High Solid Epoxy, in 2 to 3 Layers:

OR

c) Glass Flake Polyester, in 2 Layers:

OR

d) Glass Flake Epoxy, in 3 Layers:

300 to 400 micron.

300 to 400 micron.

1500 micron.

1500 micron.

2. Acid Tanks and Equipments for Smoke Purification

a) Ceramic Epoxy, in 1 to 2 Layers:

OR

b) Glass Flake Modified Vinyl Esther Resin, in 2 to 6 Layers:

3. Heavy Fuel Oil Tanks

a) High Solid Epoxy, in 2 to 3 Layers:

OR

b) Epoxy Coating, in 2 to 3 Layers:

OR

1000 to 2000 micron (Not for concrete constant immersed in the fluid).

1500 to 5500 micron.

300 to 400 micron.

300 to 400 micron.

SECTION 09960 HIGH-PERFORMANCE COATINGS

c) Glass Flake modified Vinyl Esther Resin, in 2 to 6 Layers:

4. Oil and Gas Pressure Tanks

a) Phenol modified Epoxy, in 2 to 3 Layers:

OR

b) Ceramic Epoxy, in 1 to 2 Layers:

OR

c) Epoxy Coating, in 2 to 3 Layers:

1500 to 5500 micron.

300 to 400 micron.

1000 to 2000 micron (Not for concrete constant immersed in the fluid).

300 to 400 micron.

5. Potable, Irrigation, Reclaimed and Sewage Water Above Grade Steel Tanks

a) Internal Surfaces

1)

Surface Preparation: SSPC-SP5 "White Metal."

2)

Primer

(a)

Two-component amine cured, epoxy primer, to be applied as recommended by the coating manufacturer.

3)

Intermediate and Top Coats

(a) Two-component, high build, amine cured epoxy; 2-coats of minimum thickness 200 microns per coat, for a total average DFT of 400 micron.

b) External Surfaces

1)

2)

3)

4)

Surface Preparations: SSPC-SP10 "Near White Metal."

Primer

(a) Two-component high build, zinc phosphate polyamide cured epoxy; to be applied as recommended by the coating manufacturer.

Intermediate Coat

(a) Two-component high build, polyamide epoxy; 1-coat of minimum 200 micron DFT.

Top Coat

(a) Two-component high gloss, recoatable Acrylic polyurethane; 1-coat of minimum 75 micron DFT.

c) Color

1)

Potable Water Tanks

(a) The finish coat to be applied to the tank exterior steel surfaces shall be light blue. Bands and lettering shall be dark blue and as specified in par. 3.02.

SECTION 09960 HIGH-PERFORMANCE COATINGS

2)

Irrigation Water Tanks

(a) The finish coat to be applied to the tank exterior steel surfaces shall be celtic green. Bands and lettering shall be white and as specified in par. 3.02.

6. Potable, Irrigation, Reclaimed and Sewage Water Tanks of Concrete (New and

Existing)

a) General

1) The coating materials vary for internal and external surfaces. Where the surface preparation requires blasting, the Contractor shall propose the blast media to be employed for approval by the Royal Commission.

b) Surface Filler

1)

The surface filler shall be epoxy mortar compatible with the coating system.

c) Internal Surfaces

1)

Primer

(a)

Two-component, solvent free, amine cured epoxy sealing primer, to be thinned on site as recommended by the manufacturer.

2)

Intermediate and Top Coats

(a) Two-component, solvent fee, amine cured epoxy; 2-coats of minimum thickness 200 micron per coat, for a total average DFT of 400 micron.

d) External Surfaces

1)

2)

3)

Primer

(a) Two-component, solvent free, polyamide cured epoxy sealing primer, to be thinned on site as recommended by the manufacturer.

Intermediate Coat

(a) Two-component, solvent free, polyamide cured epoxy; 1-coat of minimum 200 micron total DFT.

Top Coat

(a) Two-component, recoatable acrylic polyurethane; 1-coat of minimum 75 micron DFT.

e) Color

1)

Potable Water Tanks

(a) The finish coat to be applied to the tank exterior concrete surfaces shall be light blue. Bands and lettering shall be dark blue and as specified in par. 3.02.

SECTION 09960 HIGH-PERFORMANCE COATINGS

2)

Irrigation Water Tanks

(a) The finish coat to be applied to the tank exterior concrete surfaces shall be celtic green. Bands and lettering shall be white and as specified in par. 3.02.

7. Internal of Waste Water Handling Chambers

a) Concrete Flow Dividing Chambers and Wet Wells in Sanitary Waste Water

1)

2)

3)

4)

Primer

(a) Two-component, solvent free, amine cured epoxy sealing primer, to be thinned on site as recommended by the manufacturer.

