Surface Preparation and Paint Specification

SISHEN MINE
IMPLEMENTATION DATE 2016-04-30

REV
SURFACE PREPARATION AND PAINT SPECIFICATION 00
DOC NO SIS-ENG-SPEC-014
SURFACE PREPARATION AND PAINT

SPECIFICATION
SISHEN MINE
Refer to the Waypoint Document Management System for the latest version of the document. Copyright resides with the company. Page 1 of 63
SURFACE PREPARATION AND PAINT SPECIFICATION REV 00
CONTENTS
Page
1 PURPOSE 5
2 SCOPE 5
3 ABBREVIATIONS AND DEFINITIONS 6
4 GENERAL 7
4.1 QUALIFIED STAFF 7
4.2 EQUIPMENT 7
4.3 COATING MATERIALS 9
4.4 MATERIAL ON SITE 9
5 SURFACE PREPARATION 10
5.1 GENERAL 10
5.2 PRE-CLEANING 10
5.3 MECHANICAL CLEANING 10
5.4 ABRASIVE BLAST CLEANING 10
5.5 ACID PICKLING 12
5.6 SURFACE CLEANLINESS 12
6 COATING APPLICATION 13
6.1 APPROVAL 13
6.2 MIXING 13
6.3 COATINGS 13
6.4 CREVICES AND GAPS – CONCEALED SURFACES 14
6.5 STRIPE COATING 16
6.6 APPLICATION 16
6.7 AMBIENT CONDITIONS 18
6.8 GALVANISING 18
6.9 PRIMER COAT 18
6.10 PATCH REPAIR 18
6.11 EARTHING STRAPS 19
6.12 DESIGN CRITERIA 19
7 SAFETY PRECAUTIONS 19
7.1 GENERAL 19
7.2 SAFETY PLAN 19
7.3 FIRE HAZARDS 19
7.4 STORAGE OF HAZARDOUS MATERIALS 19
7.5 SCAFFOLDS AND RIGGING 20
8 INSPECTION AND TESTING 20
8.1 SURFACE PREPARATION 20
8.2 VISUAL INSPECTION 20
8.3 DRY FILM THICKNESS – (DFT) 20

8.4 WET FILM THICKNESS – (WFT) 20
9 QUALITY ASSURANCE 21
9.1 CONTRACTOR QUALIFICATION 21
9.2 QUALITY CONTROL 21
9.3 DAILY PROJECT REPORTING 22
9.4 DATA BOOK 23
9.5 ALTERNATIVE COATING MATERIALS 23
10 GUARANTEES 23
11 HANDLING AND STORAGE 24
11.1 HANDLING 24
11.2 LOADING 24
11.3 UNLOADING 24
11.4 COVER 24
11.5 STACKING 24
12 RELATED DOCUMENTS 25
12.1 SOUTH AFRICAN NATIONAL STANDARDS (SANS) 25
12.2 INTERNATIONAL ORGANISATION FOR STANDERDISATION 25
12.3 BRITISH STANDARDS INSTITUTION (BSI) 25
13 PROTECTIVE COATING SYSTEMS 26
13.1 PROTECTIVE COATING SYSTEM NWPCS 01 27
13.3 PROTECTIVE COATING SYSTEM: NWPCS 03 29

14 MAINTENANCE PROTECTIVE COATING SYSTEMS (MPCS) 46
14.1 PROTECTIVE COATING SYSTEM MPCS 01 46
15 COLOUR CODING 52
16 REVISION HISTORY 52
17 ANNEXURE A – EXAMPLE FORMS - CONTRACTORS 53
18 ANNEXURE B – EXAMPLE FORMS - CONTRACTORS 54
1 PURPOSE
The purpose of this specification is to support the AMRS 9 Structural Integrity Standard (GTS 19) to ensure
that structures are protected against deterioration mainly caused by corrosion. This specification makes
provision for corrosion protection on new structures and maintenance on existing structures.
During the past few years there have been numerous structural failures at Kumba Iron Ore mines, during
mine operation due to corrosion. Generally structural failures caused by corrosion are high potential incidents
because inadequate performance of structures can severely impact on safety and production and lead to
expensive repair work, so they must be prevented.
The specification has specific relevance to the following Anglo American standard:
a) AMRS 9 Structural Integrity (GTS 19)
2 SCOPE
This specification details the requirements for the application of protective coating systems and the
requirements for labour, tools and equipment.
It is intended for use in the selection of the most relevant corrosion protection system for the different
conditions at Sishen Mine. Although this document is very clear on different corrosion protection systems for
different conditions, a competent person should be involved to choose the most relevant corrosion protection
system for the specific requirements of the project/task. This specification covers the requirements for
protective coatings for all projects within Sishen Mine.
Standards contained within this document are correct at the time of writing; however, confirmation should be
sought from the Systems Administrator before embarking on configuration.
This specification covers New Works Protective Coating Systems for the following:
 NWPCS 01 - Galvanising of structural steel.

 NWPCS 02 - Painting of structural steelwork and plate work.
 NWPCS 03 - Corrosion protection of piping.
 NWPCS 04 - Painting of surfaces where ceramic tiles will be used.
 NWPCS 05 - Painting of surfaces where replaceable steel liners will be used.
 NWPCS 06 - Corrosion protection of internal surfaces of hydraulic tanks, thickeners, launder, pipes and
tanks carrying potable water, raw water, or clarified water.
 NWPCS 07 - Painting of cones internal sections where replaceable liners are not fitted.
 NWPCS 08 - Corrosion protection of black bolts, nuts, washers and holding down bolts prior to
installation.
 NWPCS 09 - Painting of galvanised items
 NWPCS 10 - Painting of all electrical equipment such as control panels, switchgear cabinets, power and
lighting distribution boards.
 NWPCS 11 - Painting of internal and external surfaces for air conditioning and ventilation ducting.
 NWPCS 12 - Painting of overhead cranes.
 NWPCS 13 - Protection of internal surfaces of boxed sections of Stackers/Reclaimers.
 NWPCS 14 - Painting of 3CR12 deck plates.
 NWPCS 15 - Temporary corrosion protection for machined surfaces and painting of machined surfaces.
 NWPCS 16 - Painting of proprietary equipment.
 NWPCS 17 - Painting of non-slip walkways.
 NWPCS 18 - Column base protection in new plants.
 NWPCS 19 - Corrosion protection of cable racking.
 NWPCS 20 - Painting of hand and knee-rails, stanchions and fittings.
 NWPCS 21 - Painting of all new structural steelwork, conveyor structures, plate work, external surfaces
of E-houses, Stackers and Drum Reclaimers in a less aggressive dry environment.
This specification covers Maintenance Protective Coatings Systems for the following:
 MPCS 01 - Full stripping and painting of structural steelwork, plate work and mechanical equipment.
 MPCS 02 - Patch repair painting of structural steelwork, plate work and mechanical equipment.
 MPCS 03 - Protective coating of column bases.
 MPCS 04 - Protective coating systems.
The use of this specification, together with appropriate qualifications, variations and additions, or
supplementary rules, shall be specified on the relevant design drawings, or in the project specification.
3 ABBREVIATIONS AND DEFINITIONS
Term Explanation
The type of abrasive medium normally dictates the limits of the blast profile. Because the
abrasive breaks down in use and is supplemented with fresh charges of “new” abrasive,
Abrasive Blast Profile the resultant profile achieved will vary between the higher and the lower limits. A higher
degree of cleanliness, combined with a relatively smaller profile, improves durability of
coatings.
AMRS Anglo American Major Risk Standard
Approved coating A coating which has been evaluated, accepted and approved for use
BS British Standard
The company appointing the Contractor do carry out the protective coating work. The
Client
company can also be the owner. Normally Sishen mine.
Coating A film applied to a substrate to provide degree of corrosion protection
A person who has sufficient training and experience or knowledge and other qualities to
Competent person properly assist the Client to meet his safety and quality obligations, i.e. Engineer or
Corrosion Specialist.
Corrosion of steel is an electrochemical process that involves the reaction of iron with
Corrosion
water and oxygen.
Crevice A gap of 1mm or less between two surfaces but excluding bonded surfaces
Fully dimensional drawings prepared by the Engineer, showing all information required
Design drawings
by the Contractor
Inexpensive or waste material used to prevent galvanised items from making contact
Dunnage / spaghetti
during transportation and storage in order to prevent damage to galvanised surfaces.
Dry film thickness
The thickness of the coating when dry
(DFT)
The company responsible for the design and the preparation of the Design Drawings (or
approval of Design Drawings prepared by others), for accepting the Fabrication
Engineer
Drawings and erection method statement and, where applicable, inspection of
construction for conformity with the design
Fabrication drawings As defined in SANS 2001 Part CS1
GTS Group Technical Standard
ISO International Standards Organisation
Kumba As per definition of the Client
Kumba welding The competent person who is authorised to inspecting all welding work done for the
inspector Client
OHS Act Occupational Health and Safety Act
Qualified All staff shall be qualified in terms of the South African Qualification and Certification
Staff Committee for Corrosion SAQCC (Corrosion) or equivalent
Produced when water comes into contact with iron. Rust forms when the oxygen in water
Rust combines with atoms in iron. This reddish coating on the surface of metals is commonly
referred to as rust.
White metal finish. Blast-cleaning to pure metal; Mill scale, rust, and foreign matter are
removed completely. Finally, the surface is cleaned with a vacuum cleaner, clean dry
Sa 3
compressed air, or a clean brush. It then has a uniform metallic colour and corresponds
in appearance to the prints designated Sa 3.
Near white metal finish. Very thorough blast-cleaning; Mill scale, rust, and foreign matter
are removed to the extent that the only traces remaining are slight stains in the form of
Sa 2½ spots or stripes. Finally, the surface is cleaned with a vacuum cleaner, clean dry
compressed air, or a clean brush. It then corresponds in appearance to the prints
designated Sa 2½.
A measure of dissolved salts in a body of water. It is calculated as the amount of salt (in
Salinity
grams) dissolved in 1,000 grams (1 kilogram) of seawater.
Sans South African National Standards
A coating applied to edges of steelwork and of sufficient width to ensure full coverage of
Stripe coating
the edge
Wet film thickness
The thickness of the coating when wet
(WFT)
ABBREVIATION DESCRIPTION
WFT Wet Film Thickness
pH Potential Hydrogen
PCS Protective Coating System
MPCS Maintenance Protective Coating System
NWPCS New Works Protective Coating System
MSDS Material Safety Data Sheet
DC Direct Current
4 GENERAL
The Contractor shall be responsible for ensuring that they are fully conversant with the requirements of this
specification and the relevant coating systems.
4.1 QUALIFIED STAFF

