C QATAR GALVANIZING CO.W.L.L METHODS STATEMENT FOR HOT DIP GALVANIZING PROJECT TITLE EPIC FOR BERTHS AND PORT INFRASTRUCTURE PHASE 2 CLIENT NAME ARCHIRODON CONSTRUCTION (OVERSEAS) CO. S.A. Doc. Ref: QG-QHSE-P20- Annexure B Sign. <3 11-AUG - 2015 | First Issue for Approval Date | Issue details Prepared byGC METHODS STATEMENT FOR HOT DIP \ GALVANIZING PURPOSE The purpose of this Quality Control Procedure is to set guidelines for the testing requirements and responsibilities for implementation in Qatar Galvanizing Co.W.L.L. SCOPE This Quality Control procedure defines the type, extent of testing and inspections to be carried out during structure steel galvanizing works by Qatar Galvanizing Co. W.L.L. HOT DIP GALVANIZING STANDARDS AND SPECIFICATION Hot Dip Galvanizing shall be carried out with reference to following standards and procedures: 1) BSENISO 1461 2) ASTM A123, 3) ASTM A385 4) ASTM A780 5) American Galvanizers Association 6) U.K. Galvanizers Association 7) ISO 8501 Part 1 8) Kahramaa Specification 9) QP-SPC-L-002 10) Reference Project Spec. Doc. No.: 3608-RPGE-9-AA-4002-001. PROCEDURE 1) RECEIVING INSPECTION AND PRE-TREATMENT TO REMOVE EXCESS GREASE Y Identification marks (Punched nos.) on the material supplied by Client (if available) shall be verified against the Delivery Note, to be provided by client along with the items. ¥ Adequacy of the supplied material for Galvanizing shall be checked to verify any local damage, weld flux, burns, drainage & vent holes, Re-galvanizing requirement, double dipping, etc. If any inadequacy requiring modification is identified, the same shall be informed Client. Y Special Wash: High pressure water washes to remove the dirt, oil and grease additives (if required). 2) BLASTING & CLEANING: Y Blasting is carried out as per [SO 8501 Part 1 SA 2.5. Issue No. | Rev. No. Date: Document No. Page on. 00 11-AUG-2015 QG-QHSE-P20- Annexure B ofSCc METHODS STATEMENT FOR HOT DIP => GALVANIZING Y Visual inspection is done to ensure that the items are free of rust & mill scales. Profile of Blasted surface shall be checked with digital profile gauge/Testex tape it shall be in the range of 40 - 80. Y Regular sieving of the grit is carried out and additions done as per Manufacturer's recommendation. The fines are filtered out through the bag filter. 3) ACID STRIPPING: Incase the steel received is pre-galvanized, then the same has to be stripped in a stripping tank containing Hydrochloric acid to chemically remove all the Zinc coating prior to acid pickling. 4) ACID PICKLING: Y Hydrochloric Acid (HCI) used for Pickling process are purchased minimum 30% strength and ited with water to the range of 16-18% & discarded at 6% strength. The strength is checked in the In house lab by volumetric Titration method. Strength below 6% does not give effective pickling. The iron content of the acid shall be maximum 200 gms per liter. 5) RINSING IN CLEAN WATER: After pickling the material some of the Acid contents will remain on the steel. To make it Acid free the Steel is rinsed with the Water (PH 5.5 - 6). Fresh water is added on regular basis. 6) FLUXING: Y After rinsing the steel item is dipped in a solution of Flux comprising of a combination of Zinc Ammonium Chloride. Fluxing is done to ensure proper catalytic reaction and ensure good binding and uniform spreading of Zinc during galvanizing, The specific gravity of Flux is maintained between 1.16 and 1.19. OR (20 - 24 Baume) the pH of the flux is maintained between 4 to 6 7) DRYING: ¥ After Fluxing the material is taken to Hot Pit for drying purpose. The Temperature of Hot Pit is around 50 - 70°C. Water drops on the Job is totally dried & visually checked for uniform drying. 8) GALVANIZING AND MONITORING OF THE PROCESS 8.1 Verification of Bath Zinc Content and Purity: Issue No. | Rev. No. Date: Document No. Page on 00 11-AUG-2015 | _QG-QHSE-P20- Annexure B 2ofsc METHODS STATEMENT FOR HOT DIP > GALVANIZING ¥ The Zn content of the bath shall be a minimum of 98% in accordance with ASTM A 123 Section 5.5. Y Zinc Bath analysis shall be carried out by Third party every SIX (6) months to check for contents of Zn, Al, and Pb. 8.2 Temperature of Zinc Bath and method of monitoring: Y The material is dipped when the temperature is 450 + 5°C. The Thermocouple in the Zinc Bath is connected to the Control Panels which indicates the temperature of the Zinc bath on a continuous basis on the panel. Any drop of temperature triggers an alarm for the operation to be alerted, 8.3 Dipping Time For Each Structural Element: Y Dipping time usually depends upon size and weight of the material. The minimum Dipping