Intermediate Coat

(a) Fiber glass reinforced epoxy lining system comprising two- components, solvent free, amine cured epoxy; 2-coats shall

open wave fiberglass

mat and a 30 g/m 2 tissue mat on top. Chopped fiberglass of

equivalent weight per square meter may be used instead of the open wave mat as an alternative.

Top Coat

(a) Two-component, solvent free, amine cured epoxy; 1-coat of minimum 250 microns DFT.

The average total DFT of the lining system shall be 1500 microns.

be applied to fully embed a 300 g/m

2

8. Marine Structures

a) Steel

1)

2)

3)

Surface Preparation: SSPC-SP10 "Near White Metal."

Primer

(a) Two-component, high build, zinc phosphate amine cured epoxy, to be applied as recommended by the coating manufacturer.

Intermediate and Top Coats

(a) Two-component, high build, free, amine cured coal tar epoxy; 2-coats of minimum thickness 200 micron per coat, for an average total of 400 micron DFT.

b) Concrete

1)

Primer

(a)

Two-component, solvent free, amine cured epoxy sealing primer, to be thinned on site as recommended by the manufacturer.

2)

Intermediate and Top Coats

(a) Two-component, solvent free, amine cured coal tar epoxy;

SECTION 09960 HIGH-PERFORMANCE COATINGS

2-coats of minimum thickness 200 micron per coat, for an average total of 400 micron DFT.

9. Miscellaneous Surfaces in Interior or Exterior Industrial Exposure

a) Steel (Piping, stairs, platforms, structural steel, etc. shall be galvanized using the hot dip process unless indicated otherwise).

1)

Galvanized Steel

 

(a)

Surface Preparation and Primer

 

(i)

Etch primer containing phosphoric acid, to be applied as recommended by the coating manufacturer.

2)

Non-Galvanized

Steel or Galvanized Steel with Extensive

Corrosion

(a) Surface Preparation and Primer

(i) SSPC-SP10 "Near White Metal," and 2-component high build, zinc phosphate polyamide cured epoxy; 1-coat of minimum 125 micron DFT.

(b) Intermediate Coat

(i) Two-component high build, polyamide cured epoxy; 1-coat of minimum 200 micron total DFT.

(c) Top Coat

(i) Two-component high gloss, recoatable acrylic polyurethane; 1-coat of minimum 75 micron DFT.

b) Concrete

1)

Primer

 

(a)

Two-component solvent free, amine cured epoxy sealing primer, to be thinned on site as recommended by the manufacturer.

2)

Intermediate Coat

(a)

Two-component, high build, polyamide cured epoxy; 1-coat of minimum 200 micron total DFT.

3)

Top Coat

(a) Two-component high gloss, recoatable Acrylic polyurethane; 1-coat of minimum 75 microns DFT.

10. Storage Places for Foodstuff

a) High Solid Epoxy, in 2 to 3 Layers:

OR

b) Epoxy Resin 100% Volume Solids, in 2 to 3 Layers:

OR

300 to 400 micron.

400 to 500 micron.

SECTION 09960 HIGH-PERFORMANCE COATINGS

c) Elastomer Polyurethane, in 2 to 3 Layers:

11. Chemical Tanks

a) Phenol Modified Epoxy, in 2 to 3 Layers:

OR

b) Ceramic Epoxy, in 1 to 2 Layers:

OR

c) Glass Flake modified Vinyl Esther Resin, in 2 to 6 Layers:

1500 to 2000 micron.

300 to 400 micron.

1000 to 2000 micron (Not for concrete constant immersed in fluid).

1500 to 5500 micron.

SECTION 09960 HIGH-PERFORMANCE COATINGS

PART 3

EXECUTION

3.01 GENERAL

A. This Section covers the shop priming and painting of steel and concrete structures including surface preparation, materials, workmanship, protection of surface, and other appurtenant work. The Contractor shall furnish all materials, tools, equipment and labor and do all painting work specified herein.

B. Unless otherwise stated, all cast iron, ductile iron and steel surfaces shall be protected by suitable paint or coatings applied in the shop. Surfaces to be field painted after equipment installation shall be shop painted with 1 or more coats of a primer which will be adequately protect the equipment until finish coats are applied. Electric motors, pumps, speed reducers, starters, and other self-contained or enclosed components shall be shop finished with a high grade, oil resistant enamel.

C. Steel equipment not in contact with the media such as framework, pipe supports, hangers, support structures for equipment, anchor bolts for machines, loose flanges for piping, bolts, nuts etc., shall be hot dip galvanized before delivery to the site.