A high standard of workmanship is required. Therefore, only qualified and experienced labour shall be used
to carry out corrosion prevention work.
The Contractor shall ensure that there are at all times sufficient suitably qualified, experienced, skilled and
certified staff to carry out and supervise all services under the constant supervision of a certified and
experienced supervisor.
All staff shall be qualified in terms of the South African Qualification and Certification Committee for Corrosion
{SAQCC (Corrosion) or equivalent} as follows:
Applicators: General Heavy Duty Coatings Applicator (PA1)

Supervisors: General Paint Supervisors (PS1)
Inspectors: Coating Inspectors (Level 1 with ISO 1461 or Level 2)
Or equivalent qualifications that is available from national or internationally recognised certification institutions.
4.2 EQUIPMENT
4.2.1 Measuring equipment
The Contractor shall have on site the required instrumentation to measure and report all the required data
as detailed in this general specification, the relevant Protective Coating Systems as well as those reflected
in the coating manufacturer’s technical product data sheets.
The electronic dry film thickness gauge shall conform to the requirements of SANS 2808 b7 for electro-
magnetic flux type gauges and d7 for eddy current type gauges.
Dry Film Thickness shall be measured above the peaks for all applications.
The instrument shall be calibrated, using a smooth flat reference disc supplied by the instrument
manufacturer. In such cases a correction factor of minus 25 microns shall be applied to all readings to make
allowance for the abrasive blast profile, alternatively the instrument shall be calibrated in accordance with
standard procedures. In the latter case a minimum of 25 microns shall be added to the minimum specified
dry film thickness.
The instrumentation utilised for the measurement of Dry Film Thickness shall be capable of measuring
coatings applied on flat surfaces, between gaps, minimum concave surfaces, minimum convex surfaces and
surfaces situated in confined spaces within the limits of the smallest possible probe. The measuring
equipment shall also be capable of measuring Dry Film Thicknesses in excess of 3mm for Epoxy compounds
and in excess of 6mm for Thick wall lining systems if and where required.
Measuring of Hot dip galvanised components shall be conducted in accordance with the standards detailed
in the ISO 1461: 1999 for the various types and grades of steel components.
Measuring the film thickness of duplex coatings applied over standard consistent Galvanised surfaces shall
be measured by obtaining the minimum value specified for each type of component as detailed in the ISO
1461: 1999 combined with the minimum value specified in the relevant protective coating system. This value
shall be reported as the total system minimum value for that particular duplex system.
Measuring of duplex coatings applied over excessively thick and inconsistent zinc substrates:
Select one component from each particular batch to be tested of the same dimensions i.e. steel profile and
steel thickness then take 10 random readings on each component selected and record the average obtained
these averages shall be used as a base reference when the same components are measured after the
application of the duplex coating in order to obtain the final average for each component selected
respectively.
Alternatively utilize the Eddy–Current type gauge for the measurement of duplex coatings in general.
All test equipment shall have current calibration certificates.
4.2.2 Spray Equipment

The spray equipment used shall be commensurate with high quality work and shall be capable of properly
atomizing the material and shall be equipped with suitable pressure regulators and gauges. Air caps, needles
and nozzles shall be of the type recommended by the coating manufacturer.
All spray-painting equipment shall be fitted with operational suitable oil and moisture traps and air shall be
free of salinity. Testing procedure shall be the same as that specified for blast cleaned air.
4.2.3 Blast Cleaning Equipment

Effective oil and water separators shall be utilized on all air hoses used for abrasive blast cleaning.
The separators shall be of the 'cartridge' type. The quality of the air shall be tested with the use of
a white cloth by placing the white cloth over the blast nozzle holder, open air supply for at least 60
seconds and visually evaluate for the presence of contaminants. In the event where contaminants
have been identified the air supply will be rejected.
4.2.4 Brushes
Brushes used for the application of coatings shall conform to the requirements of SANS 901 and shall be of
a type that will enable proper application of the coatings.
4.2.5 Paint-Rollers
Rollers used for the application of coatings shall conform to the requirements of SANS 552 and shall be of a
type that will enable proper application of the coatings.
4.2.6 Power Mixers

All coatings shall be mixed with power mixers. Low speed mixers, which do not induce air into the coating,
shall be utilized.
4.3 COATING MATERIALS

Only approved coating materials as detailed in the relevant specifications shall be used.
Coating materials from different manufacturers shall not be mixed in the same coating systems (with
exception to the epoxy compound approved for crevice sealing).
All coatings shall be supplied by the approved coating manufacturers only. The Contractor shall obtain a
copy of the coating Batch Certificate and product batch code from the coatings manufacturer prior to using
the material.
All coatings shall be applied with the use of single or plural component airless spray equipment and these
products shall not be diluted. The use of conventional air atomised spray equipment shall only be used in
specific instances with written approval from the Engineer.
The solvents used shall be those recommended and manufactured by the coating manufacturer. Where the
recommended 'solvent' and ‘clean-up thinners' for a material differ, the 'clean-up' solvent must not be added
to the coating for dilution purposes.
Dilution shall only be allowed with conventional spray systems. The solvents used shall be those
recommended and manufactured by the coating manufacturer. Where the recommended 'solvent' and ‘clean-
up thinners' for a material differ, the 'clean-up' solvent shall not be added to the coating for dilution purposes.
Excessive dilution of paints is not permitted. The maximum addition of solvents shall be as specified by the
coating manufacturer in the relevant Product Data Sheet. The maximum capacity of containers shall be 25
litres.
The coating manufacturer's recommended shelf life and other storage requirements shall be met. All
coatings identified on site with expired shelf life, shall be removed from the mine immediately.
The initial batches shall be inspected at site establishment, thereafter certification of all subsequent batches
shall be submitted to the Engineer prior to the use of the product.
Kumba shall determine the colours of the paints to be used. Colour coding shall be in accordance with Kumba
Iron Ore Equipment & Infrastructure Colour Coding Standard ENG-GEN-ADM-STD-005.
All paints and coatings shall be brought to site in new unopened containers. All containers shall be clearly
marked with the manufacturer's material batch and code numbers.
4.4 MATERIAL ON SITE