time is 3 minutes & can go up to 8/10 minutes for material which are of different thickness. Higher the thickness of the steel, more will be the dipping time. Y The Actual Dipping time is recorded in our in process inspection report & the same is determined as per the thickness and shape of material. The minimum dipping time is 3 min & can go up to 10 min. 9) SURFACE CLEANING AFTER GALVANIZIN Y Water quenching of the galvanized steel is done for ensuring the removal of ash residue from the surface of the steel, Y Special tools for removal of drainage spikes, lumps, and rinse along with tapping of the hung job are carried out before quenching 10) PIMPLES CAUSED BY INCLUSION OF DROSS: Y- Dross is a solid form of Zinc Iron particles (Zn Fe). It settles at the bottom of the Zinc bath when the material is dipped these layer get disturbed and these particles float in the bath and shifts at the layer of the material. It can be removed by sanding or by polishing with papers. The bath is also regularly drossed mechanically for removing the dross so that the Material galvanized is dross free. Y Bath is visually checked at the time of dipping and accumulation of Zn Ash is skimmed from the surface. Issue No. | Rev. No. Date: Document No. Page o1 co) 11-AUG-2015 QG-QHSE-P20- Annexure B ofSGALVANIZING | G METHODS STATEMENT FOR HOT DIP 11) 12) 13) 14) 15) WET STORAGE- STAINING: Y Wet storage stain is the white corrosion products and dark stains which may be seen on the surfaces of newly galvanized articles when they have been closely stacked and stored or transported under damp or wet conditions. Where wet storage stain has formed, the coating beneath may be stained dark grey or black. Y To prevent wet storage stain zinc coated articles shall be transported and stored under dry and well ventilated conditions. If stored outdoors, the surfaces shall not be in close contact & free circulation of air shall be ensured to prevent condensation and retention of moisture. Nesting or close packing shall be avoided as capillary action can attract water into closely contacting surfaces. Articles shall not be stored in direct contact with the ground WHITE RUST Y White rusting of material shall be avoided on the material by keeping adequate packing between the floor and the Galvanized material, and also between galvanized sheet material FINAL INSPECTION & TESTING: Y Items after Proper Visual Cleanliness shall be offered for Final Inspection, Y Coating thickness is checked with the aid of Elcometer ferrous type magnetic thickness gauge. Coating Thickness shall be as per requirement of ASTM A 123 / BS EN ISO 1461. Y Coating adhesion shall be carried out by cutting or prying with the point of a Stout knife in accordance with ASTM A 123. LOADING: Y All Galvanized material duly cleared by client shall be loaded in the respective trucks in lots & quantities as received with proper care taken to avoid any surface damage on the Galvanized Steel with appropriate Protective Slings. REPAIR Y The repair of zinc coating at hot dip galvanizing shop shall be “Repair using Zinc based alloys” per Annex Al or A2 of ASTM 780. Y The repair of zinc coating at steel fabricator shop shall be “Repair using zinc rich paint” per Annex A2 of ASTM 780. Y The repair of zinc coating at field shall be by the following method: on 00 11-AUG-2015 QG-QHSE-P20- Annexure B 4ofS Ears No. | Rev. No. Date: Document No. PageC GALVANIZING METHODS STATEMENT FOR HOT DIP 16) © Oil, grease, and other contamination shall be removed by solvent cleaning per SSPC-SP1 © Clean the damaged area per SSPC 11 * Touch-up damaged areas using Organic Zinc Rich Primer as per “ Epoxy Zinc Rich for T/U of Inorganic zinc of table 4 of BF-s B00-13A0-004” by spray or brush in multiple coats to achieve more than 150% total dry film thickness of TABLE 1 or TABLE 2, but minimum 3.0 mils to maximum 5.Omils. And apply the specified top coat or cosmetic color matching coat for original hot dip galvanizing INDICATIVE ZINC CORROSION RATES FOR DIFFERENT ENVIRONMENTS AS PER BS EN ISO 14713 (CORROSIVITY CATEGORIES FROM ISO 9223 IS AS BELOW: AVERAGE ANNUAL ZINC CORROSION CATEGORY | ENVIRONMENT NATURE RATE (um / YEAR) cL INTERIOR: DRY <0.1 INTERIOR: OCCASIONAL CONDENSATION a 0.1 00.7 EXTERIOR: RURAL INTERIOR: HIGH HUMIDITY, SOME AIR POLLUTION a 0.7702 EXTERIOR: URBAN INLAND OR MILD COASTAL INTERIOR: SWIMMING POOLS, CHEMICAL PLANTS FTC. ca 2704 EXTERIOR: INDUSTRIAL INLAND OR URBAN COASTAL EXTERIOR: INDUSTRIAL WITH HIGH HUMIDITY OR cs 4708 | HIGH SALINITY COASTAL Issue No. | Rev. No. Date: Document No. Page on 00 11-AUG-2015 (QG-QHSE-P20- Annexure B Sof5