D. Machined, polished, and non-ferrous surfaces which are not normally painted by the supplier shall be coated with rust preventive compound.

E. Except as otherwise required or directed, the following surfaces are to be left unpainted:

1. Exposed surfaces of aluminum.

2. Polished or finished stainless steel.

3. Nickel or chromium.

4. Galvanized surfaces, except piping and conduit.

5. Rubber and plastics, including fiberglass reinforced plastics.

3.02 BANDS, LETTERING SCHEDULE AND COLOR FOR EXTERIOR COATING

A. If nothing else specified in this Specification, tanks shall be banded and labeled in Arabic and in English to meet the following criteria:

1. Distance from Top of Tank:

500 mm.

2. Width of Band, Top Band:

500 mm.

3. Width of Band, Bottom Band:

330 mm.

4. Spacing between Bands:

160 mm.

5. Size of Letters, Arabic:

500 mm.

6. Size of Letters, English:

330 mm.

SECTION 09960 HIGH-PERFORMANCE COATINGS

B. Lettering shall be located at breaks in the banding at 4 places, equally spaced around tank and 10 m in total length for all 4 places for each of Arabic and English.

C. At Contractors request, a sample detail of the bands and lettering schedule will be furnished by the Royal Commission.

D. Potable Water Tanks

1. The color of the finish coat to be applied to the tank exterior steel or concrete surfaces shall be light blue. The color of the bands and lettering shall be dark blue.

E. Irrigation Water Tanks

1. The color of the finish coat to be applied to the tank exterior steel or concrete surfaces shall be "Celtic green." The color of bands and lettering shall be white.

3.03 SURFACE PREPARATION

A. General

1. All surfaces shall be dry when coated and cleaned from dirt, dust, sand, mud, oil, grease, rust, mill scale, and other substances that may interfere with proper adhesion of coating. However, in case of difficult areas where proper surface preparation cannot be achieved, the Contractor shall use special primers with rust inhibitors or use rust conversion primers as approved by the Royal Commission. Primers applied over such areas shall be very highly viscous and highly penetrating.

2. If removal of existing coating is required, the surfaces shall first receive pressure water blasting for cleaning, and then the coating shall be removed using methods approved by the Royal Commission. If removal of existing lining is performed on isolated small areas, vacuum waste equipment shall be used without causing damage to surrounding coating.

3. When top coating existing coated areas, the new coating materials shall be compatible with the original coating system. Surface preparation of sound existing coating, which will be top coated, shall be carried out as approved by the coating material's manufacturer and the Royal Commission. Any requirements for cleaning by pressure washing or abrading by sweep blasting shall be carried out at pressure that will not damage the existing coating.

4. The compressed air supply shall be free of moisture, oil and other contaminants. Blotter tests shall be performed in accordance with ASTM D4285 at the start and every 4 hours of operations. The Contractor shall provide traps, separators and dehumidifiers and other equipment as required to maintain the required air quality.

5. Blast air pressure shall be 580 to 690 kPa at the nozzle. Nozzles shall be 10 mm venture carbide. The pressure shall be verified regularly with hypodermic needle air pressure gage.

SECTION 09960 HIGH-PERFORMANCE COATINGS

6. Abrasive blasting shall not be performed when the temperature of air or surface to be coated is below 5°C, when the relative humidity exceeds 80% or when the surface temperatures is less than 3°C above the dew point.

7. The Contractor shall indicate the surface profile achieved on steel surfaces. Surface profile may be assessed using replica tape.

8. After blasting and/or grinding just prior to application of coatings, all debris and dust remaining on the cleaned surface and adjoining surface shall be removed by suction cleaner methods to leave a clean surface.

9. Emulsion cleaning or water blasting may be used to remove chalky, friable portions of existing coating systems, grease, dirt, deleterious chemicals, and other contaminants. Cleaning solutions shall be of the type that will not cause damage to coating or substrate.

10. The use of solvent-type cleaner shall not be permitted. If oil, grease etc., has contaminated a surface, it shall be removed by use of an approved emulsion cleaner, flushing with clean (potable grade) water and complete drying before blast-cleaning.

11. In repairing isolated damaged coating, feathering shall be performed at repaired areas so that there is a fairly smooth transition from the repair area to the sound coating. Recommendation given in NACE RP0184 shall be followed for feathering repair areas.

12. At all times after cleaning, the Contractor shall protect both cleaned and painted surfaces from contamination and damage from any cause whatsoever, including contact between the surface and human skin, clothing or other fabric or sweat drops or other substances.