No coatings or paints other than the materials utilized in the relevant systems may be stored on site.
The Contractor shall ensure that the colour selection of the coat immediately prior to the finishing coat shall
be suitable for complete obliteration by the final coat.
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DOC NO [Document Number]
5 SURFACE PREPARATION
5.1 GENERAL
Sharp edges, burrs, rags and any other surface irregularities shall be dressed to a radius of not less than
2mm.
Welds and adjacent parent metal shall be deslagged, inspected and approved and all splatter shall be
removed.
The weld areas shall then be abraded and/or fettled by grinding if required, and contaminants such as flux
shall be removed prior to painting or galvanising.
Any discontinuities in welds can lead to premature failure of protective coatings especially those based on
high solids with high viscosities that exhibit poor flow characteristics therefore all such defects shall be
rectified by grinding and re-welding if and where necessary under no circumstances shall sealants (putties)
be used for the repair of any such defects.
Flame cut edges shall be fettled by grinding to remove hardened surfaces so that the required blast cleaning
profile can be achieved as specified in the relevant coating system.
5.2 PRE-CLEANING
Surfaces shall be tested for oil and grease by means of a water break free test. If surfaces are not water
break free, oil and grease shall be removed by washing with a water-soluble degreaser. The water-soluble
degreaser shall be supplied by the same manufacturer that is supplying the coatings being used. A water
break free surface shall be achieved prior to further surface preparation.
Chemical contamination shall be removed by means of neutralizing or flushing or both prior to additional
surface preparation.
5.3 MECHANICAL CLEANING

No mechanically cleaned items shall be primed until they have been inspected and cleared and a certificate
issued that the work has been carried out to specification.
All items to be mechanically cleaned shall be raised off the ground 500mm.
Mechanical cleaning shall be in accordance with the procedure specified in SANS 10064.
The standard of surface preparation shall be in accordance with ISO 8501/1:1988 to standards CST3 and
DST3 respectively, and as specified in the relevant coating system.
5.4 ABRASIVE BLAST CLEANING

No blast-cleaned items shall be primed until they have been inspected and cleared and a certificate issued
that the work has been carried out to specification.
All items to be blast cleaned shall be raised off the ground at least one metre. Steel Trestles shall be fitted
with timber on bearing surfaces to ensure that the angular peaks of the blast profile are not flattened off with
handling. In the event where blast cleaning will be carried out on site or in the field, the soil shall be covered
with plastic sheets to avoid contamination from the soil.
Abrasive blast cleaning shall be carried out in accordance with SANS 10064 and the degree of cleanliness
achieved shall be in accordance with ISO 8501/1: 1988 as specified in the relevant coating system.
All blast cleaning shall be done in accordance with ISO 8501:1 1988 to standards ASA3, BSA3, CSA3 and
DSA3 respectively.
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When handling blast cleaned steel, gloves shall be worn at all times and care must be taken to eliminate the
dragging of blasting and air hoses over blast cleaned steel surfaces.
5.4.1 Profile
The profile, peak to valley, when measured by SANS 5772, shall be as specified in the relevant Protective
Coating Systems.
5.4.2 Abrasive material

The abrasive may be any abrasive material (except silica sand), which meets the following requirements:
 It shall be composed of clean, sound, hard particles free from foreign substances such as dirt, oil,
grease, toxic substances, organic matter and water-soluble salts.
 It shall be capable of producing the surface profile as specified for the relevant coating system.
Expendable grits may not be recycled.
5.4.3 Material Certification

The abrasive supplier shall certify that any product to be delivered conforms to all requirements stated herein.
5.4.4 pH
A slurry mixture prepared as described here shall not have a pH below 6.20. This slurry mixture shall be
prepared as follows:
 A 100-gram representative abrasive sample is crushed using a mortar and pestle.
 Approximately 50 grams of the crushed sample is added to 200ml de-ionized water.
 The pH of this slurry is then determined through the use of an electronic pH meter with accuracy of ±
0.01 pH unit.
5.4.5 Water Soluble Salts

The conductivity of the water-soluble salts of the abrasive shall not exceed 150uS/cm when tested as follows:
Abrasive is mixed with de-ionized water, conductivity max 1uS/cm, in the proportion of 1:2, e.g. 50 cm 3
abrasive to 100cm3 water.
The mixture is shaken for 5 minutes, is allowed to settle for at least 1 hour and is then shaken again for 5
minutes.
Some of the water is decanted, the temperature is recorded and the conductivity measured by a conductivity
gauge.
If the conductivity gauge does not have any temperature compensation adjustment the conductivity should
be converted to 20º C and measurement should be carried out at this temperature.
If the conductivity exceeds 150 uS/cm the abrasive is rejected. Reference: Dansk Ingeniorforening,
Recommendation for the Corrosion Protection of Steel Structures 1982.
5.4.6 Moisture Content

The moisture content for abrasive material delivered in bags or in bulk shall not exceed 0.5% when tested
as follows:
Approximately 200 grams of the sample shall be weighed to the nearest 0.1g in a tared weighing dish and
dried at 105 to 110º C for 3 hours or more until successive weightings after additional 1 hour heating periods
show a weight change of not more than 0.1%.
The percentage of moisture is calculated as follows:
Original weight – final weight

Percentage Moisture = ------------------------------------- x 100
Original weight of sample
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5.4.7 Oil and Grease

The abrasive material shall not be polluted with oil and grease when tested as follows:
10cm3 abrasive is shaken with 10 cm 3 methylene chloride for about 5 minutes.
5 Drops of the solvent are applied to a clean glass plate.
After complete evaporation of the solvent the glass plate is exposed to ultraviolet light in total darkness.
If there is a blue fluorescence the abrasive is rejected.
5.4.8 Hardness
The abrasive materials shall have a minimum of 6 on Moh’s scale when tested as follows:
Examine the abrasive material under a low power microscope (10x) and, if grains of different colour or
character are present, select a few grains of each.
Separately place the grains thus differentiated between two glass microscope slides.
While applying pressure, slowly move one side over the other with a reciprocating motion for 10 seconds.
Examine the glass surface and if scratched the material shall be considered as having a minimum hardness
of 6 on Moh’s scale.
If any grains that fail to scratch glass are present, in any appreciable quantity, the total batch is rejected.
5.4.9 Grain Shape

The individual abrasive particles for all standard blast cleaning procedures shall be angular in shape. The
individual abrasive particles for sweep cleaning procedures shall be sub-angular in shape.
5.4.10 Surface Profile

The abrasive materials shall produce the specified surface profile as given in the relevant Protective Coating
Systems.
5.5 ACID PICKLING

Acid pickling shall be done in accordance with the procedure given in SANS 10064.
5.6 SURFACE CLEANLINESS

No coating shall be applied to any surface containing traces of grit, grease, oil, loose rust, mill scale, surface
contaminants (i.e. dust) or corrosion products of any kind.
The following requirements shall apply prior to coating application:
a) All traces of oil, grease and other contaminants shall be washed by a method acceptable to the
coating manufacturer from the surface and the surface dried prior to painting.
b) All surfaces to which coating is applied shall be free of moisture.
c) Dust and debris shall be tested in accordance with SANS 8502-3:2008 factor 3. In addition the dust
tape specimen shall be removed from the glazed tile and transferred to a clean white paper of the
same dimensions in order to be placed on record for future references.
d) If the blast cleaned surface changes colour, or rust bloom begins to form, the surface shall be re-
blasted.
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e) The surface to be coated shall be free of soluble salts.
The maximum allowable level of soluble salts is 120 mg per m² and may be tested with the use of
any of the standard test methods available for the evaluation of soluble salts, however, at least one
test for metallic salts shall be conducted for each area tested with the use of a ferric cyanide paper
(Wattman paper test) in order to be placed on record for future references.
6 COATING APPLICATION
6.1 APPROVAL
No work shall be performed until the Contractor has submitted his Quality Control Plans together
with the required Quality Control reports to confirm compliance to the Kumba Quality Control hold
point guidelines.
6.2 MIXING
All material shall be thoroughly mixed for a minimum of five minutes by means of a power driven mixer.
The induction time recommended by the coating manufacturer shall be observed.
The Contractor shall ensure that all paints are mixed in accordance with the manufacturer's instructions.
No partial paint kits shall be mixed by volume but may be mixed by weight. It is preferred that complete kits
are mixed as far as practically possible.
During application containers shall be agitated often enough to keep pigments in suspension.
Pneumatically agitated pressure pots shall be used to spray both single and twin pack inorganic zinc silicate
coatings.
6.3 COATINGS
All surfaces shall be coated as specified. Surfaces, which do not require coating, shall be suitably protected.
Successive coats shall be of distinctly different colour to the previous coat to ensure correct inter-coat
coverage. Special attention shall be given to cracks, crevices and edges to ensure complete coverage and
paint thickness.
All items to be coated shall be raised off the ground at least one metre. Steel trestles shall be fitted with
timber on bearing surfaces to ensure that no chafing of the coating takes place. In the event where coating
will be carried out on site or in the field, the soil shall be covered with plastic sheets to avoid contamination
from the soil.
The primer shall be applied as soon as possible after the blast cleaning operation, but within 4 hours.
On pre-coated surfaces all traces of soluble salts and other corrosive airborne contaminants shall be removed
with potable water and surfaces shall be allowed to dry prior to further paint application.
The Contractor shall complete the materials to be used form see Annexure A.
This form is to be included in his tender in order for Kumba to identify and contact the selected supplier to
inform him of the relevant project time schedules and meetings and other mine related requirements.
In the event where more than one Contractor is employed especially where shop and site work is involved
they shall both use the same supplier.
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Products from different suppliers shall not be used in a given system.
6.4 CREVICES AND GAPS – CONCEALED SURFACES