13. In repairing isolated damaged coating, the same original number of coats and coat thickness shall be applied during the repair procedure. In small repair areas, application of coating by brush is permissible; however, large isolated areas shall be coated by spraying, except the primer shall be applied by brush. The coating shall be applied from the substrate out over the feathered edge of the coating and on to a lightly abraded area beyond the feathered edge.

14. Painters and their assistants and inspectors who necessarily have to walk on or traverse cleaned floor surfaces shall wear soft soled footwear, and all such traffic shall be kept to a minimum.

15. Blast cleaning or other surface preparation shall not be performed at the same time as painting or whenever flammable vapor from paint solvents may be present in the atmosphere.

16. If not specified, all surface defects such as blemish, cracks, etc., shall be filled with an approved filler material. The method of application shall be as approved by the manufacturer.

B. Ferrous Metal (Steel) Surfaces

1. All steel surfaces shall be prepared for coating by being thoroughly cleaned by blasting as specified in this Specification. The surface profile after blast

SECTION 09960 HIGH-PERFORMANCE COATINGS

cleaning shall be in the range 35 to 75 micron. Other surface preparation may be proposed by Contractor for approval by the Royal Commission.

2. The primer shall be applied within 4 hours of blast cleaning and before any surface deterioration occurs.

3. Shop primed and galvanized surfaces shall be cleaned of oil, grease and other contaminants by cleaning agent, rinsed and allowed to dry before further surface preparation or coating operations.

4. Surface of welds shall be ground smooth as necessary to remove all slag and weld spatter. Sharp points and edges shall be rounded to radius of 3 mm or greater before coating. The use of chipping tools which produce cuts, burrs, or excessive roughness is not acceptable. Paint made brittle by heat of welding, or which has been otherwise damaged, shall be removed and the edges of undamaged paint feather-edged so that patches will not be noticeable when the painting has been completed. Before any field painting is done, all field welded seams and joints, together with all surface of plates and structural members not previously painted and surfaces from which damaged paint has been removed, shall be prepared for painting by blasting. All lapped joints shall be sealed internally to eliminate crevices.

5. Maintenance of pinpoint rusting of coatings shall be carried out by removing the coating over the pinpoint rusting areas. Other surface preparation and coating requirements shall be as specified in this Specification.

6. Grinding shall also be used to smooth off all sharp edges and rough welding seams and to remove spatters on welded details.

7. Surface cleaning after possible grinding and degreasing prior to hot dip galvanizing shall be made by pickling and washing in water.

C. Galvanized Metals (Steel)

1. New Galvanized Metals (Steel)

a) Clean unpainted galvanized metal surfaces of all oil, grease, and other contaminants in accordance with the applicable requirements of SSPC- SP1 “Solvent Cleaning” and pretreatment in accordance with SSPC-PT2 “Cold Phosphate Surface Treatment,” prime with Polyamide epoxy primer and Polyurethane topcoat finish paint with UV protection coating system.

2. Corroded Galvanized Metals (Steel)

a) Clean and prime existing painted galvanized metal surfaces in accordance with the requirements of SSPC-SP1 “Solvent Cleaning” followed by preparation of any abraded or corroded areas methods complying with SSPC-SP2 “Hand Tool Cleaning” or SSPC-SP3 “Power Tool Cleaning” and primer as herein before specified.

3. Repair of Existing Galvanized Metals (Steel)

a) Clean unpainted galvanized metal surfaces of all oil, grease, and other

SECTION 09960 HIGH-PERFORMANCE COATINGS

contaminants in accordance with the applicable requirements of SSPC- SP1 "Solvent Cleaning" and pretreat in accordance with SSPC-PT2 "Cold Phosphate Surface Treatment," prime with a zinc dust, zinc oxide, or alkyd paint.

4. Prior to application of subsequent coats, thoroughly clean all surfaces to ensure the removal of any grease, soil, dust, or foreign matter. Take particular care to prevent the contamination of cleaned surfaces with salt, acids, alkali or other corrosive chemicals before prime coating and between subsequent coats of paint.

5. Application of new paint on existing paint on Galvanized Metals (Steel). Clean and prime existing painted galvanized metal surfaces in accordance with the requirements of SSPC-SP1 "Solvent Cleaning" followed by preparation of any abraded or corroded areas by methods complying with SSPC-SP2 "Hand Tool Cleaning" and primer as herein before specified.