With the use of multi-coat and one coat systems the prescribed surface preparation shall be performed far
into the gaps or concealed surface as practically possible prior to the mastic epoxy compound being applied.
A crevice is defined as a void between two structural components to a maximum of 1mm. Gaps are defined
as voids between two construction components in excess of 1mm up to 15mm.
All crevices may be sealed by spray painting in accordance with MPCS 01 system. All gaps shall be sealed
with the use of reinforced epoxy compound. All gaps in excess of 15mm shall be coated in accordance with
MPCS 01 specification.
For a list of the approved brands of the mastic epoxy compound see specifications listing sealant – e.g. see
paragraph 16.3.7 of Protective Coating System MPCS 03.
6.4.1 Concealed Surfaces Or Back-To-Back Angles

Concealed surfaces or back-to-back angles with a gap of 15mm between each other or above may be able
to be blast cleaned and painted, using suitable brushes or sponges and steelworks.
Gaps of less than 15mm between each other – e.g. back-to-back angles, must be blast cleaned and primed
as far as is possible. Where this cannot be effectively performed, such gaps / crevices / concealed surfaces
must be sealed using the approved mastic epoxy compound.
The mastic epoxy compound may sag out of wide gaps.
It is then recommended to use some suitable ‘packing’ material e.g. rope, etc. to wedge into the gap, both at
the top and at the bottom of a back-to-back angle, recessing such a material into the gap by about 10mm.
The mastic epoxy compound shall then be applied to fill the 10mm recess on either side of the back-to-back
angle – filling it flush with the edges of the steel work of the back-to-back angle. See Figure 1.
Back-to-back angle Packing material e.g. rope

Mastic epoxy
compound
Figure 1
In the case where the crevices have previously been filled with soft Denso Mastic or Denso Paste or other
soft substance, such as silicon sealer, (this will mostly occur on maintenance work) this must be removed
from the crevices to a minimum depth of 10mm to allow for the approved epoxy compound sealant to be
applied.
In the case of back to back angles it must be removed to a minimum depth of 10mm on either side, prior to
degreasing and abrasive blast cleaning.
6.4.2 Discontinuous Welding

Where discontinuous welding has been specified for fabrication such discontinuous welding shall be
regarded as a crevice or gap between the welds.
The crevice or gap between the two materials welded together shall be sealed with the approved epoxy
compound after abrasive blast cleaning and priming.
The compound shall be applied as a bead to match the weld bead, but may not be applied less than 3mm
thick (should the welding have been ground flat). See Figure 2.
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Mastic epoxy compound Welding

Figure 2
Note: Where continuous welding has been specified for fabrication, sealing these crevices and gaps in this
manner shall not be accepted as a substitute for continuous welding.
6.4.3 Pin Holes/ Porosity In Welding And Castings

Pin holes in welding or porosity in welding allowable in terms of the welding standard specified for fabrication
shall be interpreted as a crevice or gap for corrosion protection and shall be sealed using the approved
mastic epoxy compound.
Note: Poor welding may not be covered up using the mastic epoxy compound. Only where such welding
has been passed by the Kumba Welding Inspector, may the remaining pin holes / porosity be sealed in this
manner.
The mastic epoxy compound may not be used as a “body putty” to repair every blemish in castings and welds
but in the case where the bottom of a pin hole or form of porosity cannot be seen and where after painting it
cannot be guaranteed to have been painted inside such a pinhole or porosity, such a place shall be sealed.
6.4.4 Mating Surfaces

For new work – mating surfaces that have been primed and painted with the intermediate coating as a
minimum do not have to be sealed, unless otherwise specified in the relevant specification.
Mating surfaces not coated with a minimum of two coats shall be sealed around the edges on all sides using
the approved mastic epoxy compound.
The mastic epoxy compound shall be applied at the same thickness as the gusset plate, tapering at a 45%
angle to meet the beam forming the matching mating surface (see Figure 3a).
Where the edges of the mating surfaces to be sealed are two identical gusset / base plates / flanges and no
angle is present the epoxy compound shall be applied to these edges ensuring a minimum thickness of 3mm
(see Figure 3b).
For all maintenance painting, such mating surfaces as illustrated in Figure 3a and 3b and in any other
combination or form shall be sealed in this way.
Mastic epoxy
compound
a) b)
Figure 3
6.4.5 Concealed Surfaces Between Q-Decking Or Concrete And The Support Steel
For new work – concealed surfaces between Q-decking or concrete and the support steel shall receive the
full specification prior to the Q-decking being placed on the support steel and / or prior to concrete being
poured.
Unless otherwise stated in the relevant new works protective coating system (NWPCS) concealed surfaces
that have received the full coating system do not have to be sealed, unless otherwise specified in the relevant
specification.
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Concealed surfaces not coated with a minimum of two coats shall be sealed around the edges on all sides
using the approved mastic epoxy compound.
For maintenance painting the concealed surfaces can no longer be inspected for corrosion purposes and
cannot be painted again.
Such concealed surface shall be sealed by applying the approved mastic epoxy compound all around such
a concealed surface so that the mastic epoxy compound shall be applied at the same thickness as the flange
of the support steel, tapering at a 45% angle to meet the Q-decking or concrete above (see Figure 4).
Q-DECKING
Mastic epoxy
compound SUPPORT BEAM
Figure 4
6.5 STRIPE COATING

6.5.1 Multicoat System
All edges, corners, bolt holes and cut ends shall be stripe coated by brush application, prior to the
application of the second coat.
All edges, corners, bolt holes, cut ends and weld beads shall be stripe coated by brush application, prior to
the application of the intermediate coat.
The stripe coating shall be an additional coat of the specified intermediate or final coat where an intermediate
coating is not specified.
In order to assist in its identification, the stripe coat shall be a different colour to both the specified primer
coat and intermediate coat.
6.5.2 One Coat System

All stripe coating shall be done “wet on wet” stripe coating on bolts and welds shall be done by brush and
can be done prior, during, and after spray application.
Stripe coating of edges shall be done: wet on wet” by spray application.
6.6 APPLICATION
Unless otherwise specified by Kumba, all coatings shall be spray applied.
In instances where spray application is considered not to be possible, practical or feasible, this must be
brought to the attention of Kumba at the time of tendering.
The Contractor should note that many of the high build coatings specified in the relevant systems are only
capable of achieving their recommended film thicknesses by spray application. Other application methods
such as brush and roller can result in lower film builds being achieved per coat. The Contractor must take
cognizance of this in his tender.
If during the course of the project the Contractor is instructed to change his method of application any labour
cost implications must be brought to the attention of Kumba before any such costs are incurred.
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All coatings shall be evenly applied to form a smooth, continuous, unbroken coating free from sags, runs,
mud cracking and other defects.
All application work shall be carried out in strict accordance with the recommendations and instructions given
in the most current Product Data Sheet supplied by the coating manufacturer notwithstanding the criteria as
specified by Kumba in their relevant protective coating systems.
This includes required climatic conditions, blast profiles, over coating times, application equipment and
methods to be utilised and pertinent requirements not listed in this specification. The Product Data Sheet
shall be deemed to be part of this specification.
All coatings intended for service in immersed conditions and all one coat systems shall be tested for coating
discontinuities (Electrical Insulation Defects) in accordance with SANS 1217 before being put into service.
All coatings applied up to a maximum of 500 microns shall be tested with the use of a low voltage wet sponge
tester a Kodek photo initiator may be used to increase the surface conductivity at the higher end of the
thickness range.
All coatings applied in excess of 500 microns shall be tested with the use of a high voltage spark tester and
shall be of the pulsating type DC detectors to ensure lower electrical stress to the coatings and lower safety
risk to the operator.
Application of coating to previously coated surfaces shall be within the time limits specified by the coating
manufacturer.
Surfaces, which rest on concrete or other floors, shall receive the full coating system prior to erection.
The Contractor shall take adequate precautions to protect areas being painted against contamination and
fall-out from adjacent sections of the plant during painting operations, should this become necessary.
Steel to be embedded in concrete shall be blast cleaned and painted with the full coating system as per the
relevant protective coating specification before being embedded.
Where surfaces are to be welded, no paint shall be applied within a reasonable distance of the weld (50mm),
unless otherwise stated.
All non-friction grip-mating surfaces of painted steel shall have at least the primer and intermediate coat paint
system applied prior to assembly.
All friction grip and splice plate contact surfaces to be left uncoated with the exception of steel work that is
either galvanised or primed with inorganic zinc silicate. In these cases the friction grip surfaces and the
packer plates shall either be galvanised or primed with inorganic zinc silicate as per the relevant coating
specification.
Patch repair to the primer and intermediate coats and the application of the final coat shall be carried out
after erection of the steel and not before erection unless otherwise instructed by the Engineer.
The Contractor shall apply the full painting system specified on the bearing surfaces of walkways, for both
maintenance and new work. Install a layer of rubber insertion on the bearing surfaces of the beams secured
with a contact adhesive to the extent that the rubber insertion cannot be lifted from the beam edges. The
rubber insertion shall overlap the bearing face of the beam (flanges) with a minimum overhang of 20mm on
either side of the beam.
The saddle clamps contact face shall also receive the same lining with the same overlap of 20mm minimum.
For all shop work no coated items shall be dispatched until they have been inspected and cleared and a
certificate issued that the work has been carried out to specification.
The Contractor shall apply the full painting system specified on the bearing surfaces of walkways before the
gratings or relevant floor sections are put in place.
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No coated items shall be dispatched until they have been inspected and cleared and a certificate issued that
the work has been carried out to specification.
6.7 AMBIENT CONDITIONS

Coatings shall not be applied under the following conditions:
a) When the surface may become damaged by rain, air borne dust, fog or condensation. When it is
anticipated when these conditions will prevail during the drying period, suitable enclosures shall be
provided to protect the surfaces.
b) When the ambient air temperature or the steel temperature is outside the coating manufacturer’s
recommended range.
c) When the ambient relative humidity exceeds 85%.
6.8 GALVANISING
Unless otherwise specified in the relevant protective coating systems, galvanising shall be done in
accordance with the relevant requirements of SANS 121 (SABS ISO 1461), with special reference to the hot
dip galvanising information sheet NO 7 hot dip galvanising of nuts and bolts.
For structural components not Galvanised all bolt holes shall be coated prior to installation of bolts. Painting
of hot dip galvanised nuts and bolts shall be done after tensioning by removing both passivation as well as
lubricants utilized with high strength nuts and bolts by degreasing with an approved galvanised iron cleaner
followed by rinsing with clean running potable water to achieve a water break free surface. Apply one
complete coat of multi-purpose epoxy as detailed in the relevant protective coating system selected.
For the use of any zinc based product as a single coat system including hot dip galvanising in a IM 3
environment as detailed in ISO 12944 – 2: 1998 classification of environments, a detailed soil analysis shall
be conducted prior to the use of these systems and the soil resistivity shall not be lower than 50 ohm meter
for complete burial of steel coated with these systems but under no circumstances shall any single zinc
coated component be partly buried (embedded) in soil especially where the smallest part of the component
are to be buried (embedded) in the soil.
It is strongly recommended to involve the Hot Dip Galvanisers Association at (011) 456 7960, for assistance
during the design stage, with designing for hot dip galvanising.
6.9 PRIMER COAT

The primer and patch primer coats shall be applied within 4 hours of the blast cleaning operation, but under
no circumstances may the primer or patch primer be applied over rust bloom or over surfaces that have
changed colour due to humidity or other contamination.
All zinc rich primers shall meet the zinc content requirements of SABS ISO 12944:1998, i.e. a minimum of
80% zinc in the dry film.
6.10 PATCH REPAIR

Following erection, all areas of damage shall be patch repaired by brush application.
Areas to be primed shall be cleaned of dust, dirt, grease or other deleterious matter and mechanically cleaned
to grade Sa 3 of ISO 8501/1. All edges of existing coatings shall be feathered. The patch primer used shall
be in accordance with the requirements of the relevant coating system. Where the patch primer differs from
the primer of the relevant coating system this will be indicated in that coating system.
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Upon completion of the patchwork and the drying of the coats, all surfaces shall be washed down using a
scrubbing brush and copious quantities of potable water. The surfaces shall then be allowed to dry. Only
areas which can be coated in the same shift shall be washed to prevent further contamination.
Where a concession is granted to the Contractor to apply the full coating system prior to erection, the patch
repair procedure shall include all specified coatings and not just the primer coat.
It must be noted that the final coat will not be applied to only the repaired area but a complete final coat
applied to the repaired component to form a smooth, continuous, unbroken coating free from pinholes, sags,
runs over spray and other defects.
6.11 EARTHING STRAPS

Before the placement of earthing straps, the area of contact shall be cleaned of all protective coatings that
could offer electrical resistance to the earth.
After fitting of the straps either by bolting or cad welding, the fixing, together with the area of damage to the
adjacent coating, shall be patch repaired and recoated with the full specified coating system.
6.12 DESIGN CRITERIA

The basic criteria for the design of steel structures to be coated by protective coatings shall be done in
accordance with the guidelines as detailed in ISO 12944-part 3: 1998
Dissimilar metals shall not be used in the same construction. In the event where this is unavoidable ensure
that both contact faces receive the full coating system or alternatively install a 3mm rubber insertion gasket
in between the two components.
7 SAFETY PRECAUTIONS
7.1 GENERAL
The Contractor shall ensure that he complies with all statutory regulations, municipal by-laws, etc. concerning
pollution and the health and safety of his personnel and members of the public who may be affected by his
work.
The Contractor shall provide for all necessary safety precautions.
The Contractor shall advise the Kumba Construction Manager / Engineer of all hazardous materials to be
brought on site. The Contractor will have in his possession the correct procedure for the disposal of excess
paint and empty paint tins. The Client must approve this procedure.
7.2 SAFETY PLAN

The Contractor shall prepare a fully comprehensive safety plan (Risk Assessment) for the project, reflecting
all the activities to be carried out during the project as detailed in the relevant Protective Coating Systems as
well those detailed in the Kumba General Specification for Corrosion Control.
No work shall commence prior to the approval of the Safety plan by the mine’s Safety Officer or Project
Engineer.
7.3 FIRE HAZARDS

The Contractor shall ensure that adequate precautions are taken to avoid fire hazards.
7.4 STORAGE OF HAZARDOUS MATERIALS
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Oily or solvent rags shall be kept segregated in closed containers and in minimum quantity to avoid
spontaneous combustion. Any spillage of volatile material shall be wiped up immediately.
7.5 SCAFFOLDS AND RIGGING

The Contractor shall provide and erect such scaffolds and rigging as may be required. All scaffolds and
rigging shall comply with the requirements of the OHS Act and the Mine Health and Safety Act (whichever is
applicable).
Temporary welded support elements are not permitted except where written approval has been granted by
the Kumba Construction Manager / Engineer. Where approval has been granted, all welded areas shall be
ground flush after finish and the complete coating system applied.
8 INSPECTION AND TESTING

The frequency or intensity of inspections for each of the activities detailed in the various specifications shall
be determined at the Post Award site meeting for each project respectively and shall be confirmed by written
instruction.
Inspection shall be 100% of all items at all phases of the coating system including galvanised components
and not as per sample sizes of batches.
8.1 SURFACE PREPARATION

The blast profile shall be measured in accordance with SANS 5772.
8.2 VISUAL INSPECTION

Visual inspection for paint film defects shall be performed after each coat is applied. All visible paint defects
including pinholes, dry spray, unclosed film, runs, sags and any other film forming defects shall be corrected
before the next full coat is applied.
8.3 DRY FILM THICKNESS – (DFT)

The required DFT is given in ‘windows’ for each coat in the relevant coating system; i.e. required acceptable
minimum and acceptable maximum thickness for each protective system. Any reading outside these given
parameters is cause for rejection and may lead to the removal of the entire coating applied.
Where excessive film thickness can be detrimental to the integrity of the coating, the manufacturer’s
recommended maximum thickness shall apply.
The increase in thickness created by the application of the stripe coat shall not be used to increase the
maximum specified thickness of the system away from the edge.
All deficient film thicknesses shall be rectified to the approval of Kumba at the applicator’s expense.
Actual readings and not averages shall be recorded. The Contractor shall take approximately 10 readings
per square meter to ensure coating thickness compliance with specification.
8.4 WET FILM THICKNESS – (WFT)