D. Concrete Surfaces

1. Coatings shall be applied to the concrete surfaces only after the concrete has completely cured.

2. Surface Condition

a) Existing coatings shall be removed to the extent identified on Contract Drawings by abrasive blast cleaning. When coating new concrete surfaces, laitance and efflorescence shall be removed from concrete surfaces by blast cleaning. Care shall be taken to ensure that aggregates are not unduly exposed during the cleaning process. Unsound concrete containing defects such a cracks, spalling and large cavities shall be repaired prior to the application of primer sealer, using concrete repair procedures approved by the Royal Commission. The concrete surface shall be free from sharp protrusions which would reduce coating thickness locally.

b) Minor surface defects in the concrete shall be repaired in accordance with par. 3.03 D.3 below before the application of the primer sealer.

c) After all blast cleaning and repairs to unsound concrete have been completed by approved procedures, the concrete surfaces shall be swept to remove loose debris and dust particles. All concrete surfaces to be coated shall be washed free of salt. Any oil/grease contamination shall be removed using degreasing agents. Further contamination of surfaces prior to the application of the primer sealer coat shall be avoided.

d) Areas of concrete repairs must be dry. The primer sealer coat shall be applied immediately after vacuum cleaning of the surfaces to remove dust and debris and within 3 days of blast cleaning. Moisture levels of all concrete (existing and repaired) shall be less than 5% to a depth of approximately 75 mm. The actual depth and the method of moisture measurement shall be in accordance with the coating manufacturer recommendations and shall be approved by the Royal Commission.

SECTION 09960 HIGH-PERFORMANCE COATINGS

3. Test Area

a) An acceptable in-situ concrete test area representative of the overall tank surface condition shall first be prepared to establish the required level and degree of surface preparation. A minimum of concrete surface preparation acceptance level shall be established on colored photographs of the test area after approval by the Royal Commission.

4. Surface Filling

a) Exposed holes, blemishes, and similar surface defects shall be filled with an approved epoxy mortar. The method of application shall be as recommended by the manufacturer.

E. All other Cementitious Materials

1. Prepare cementitious surfaces of cast concrete, glass fiber reinforced concrete, concrete masonry, cement plaster, and cement-asbestos board to be painted by removing all efflorescence, chalk, dust, dirt, grease, oils, loose or excess mortar by roughening as required to remove glaze, or provide sufficient bite on existing painted surfaces. Wash all cementitious surfaces with a diluted acid solution of 10 parts water to 1 part muriatic (hydrochloric) acid. Wash down acid etched surface to neutralize acid and let dry before applying paint.

2. If form oils or incompatible curing compounds are used, the surface shall receive a sweep sandblast.

3. Determine the alkalinity and moisture content of the surfaces to be painted by performing appropriate tests. If the surfaces are found to be sufficiently alkaline to cause blistering and burning of the finish paint, correct this condition before application of paint.

4. Do not paint over surfaces where the moisture content exceeds 5%, unless otherwise permitted in the manufacturer's printed directions.

5. Cut out cracks, holes, indentations and other imperfections in cement plaster surfaces to the extent necessary to provide a good bonding surface; fill with patching plaster and sand smooth and flush with adjacent surfaces with fine sandpaper.

3.04 APPLICATION OF COATINGS

A. General

1. Coating materials shall not be applied when there is moisture, dirt or other deleterious material on the surface, when dust is present which can contaminate freshly applied material or when the surface temperature is not in the range specified in this Section or as recommended by the manufacturer. The application temperature shall be determined prior to beginning of coating operations and every 4 hours afterwards until the application is complete. See also par. 1.10 in this Specification.

2. The Contractor shall clean surfaces to be painted before applying paint or

SECTION 09960 HIGH-PERFORMANCE COATINGS

surface treatments, and remove oil and grease with clean cloths and cleaning solvents, prior to mechanical cleaning. Cleaning solvents shall be of low toxicity with a flashpoint in excess of 40°C. The cleaning and painting shall be programmed so that dust and other contaminants from the cleaning process will not fall on wet, newly painted surfaces.

3. Paint shall not be applied, except under shelter, during wet, damp, or foggy weather or when windblown dust, dirt, debris or insects will collect on freshly applied paint. See par. 1.10 in this Section for more details.

4. Apply paint and coatings with brush, roller, airless spray, or other acceptable practice in accordance with the manufacturer's directions and at a uniform rate that will produce the required DFT.

a) Use brushes best suited for the type of material being applied.

b)

Use

recommended.

rollers of

carpet,

velvet

back,

or high pile sheep’s wool

as

c) Sprayed paint shall be uniformly applied with airless suitable equipment. Provide for periodic supervision by representatives of paint manufacturers.

5. Apply materials with care, in strict conformance with the manufacturer's recommendations and at a uniform rate that will produce the manufacturers recommended WFT and DFT. WFT shall be checked periodically with a wet film gage. Coating shall show no runs, holidays, sag, crawls or other defects. Finish surface shall be uniform in sheen, color and texture.