For the application of coatings by brush or roller every painter shall have a wet film gauge and they must
have a good understanding regarding the use of the wet film gauges and shall be used throughout the
application period.
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In the case of spray painting the spray painter and more importantly his pointer man as well as the supervisor
shall have a wet film thickness gauge to monitor the application thickness of the wet film throughout the
application period.
9 QUALITY ASSURANCE
9.1 CONTRACTOR QUALIFICATION
a) Prior to commencement of work, Kumba will require a quality audit of the painting Contractor to ensure
that he has the management, facilities, skilled staff and quality control facilities and staff to carry out
quality control during application of coatings to ensure compliance with specification.
b) The Contractor shall accept full responsibility for the quality of his work and of materials used,
irrespective of any quality control that may be carried out by Kumba or its QA/QC Consultant.
c) The Contractor shall obtain confirmation from the material supplier, in writing, that the materials used
comply with the specification and are suitable for the intended use.
9.2 QUALITY CONTROL

a) The Contractor shall have the necessary equipment and staff knowledgeable in test procedures to
carry out the quality control required ensuring compliance with the specification.
b) The cost of quality control shall be inclusive in the Contractor's tender price.
c) Before the commencement of the contract, the Contractor shall prepare a Quality Control Plan
detailing each activity to be carried out during the execution of the works. Each activity shall be
supported by a detailed Procedure for that activity. The Quality Control Plan will also detail the
inspection requirements of each specific activity, (e.g. Listing whether it be a witness, hold point etc.),
and defining the responsibilities of the various parties at these stages of the works.
d) The Contractor shall provide the necessary documentation to be used during these inspections. Such
documentation shall be reviewed and approved by Kumba beforehand.
e) The Contractor shall be fully responsible for the Quality Control of his work. The Contractor shall
provide a Quality Control Plan (single sheet) for each specification respectively, reflecting all of the
specified activities as detailed in the relevant protective coating systems in accordance with the above
guidelines. The Contractor shall also confirm that the required Quality control reports conform to the
Quality Control Plan. Quality Control shall play a critical role in satisfying the conditions of the
guarantee.
f) For the purpose of carrying out quality control, the Engineer shall be granted access to any part of the
Contractor's premises relevant to the work being carried out, at any reasonable time. The Contractor
shall provide, at his own cost, any equipment or labour necessary to gain access to surfaces which are
coated, to be coated or are in the process of being coated.
g) Kumba may carry out reasonable destructive tests to ascertain compliance with the specification. In
the event where bridge of specification has been confirmed, all cost incurred for the rectification of
damaged areas shall be for the sole account of the Contractor or supplier, whoever is at fault. In the
event where no bridge of specification has been confirmed, the cost incurred for the rectification of the
damaged areas will be for the sole account of Kumba.
h) Kumba reserves the right to select samples of any of the approved paints throughout the duration of
any given project and to submit such samples to an independent laboratory for testing in order to
confirm full compliance to the technical criteria as detailed in the relevant data sheets. In the event
where it is found that any product fails to conform, all such products shall be removed from the mine
immediately and Kumba reserves the right to call for the removal of coatings from components
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protected with these sub-standard products. In the event where such failures have occurred the re-
application of the effected components shall be for the sole account of the supplier.
i) For shop inspection work, the inspector shall complete a report at each visit and a copy of the report
will be given to the Contractor on completion of each workshop visit.
j) When any deviation from, or breach of, specification is found, it may be considered that this deviation
or breach has been occurring since commencement of work. Any and all re-work caused by faulty
workmanship, application; failing to comply with specifications, and / or non-standard procedures will
be for the sole account of the Contractor.
As part of the Quality Control Plan, it will include at least the following hold points.
For painting:
Release Parties to
Hold Point Description Validity
Certificate sign/agree
Preparation completed for Expires if not
abrasive blast cleaning or at any blasted,
Inspector /
Pre-cleaning other phase where preparation Pre-cleaning prepared or
Contractor
are required according to covered within
specifications. 8 hours
Expires if not
Abrasive Abrasive blast cleaning Abrasive blast Inspector /
primed within 4
blast cleaning complete. cleaning Contractor
hours.
Expires if not
Mechanical Mechanical Inspector /
Mechanical cleaning complete primed within 4
cleaning cleaning Contractor
hours.
Expires if not
Primer Primer coating complete and Inspector /
Primer covered within
coating cured. Contractor
45 days.
Crevice filling completed and Inspector /
Crevice filling Crevice filling
cured. Contractor
Stripe Stripe coating completed and Inspector /
Stripe coating
Coating cured Contractor
Final coating completed and Inspector /
Final coating Final
cured Contractor
Rubber Rubber Inspector /
Rubber insertion completed
insertion insertion Contractor
For Hot Dip Galvanised:
Release Parties to
Hold Point Description Validity
Certificate sign/agree
Preparation for HDG is complete
e.g. clear of welding splatter,
Before acid Preparation Inspector /
clean of any paint markings, Unlimited
bath cleaning for HDG. Contractor
detailing of steel for HDG in
accordance with SANS 121.
After
HDG Inspector /
galvanised Black spots, misses and DFT. Unlimited.
Complete Galvaniser
bath
9.3 DAILY PROJECT REPORTING

The Contractor shall keep at least the following daily records:
 Supervisor on site
 Work performed today
 Times of mechanical and chemical cleaning
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 Times of blast cleaning

 Times of painting
 Substrate temperature every three hours
 Psychrometric recordings every three hours
 Dry film thickness measurements per coat
 Material batch numbers
 Quantities of materials used
The above shall be traceable to the relevant area of work.
These records shall be kept in a format that meets the approval of Kumba.
9.4 DATA BOOK

a) Upon completion of the works, the Contractor shall provide Kumba with a Data Book containing all the
relevant Quality Control documents and records pertaining to the works.
b) The Contractor shall submit one copy of the Data Book to Kumba and keep one copy for his own
records.
c) The Contractor shall keep a site instruction book in triplicate on site at all times. The site instruction
book shall be accessible to all parties involved in order to issue instructions or request as may be
deemed necessary.
9.5 ALTERNATIVE COATING MATERIALS

Should the applicator or manufacturer wish to propose alternative products or coating materials he shall
submit a detailed motivation to Kumba. The motivation shall include, but not be limited to, the following:
a) Benefit to Kumba
b) Product licensor and technical back-up available
c) Location, experience and ISO quality rating of the production facility
d) Detailed case histories
e) Performance guarantee offered
f) The long term advantages
g) Manufacturer's data sheets and MSDS sheets for each product
10 GUARANTEES
Kumba will require performance guarantees for the applied coating systems.
We require two separate guarantees the Contractor shall provide the guarantee for the quality of his
workmanship and the supplier shall provide a guarantee for the quality of his products manufactured for each
specific application respectively, relevant to all corrosion protection work. The guarantee for all surface
atmospheric conditions shall be 10 years and for all immersed services shall be 5 years the coating condition
shall be at RI 0 for both conditions in year ten and year five respectively, when compared to the ISO 4628 –
3: 2003 standard.
For process plants final release certificates shall be issued for each floor level of plant completed respectively
and the base reference effective date for the guarantee shall be in accordance with the dates reflected on
these certificates.
No work shall commence prior to receipt of concept guarantee signed by all parties involved.
Although visible coating defects such as blistering, cracking, flaking and peeling are not always associated
with visible rusting, they indicate defects that could either lead to substrate corrosion or are shielding
substrate corrosion that has already taken place beneath the coating. Any such defects noted during the
guarantee period shall be repaired by the Contractor or supplier, whoever is at fault.
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The technical representative from selected supplier shall attend all bi-weekly or monthly meetings scheduled
by the project engineer and he shall accompany the project team with the site inspections and submit a report
on his findings one copy to the engineer and one copy to the Contractor.
All documentation pertaining to the guarantee shall be kept on the mine for the entire guarantee period.
11 HANDLING AND STORAGE

The following precautions shall be taken for the site storage of coated items.
11.1 HANDLING
All coated components shall be handled using soft slings.
11.2 LOADING
All coated components (incl. galvanising) to be transported shall be loaded on dunnage and lashed to avoid
chafing and steel to steel contact.
Spaghetti must be used to protect smaller items of steel and angles (5-mm spaghetti rubber coil). Coated
steel shall be secured on the truck preferably with nylon securing straps. Where chains must be used, rubber
insertion must be placed between the coated steel and chains at all contact points.
11.3 UNLOADING
Off-loading at site shall be conducted using the same care and precautions for on loading.
Components shall not be tipped off the transportation.
11.4 COVER
Coated items shall be stored under cover where possible.
Items not stored under cover shall be stored in such a manner as to avoid retention of water and allow good
air circulation.
Items shall be stored on bulks of timber or on trestles fitted with timber on bearing surfaces to raise the lowest
level 500 mm above the ground.
The Contractor shall provide sufficient cover to avoid damage to any of the plant surfaces not scheduled for
painting during his blasting and painting operations.
In the event where such damage has occurred the Contractor shall be responsible for the rectification of any
such areas at the sole expense of the Contractor.
11.5 STACKING
Items shall be stacked using timber packaging or other approved means to avoid coating-to-coating contact.
Sufficient bearing area of packing shall be used to avoid damage to coatings.
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12 RELATED DOCUMENTS
This general specification and protective coating systems are designed in the format of the AAC 164050
specification.
All national and international standards referred to in this document shall form part of this specification.
Where reference is made to a code, specification or standard the reference shall be taken to mean the latest
edition of the code, specification or standard, including addenda, supplements and revisions thereto.
12.1 SOUTH AFRICAN NATIONAL STANDARDS (SANS)

12.1.1.1 Codes Of Practice, Specifications And Methods
 SANS 10064: The preparation of steel surfaces for coating

 SANS 10140: Identification colour marking
 SANS 552: Paint Rollers for application of coatings
 SANS 901: Brushes for application of coatings
 SANS 121 (SABS ISO 1461): Hot dip (galvanised) zinc coatings (other than continuously zinc-coated
sheet and wire)
 SANS 1091: National colour standards for paint
 SANS 1217: Standard specification for the production of painted and powder coated steel pipes
12.1.2 Methods
 SANS 2808: Dry film thickness of paints by means of electromagnetic flux type b7 and eddy current
type gauges d7
 SANS 8502-3: 2008: Factor 3 Cleanliness of blast cleaned surfaces for painting (assessed by freedom
from dust and debris)
 SANS 5772: Profile of blast cleaned surfaces for painting (determined by a micrometre profile gauge)
12.2 INTERNATIONAL ORGANISATION FOR STANDERDISATION

 ISO 8501/1:1988: Preparation of steel substrates before application of paints and related products -
visual assessment of surface cleanliness.
 ISO 9002: Quality Management System.
 ISO 12944:1998: Paints and Varnishes – corrosion protection of steel structures by protective paint
systems.
 ISO 4628-3:2003: Paints and Varnishes – Evaluation of degradation of paint coatings – Designation of
degree of rusting.
12.3 BRITISH STANDARDS INSTITUTION (BSI)

12.3.1 South African Hot-Dip Galvanisers’ Association
 No SAHDGA 1-1990 Specification for the Performance Requirements of Coating Systems
 No SAHDGA 01-1990 Code of Practice for Surface Preparation and Application of Organic Coatings
 Weber-Reilly soluble salts test method: Test for soluble salts.
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13 PROTECTIVE COATING SYSTEMS

New Works Protective Coating Systems (NWPCS)
Number Description Page
NWPCS 01 Galvanising of structural steel and bought out items including open Page 40
grid and expanded metal floor grating, stair-treads and fixing
accessories.
NWPCS 02 Painting of structural steelwork and plate work. Page 42
NWPCS 03 Corrosion protection of piping (regularly replaced due to internal Page 44
wear).
NWPCS 04 Painting of surfaces where ceramic tiles will be used. Page 44
NWPCS 05 Painting of surfaces where replaceable steel liners will be used. Page 45
NWPCS 06 Corrosion protection of the internal surfaces of hydraulic tanks, Page 46
thickeners, launder, pipes and tanks carrying potable water, raw water
or clarified water.
NWPCS 07 Painting of cones internal sections where replaceable liners are not Page 49
fitted
NWPCS 08 Corrosion protection of all black bolts, nuts, washers and holding Page 50
down bolts prior to installation.
NWPCS 09 Painting of galvanised items (duplexing). Page 50
NWPCS 10 Painting of all electrical equipment such as control panels, Page 52
switchgear cabinets, power and lighting distribution boards.
NWPCS 11 Painting of internal and external surfaces for air conditioning and Page 54
ventilation ducting.
NWPCS 12 Painting of overhead cranes. Page 54
NWPCS 13 The protection of the internal surfaces of boxed sections of Page 56
Stacker/Reclaimers.
NWPCS 14 Painting of 3CR12 deck plates. Page 59
NWPCS 15 Alternative specification for corrosion protection of electrical, control Page 59
panels, switchgear cabinets, power and lighting distribution boards.
NWPCS 16 Temporary corrosion protection for machined surfaces and painting Page 61
of machined surfaces.
NWPCS 17 Painting of proprietary equipment. Page 62
NWPCS 18 Painting of walkways – Non-slip. Page 62
NWPCS 19 Column base protection in new plants. Page 64
NWPCS 20 Corrosion protection of cable racking. Page 64
NWPCS 21 Painting of hand and knee-rails, stanchions and fittings. Page 65
NWPCS 22 Painting of all new structural steelwork, conveyor structures, plate Page 65
work, external surfaces of E-houses, Stackers and Drum Reclaimers
in a less aggressive dry environment.
MAINTENANCE PROTECTIVE COATING SYSTEMS (MPCS)
Number Description Page

MPCS 01 Maintenance painting of structural steelwork, plate work and Page 67
mechanical equipment – full strip and paint.
MPCS 02 Maintenance painting of structural steelwork, plate work and Page 69
mechanical equipment – patch repair.
MPCS 03 Maintenance coating protection of column bases. Page 72
MPCS 04 Maintenance protective coating systems. Page 73
New Works Protective Coating Systems (NWPCS)
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13.1 PROTECTIVE COATING SYSTEM NWPCS 01

13.1.1 Scope
Galvanising of all structural steel and bought out items including open grid and expanded metal floor grating,
stair-treads and fixing accessories.
13.1.2 General
This system shall be applied in accordance with the general requirements of this document.
13.1.3 Hot-Dip Galvanising

Hot dip galvanising of fabricated items shall be in accordance with SANS 121 (SABS ISO 1461), and to
attached specification of the Hot Dip Galvanisers Association.
Double end dipping shall be permitted provided that it will not result in distortion of the product and an
acceptable surface finish of the zinc coating is achieved.
No uncoated areas or ‘black spots’ will be accepted including un-coated areas on welding. (The fabricator is
strongly recommended to blast clean all welding to remove all contaminants prior to dispatch to the
galvaniser).
Un-coated areas and defects shall not exceed that allowable for repair as stated in SANS 121 (SABS ISO
1461) and shall be repaired by abrading surfaces with 80 grit sandpaper and painting with Zincfix (zinc rich
epoxy paint) achieving an overlap of at least 25mm and to a minimum thickness of 25% above the minimum
specified for the galvanised coating. Steel shall not be inspected until the paint has dried and can be
inspected. Loading shall take place only once steel has been released for loading.
Inspection shall be 100% of batch.
13.1.4 Patch Repair

Modifications (not involving black steel), transportation and erection damage, shall be repaired by abrading
with 80 grit sand paper and painting with ZincFix (twin pack zinc rich epoxy paint) achieving an overlap of at
least 25mm onto the surrounding sound zinc coating and to a minimum thickness of 25% above the minimum
specified for the galvanised coating.
Steel shall not be inspected until the paint has dried and can be inspected.
Black steel utilized in modifications with galvanised steel shall be abrasive blast clean to Standard SA 2½
per International Standard ISO 8501/1-1988 to obtain a surface profile of 40 to 70 microns. Once the surface
preparation has been inspected and certified, apply one coat of ZincFix (twin pack zinc rich epoxy paint)
achieving an overlap of at least 25mm onto existing sound galvanised coating where black steel is welded to
galvanised components.
Dry film thickness shall be a minimum of 25% above the minimum specified for the galvanised coating.
13.1.5 Stair treads
Stair treads shall be of the open grid type with non-slip nosings and drilled side-plates.
Side-plates shall be pre-drilled to the required centres before hot-dip galvanising.
13.1.6 Kick-plates
Kick-plates shall be welded to either the transverse bars or bearer bars prior to hot-dip galvanising.
Where kick-plates are welded to the bearer bars a 3 to 5 mm gap must be allowed between the bearer bar
and the kick-plate to facilitate the hot-dip galvanising of the inaccessible areas.
13.1.7 Fixing Accessories

Locking plates, saddle clamps, fixing clip sets and all associated nuts and bolts shall be hot-dip galvanised.
13.1.8 Approved Coatings
REV
Brand Name Manufacturer

Primer:
Zincfix Speccoats
13.2.1 Scope
This system details the painting of all new structural steelwork, conveyor structures, plate work, the external
surfaces of piping, chutes, hoppers, tanks, boxes, screen frames, equipment and the external surfaces of E-
houses, Stackers and Drum Reclaimers in a mining or plant environment in a general heavy duty mining or
plant environment.
13.2.2 General
Dry film thickness is given in windows. In each case, only the minimum coating thickness has been specified.
For the maximum DFT allowed for each specified coating, consult with the technical division of the paint
manufacturer. (It is strongly recommended that the main Contractor establish the maximum allowed DFTs
from the chosen paint manufacturer at the commencement of a contract and prescribe such limitations on
each of their Sub-Contractors to establish consistent requirements).
The primer must have a minimum of 85% zinc in the dry film.
The patch primer must have a minimum of 80% zinc in the dry film.
13.2.3 Application
All coatings shall be applied in accordance with the manufacturer’s recommendations and instructions,
including over coating times and surface preparation which may be required between coats.
Unless otherwise specified all coatings shall be spray applied.
Edges, corners, bolt holes and cut ends shall be stripe coated by brush application with an additional coat of
the intermediate coat. The stripe coat shall overlap the sharp edges on either side for a minimum distance of
15 mm. The colour shall contrast with the primer and the full intermediate coat.
13.2.4 Surface Preparation In The Shops