6. Spread paints evenly and smoothly without runs, streaks, or other defects. Make edges of paint adjoining other materials or colors sharp and clean,

Allow sufficient time between coats to ensure proper

without overlapping. drying.

7. Paint films showing sags, checks, blisters, teardrops or flat edges will not be accepted. Paint containing any of these defects shall be entirely removed and the surface repainted.

8. Do not apply succeeding coats until the previous coat has completely dried. Allow a minimum of 24 hours between applications on any surface unless otherwise specified by the coating materials manufacturer.

9. Concrete Surfaces

a) If nothing else is mentioned in this Specification, coating shall only be applied when the surface temperature is in the range recommended by the manufacturer.

b) Before application of first coat, all concrete surfaces shall be thoroughly examined to ensure that all voids and surface defects have been repaired and filled with suitable filler.

c) Coating shall not be applied on surfaces, which is not fully cured and has not attained the specified strength.

SECTION 09960 HIGH-PERFORMANCE COATINGS

d) If nothing else is mentioned in this Specification, the concrete surfaces shall be dry and surface moisture content, measured with moisture meter, or by plastic sheet method in accordance with ASTM D4263, shall not exceed 5% on the top 3 mm of the concrete surface.

e) The cured surfaces shall be visually examined for film defects. Runs, sags, drips, blistering and any loss of adhesion shall be subject to repair at Contractor's expense.

f) The finish coat shall be dense and of uniform texture and free from sharp protuberances. Blemishes of any kind covering more than 5% of the coated area will result in the rejection of the whole area.

g) Any coat which is rejected after application or which has deteriorated to such an extent that adhesion cannot be guaranteed for follow-on coat shall be removed and the surfaces cleaned in accordance with par. 3.03 D.2 above and recoated in accordance with the preceding Specification.

B. Glass Fiber Reinforced Lining

1. The surfaces shall be blast cleaned with specified anchor profile and shall be free of all dust, salts and other contaminants.

2. Unsound areas shall be repaired as conventional concrete surfaces.

3. Apply a coat of epoxy primer/sealer on the surfaces at a rate recommended by the manufacturer of paint.

4. Apply an intermediate coat of epoxy to the primed surface. Apply glass fiber mat and work out all wrinkles, folds and entrapped air by means of ribbed rollers to ensure full saturation of the mat.

5. Abrade the entire surface lightly to remove protruding glass fibers and vacuum clean the entire surface.

6. Apply one more intermediate coat of epoxy to the work surface. Apply glass fiber tissue mat and embed in the epoxy by means of rollers.

7. Apply a top coat of epoxy.

8. Where bottom floor is included in the lining system, the floor lining shall be finished after the walls and other areas have been completed. The lining shall extend to 300 mm above the top of the floor surface.

9. For application of lining on floor, blast to feather into the prelaminated wall surface. The lamination of the floor shall follow the same application procedure as specified above.

C. Steel Surfaces

1. The main primer coat shall be applied soon after the steel surfaces have been blast cleaned. The primer or primary coat shall be applied within 4 hours after blast cleaning. Care shall be taken to ensure that contamination does not

SECTION 09960 HIGH-PERFORMANCE COATINGS

spread to areas that have already been prepared.

2. For large surface areas, the sequence of blast cleaning shall be carried out in stages so that the application of primer occurs within the 4 hours period.

3. The Contractor shall ensure that no condensation occurs on blasted steel or between coats during painting operations.

4. Paint shall be worked into all crevices and corners. All areas such as corners, edges, welds, small brackets, bolts, nuts and interstices shall receive an additional stripe coat of the parent coating material to ensure that these areas have at least the minimum specified film DFT and the continuity of the coating.

D. Tinting

1. The Contractor shall tint each undercoat a lighter shade to facilitate identification of each coat where multiple coats of the same material will be applied. The Contractor shall tint undercoats to match the color of the finish coat, but shall provide sufficient differences in shade of undercoats to distinguish each separate coat.

E. Alkyd Enamel

1. Alkyd enamel coatings shall be applied by brush or by a liquid spray method.

F. Zinc Coating

1. Steel shall be zinc coated by hot dip galvanizing.

G. Epoxy or Polyurethane Systems

1. Coatings or epoxy, epoxy bitumen or polyurethane may be applied either by liquid-spraying, electrostatic powder-spraying or by dipping the part to be coated in a fluidized bed of coating powder.

H. Repairing Damaged Paint on Equipment

1. Painted surfaces of equipment which have become damaged prior to acceptance by the Royal Commission shall be repainted with the same or equivalent paint as that used in the original application.

2. The system of repairing proposed by the Contractor shall be approved by the Royal Commission.

3. Repairing Damaged Coating on Concrete Tanks

a) The Contractor shall protect the newly applied coating from damage. Where coating was damaged from his operations or from testing, repair procedures shall be as follows:

1)

Areas of damaged coating shall be mechanically wire brushed to bare concrete and edges of the sound undamaged coating smoothed with sandpaper to a gentle bevel transition.

2)

The exposed concrete shall be thoroughly cleaned of all salt or oil

SECTION 09960 HIGH-PERFORMANCE COATINGS

deposits and completely dried before recoating.

3)

A repair method shall be implemented as recommended by the manufacturer.

4)

Areas of coating on which concrete or adherent type of matter has fallen shall be cleaned, washed and, if needed, repaired to its original condition.

I. Organic Coatings

1. The coating shall have a total dry film thickness of no less than 300 micron and be applied at the place where the pipe material is manufactured either by liquid-spraying, electrostatic powder-spraying of by dipping the part to be coated in a fluidized bed of coating powder.

2.

The

specification.

coating

shall

be

applied

in

accordance

with

the

manufacturer's

3. The coatings shall be free from flaws such as blisters, cracks, voids, missed spots and pinholes, etc. All flaws shall be carefully repaired.

4. Parts which are to be installed above ground shall be given a white or light- colored coating in order to keep down surface temperature on exposure to sunlight.

J. Polythene Encasement

1. Straight DCI pipes shall be provided with a polythene encasement as an extra corrosion protection. This shall be done by enclosing the pipe in loose polythene tubes. The film thickness of the polythene tube shall be not less than 250 micrometers. Both the polythene film and the raw materials used in its manufacture shall fulfill the requirements stated in ASTM D1248 and ANSI A21.5.

2. The polythene encasement on straight DCI pipes shall be applied during the course of pipe laying, in accordance with method A in ANSI A21.5, in order to prevent direct contact between the coated pipe and the surrounding water, soil, backfill and bedding material. Overlaps shall be secured by the use of adhesive tape or plastic strings.

3. Rips, punctures or other damage to the polythene encasement shall be repaired with adhesive tape or with short lengths of polyethylene tube cut open, wrapped around the pipe and secured in place.

4. The polythene tubes during storage and transport, shall be protected from direct sunlight.

K. Prior to Contract completion, the Contractor shall provide a detailed coating matrix describing as-built coating systems applied to the facility. This matrix shall be all inclusive. See par. 1.06 B for more details.

SECTION 09960 HIGH-PERFORMANCE COATINGS

3.05 FIELD QUALITY CONTROL

A. The Contractor shall be responsible for inspection and testing of the areas coated to verify conformance with the requirements of this Specification.

B. All vessels and/or equipment shall be subjected to inspection by the Royal Commission or its authorized representative during surface preparation, priming, coating, testing, curing and repair work. Notice shall be given to the Royal Commission or its authorized representative at least 24 hours in advance to witness the testing and/or inspection at predetermined stages of work. These stages shall be considered as “hold points” and work shall not proceed without compliance with the test and inspection requirements.

C. The installed coating system shall present smooth workmanlike appearance and shall be free of voids, blisters, pinholes, cracks, pits, bubbles, soft spots, disbanding, open seams, lifted edges or any other defects that will impair its usage. Evidence of poor workmanship shall be cause for rejection.

D. In addition to the requirements for inspection by the Contractor in compliance to Quality Control, the following particular requirements shall be carried out by the Contractor:

1. Checking (Blast) Cleaned Surfaces

a) Regular mill scale detection tests shall be carried out using the "Copper Sulfate" method of test.

2. Checking WFT

a) Wet Film Thickness gages of an approved type shall be provided for each painter to check the rate of paint application.

3. Checking DFT

a) The thickness of the built-up dry film after each paint coat applied to steel or other magnetic surfaces shall be measured systematically, with an Elcometer dry thickness gage.

b) The thickness of the built-up dry film after each paint coat applied to non-magnetic surfaces shall be measured by a pit gage or micrometer.

c) The number and location of test areas for checking of DFT shall be agreed upon and approved by the Royal Commission before work commences. All tests shall be witnessed by the Royal Commission. Local areas where continuity of coating surface had been disrupted by testing shall be repaired.

4. Concrete Surfaces

a) Adhesion testing using an Elcometer or an approved equal pull-off adhesion tester. An acceptable sample shall retain a layer of concrete paste.

SECTION 09960 HIGH-PERFORMANCE COATINGS

b) The number and location of test areas for checking adhesion shall be agreed upon and approved by the Royal Commission before work commences. All tests shall be witnessed by the Royal Commission. Local areas where continuity of coating surface had been disrupted by testing shall be repaired.

5. Steel and Iron Surfaces

a) The Contractor shall use a suitable Royal Commission approved method of detecting pinholes in the coating system after trials on test plates. The sweet voltage on high voltage spark testing equipment shall not exceed half the voltage required to spark through the complete paint system specified.

b) Coated areas shall be spark tested for “pinholes” leaks using a high potential spark tester adjusted to 15,000 and 20,000 V or recommended by the coating manufacturer.

6. Coated surfaces shall be inspected for blisters (trapped air), pulls or lifted edges at seams and surface defects. Any dimensional tolerances required should also be checked. All defects noted in the coating shall be repaired and retested to the satisfaction of the Royal Commission or its authorized representative.

7. The number of pinholes and surface imperfections repair shall be recorded for each area or item.

E. The Royal Commission may engage the services of his designated Independent Testing Laboratory to sample any of the paint being used. Samples of materials delivered to the Project site will take, identified and sealed, and certified in the presence of the Contractor.

F. The Royal Commission designated Independent Testing Laboratory will perform appropriate tests for any or all of the following characteristics:

1. Abrasion resistance.

2. Apparent reflectivity.

3. Flexibility.

4. Washability.

5. Absorption.

6. Accelerated yellowness.

7. Recoating.

8. Skinning.

9. Color retention.

10. Alkali resistance.

SECTION 09960 HIGH-PERFORMANCE COATINGS

11. Quantitative material analysis.

G. If any of the test results show that the material being used does not comply with the specified requirements, the Contractor shall be directed to stop the painting work and remove non-complying paint; bear the financial costs associated with laboratory testing; repaint the surfaces coated with the rejected paint; remove rejected paint from previously painted surfaces if, upon repainting with the specified paint, the coatings are non-compatible.

H. Certificates and tests performed throughout the coating operation and all inspection service involved shall be submitted to the Royal Commission. Documentation shall consist of, but not be limited to the following:

1. Material supply.

2. Surface inspection.

3. Surface preparation.

4. Coating procedure and application.

5. Inspection and testing of coated areas.

6. Location or identification of area coated or tested.

I. The above documentation shall be dated and signed by the Contractor and submitted to the Royal Commission.

J. Inspection, approval and acceptance by the Royal Commission or its authorized representative will not relieve the Contractor of its obligation to meet requirements and guarantees specified in par. 1.09 of this Section.

3.06 REMEDIAL WORK

A. All damaged coating and other defects shall be repaired to the entire satisfaction of the Royal Commission before application of the next coat or before acceptance of the final coat.

B. Areas with inadequate coating thickness shall be thoroughly cleaned and abraded to provide adequate key for the coating to be applied. Additional compatible coats shall be applied until the specified film thickness is achieved. The additional coats shall blend in with the final coat on adjoining areas.

C. Areas with pinholes and excessive holidays shall be blast cleaned to remove defective coating completely and recoated. The recoated area shall carry over on to the adjoining coating for not less than 50 mm all around and the edges shall be feathered.

D. The repair methods shall be as recommended by the coating manufacturer and approved by the Royal Commission.

SECTION 09960 HIGH-PERFORMANCE COATINGS

3.07 PROTECTION

A. Protect work of other trades, whether to be painted or not, against damage by the painting and finishing work. Leave all such work undamaged. Correct damages by cleaning, repairing or replacing, refinishing, or repainting, as necessary and as acceptable to the Royal Commission.

B. Provide "Wet Paint" signs as required to protect newly painted finishes. Remove temporary protective wrappings provided by others for protection of their work after completion of painting operations.

C. Provide sufficient drop cloths, shields and protective equipment to prevent overspray from surfaces not being painted.

D. Materials which may constitute a fire hazard shall be enclosed in metal containers and removed from site daily.

E. Remove all electrical plates, surface hardware, fittings and fastenings, prior to paint application. These items are to be carefully stored, cleaned and re-installed on completion of work in each area. Do not use solvent that may remove permanent lacquer finish to clean hardware. Items which are not practical to remove shall be taped over. Do not use any tape containing chlorides on stainless steel surfaces.

3.08 CLEAN-UP

A. During the progress of the work, remove from the site all discarded paint materials, rubbish, cans, and rags at the end of each work day.

B. As work proceeds and upon completion of painting work, promptly remove and clean paint-spattered surfaces. Remove spattered paint by proper methods of washing and scrapping, using care not to scratch or otherwise damage finished surfaces.

C. At the completion of work of other trades, touch-up and restore all damaged or defaced painted surfaces.

D. During progress of work keep premises free from any unnecessary accumulation of tools, equipment, surplus materials and debris.