Surfaces shall be tested for oil and grease by means of a water break free test.
If surfaces are not water break free, remove all oil and grease by high pressure water washing or by using a
water-soluble degreaser followed by rinsing with clean potable water.
Any chemical contamination shall be eliminated by means of neutralization or flushing or both, prior to
additional surface preparation.
Abrasive blast clean to Standard Sa 2½ as per ISO 8501/1-1988 to obtain the surface profile recommended
by the coating manufacturer for the primer being used.
13.2.5 Primer
Apply one coat of Inorganic Zinc Ethyl / Alkyl Silicate to a DFT of 75 to 110 micron. MEK test to be done.
13.2.6 Patch Repair On Site

Repair damaged areas using 80 grit sandpaper to remove loose contaminants, followed by washing with
clean running water to remove salts and allow to dry. Re-instate the damaged primer or intermediate coat or
both as required. Small areas of damage may be coated by brush. Repairs shall be neat and shall overlap
the adjacent sound coating for a minimum distance of 25 mm.
13.2.7 Sealant
All crevices must be prepared and filled as described in the Kumba Specification.
Apply one coat of sealing compound to seal all crevices.
REV
13.2.8 Stripe Coat On Edges Of Steel

White multi-purpose epoxy 15mm wide, 100-250µm thick.
13.2.9 Final Coat

Apply one coat of polyamide cured multipurpose epoxy. DFT shall be 100 to 250. In highly corrosive areas
e.g. at the coast or an aggressive environment the DFT will be 150 micron minimum.
13.2.10 Total Thickness

Total DFT of system shall be 75 to 110 microns.
Primer
Resist 86 Jotun
Aquazinga Zinga Industries
Carbozinc 11 StonCor
Interzinc 687 International Paint
Patch Primer
Barrier Zinc Primer Jotun
Sigmarite CT Zinc Primer Sigma Coatings
Corpro 100 O’Grady’s Paint
Sealant
Epoxy Putty Lite Jotun
Carboguard 165 StonCor
Protecton Sealer Sigma Coatings
Varguard 46 Varcol
NOTE:
It is the responsibility of the applicator to ensure that he can achieve the required dry film thickness (DFT) of
any and all of the required coats in a single application.
If multi-coats are required, they shall be applied within the recoat restrictions of that particular coating and all
additional labour shall be for the sole account of the applicator.
13.3 PROTECTIVE COATING SYSTEM: NWPCS 03

13.3.1 Scope
This system details the protection of the internal and external surfaces of piping.
13.3.2 Application
To be hot dipped galvanised in accordance with ISO 1461.

13.4.1 Scope
This system details the painting of surfaces where replaceable steel liners will be used.
13.4.2 General
REV
13.4.3 Coating Application

13.4.4 Surface Preparation (In The Shops)

break free, remove all oil and grease by high pressure water washing or using a water-soluble degreaser
followed by rinsing with clean potable water.
Abrasive blast clean to Standard Sa 2½ as per ISO8501/1-1988 to obtain a surface profile as recommended
by the primer manufacturer.
13.4.5 Paint System

The surfaces where replaceable steel liners are fitted shall be painted as per the relevant specification for
the external surfaces of the bin or chute.
13.4.6 Coating From Steel Liners To Top Of Chute

If not specified otherwise on the drawings, paint surfaces in accordance with the paint system as specified
for the external surfaces.

13.5.1 Scope
This system details the painting of surfaces where ceramic tiles will be used.
13.5.2 General
Dry film thickness is given in windows.
In each case, only the minimum coating thickness has been specified. For the maximum DFT allowed for
each specified coating, consult with the technical division of the paint manufacturer. (It is strongly
recommended that the main Contractor establish the maximum allowed DFTs from the chosen paint
manufacturer at the commencement of a contract and prescribe such limitations on each of their Sub-
Contractors to establish consistent requirements).

13.5.4 Surface Preparation (In The Shops)

REV
If surfaces are not water break free, remove all oil and grease by high pressure water washing or using a
13.5.5 Primer Coat

None prior to the abrasion resistant tiling operation.
13.5.6 Coating Adjacent To Abrasion Resistant Tiles

Abrasive blast clean to Standard SA 2½ as per ISO 8501/1-1988 to obtain a surface profile as recommended
If not specified otherwise on the drawings, paint surfaces in accordance with the paint system as specified
for the external surfaces.
NOTE:
It is the responsibility of the applicator to assure that he can achieve the required dry film thickness (DFT) of
any and all of the required coats in a single application. If multi-coats are required, they shall be applied
within the recoat restrictions of that particular coating and all additional labour shall be for the sole account
of the applicator.

13.6.1 Scope
This system details the lining of the internal surfaces of pipes and tanks, thickeners, launders, pipes and
tanks carrying potable water, raw water or clarified water.
13.6.2 General
In each case, only the minimum coating thickness has been specified.
13.6.3 Application
Pipes to be hot dipped galvanised in accordance to HDG Association Specification (attached).
OR AS AN ALTERNATIVE WHERE HOT DIP GALVANISING IS NOT POSSIBLE
Unless otherwise specified or instructed all coatings shall be spray applied.
13.6.4 Surface Preparation

If surfaces are not water break free, remove all oil and grease by high pressure water washing or using a
REV
For Internal Surfaces
13.6.5 Lining System

Spray apply two coats of potable water grade two component polyamine cured epoxy, each to a minimum
DFT of 125 microns.

Interline 850 International Paint
Penguard HSP Jotun
Sigmaguard Sigma Coatings
Varcon 007 Varcol
For External Surfaces
13.6.7 Primer
Apply one coat of aluminium filled epoxy. DFT shall be a minimum of 75 microns.
13.6.8 Final Coat

Apply one coat of aliphatic isocyanate cured acrylic polyurethane. DFT shall be a minimum of 40 microns.

Total DFT of system shall be a minimum of 115 microns.
Primer:
Barrier Plus Jotun
Varguard 30 Varcol
Final Coat:
Interthane 990 International Paint
Futura AS Jotun
Sigmadur Sigma Coatings
Carboline 134 StonCor
Varthane 099 Varcol
NOTE:
It is the responsibility of the applicator to assure that he can achieve the required dry film thickness (DFT) of
any and all of the required coats in a single application. If multi-coats are required, they shall be applied
within the recoat restrictions of that particular coating and all additional labour shall be for the sole account
of the applicator.
REV

13.7.1 Scope
This system details the painting of the internal sections of cones where replaceable liners are not fitted.
13.7.2 General
13.7.3 Application
All coatings shall be applied in accordance with the manufacturer’s recommendation and instructions,
including over coating times and surface preparation, which may be required between coats.

13.7.5 Primer
Apply approved low friction lining coating as detailed by the design requirements.
Where design requirements do not specify coating system, consult the Project Engineer.
13.7.6 Final Coat

Take note of surface preparation required between coats.
Apply the protective coating system as detailed by the design requirements. Where design requirements do
not specify coating system, consult the Project Engineer.

13.8.1 Scope
This system details the HDG of all black bolts, nuts, washers and holding down bolts prior to installation.
13.8.2 Treatment
To be hot dipped galvanised in accordance to the HDG Association Specification (attached).

13.9.1 Scope
This system details the coating of all hot dip galvanised steel, i.e. the duplex coating of galvanised steelwork
(including galvanised handrails and stanchions both internal and external to buildings)
Where possible, the galvanised steelwork should be ordered in the ‘unpassivated’ condition if
painting takes place at the galvanisers. If passivation is removed on site prior to painting, the
specified cleaning methods for removal of the passivation must be carried out.
REV
13.9.2 General
13.9.3 Application
including over coating times and surface preparation which may be required between coats. Where
dark/bright colours are preferred and it is exposed to UV rays, polyurethane instead of epoxy should be used.
The use of dark/bright colours should be avoided.

Clean the galvanised surface by using scotch brite pads in conjunction with galvanised iron cleaner as
supplied by the primer manufacturer. Allow 5-10 minutes for the solution to react with the passivation layer.
Remove galvanised iron cleaner residues using nylon scrubbing brushes and running water to obtain a water
break-free surface.
If the surface is not water break-free repeat the above until water break-free. Allow to dry before painting.
13.9.5 Final Coat

Apply one coat of polyamide cured multipurpose epoxy. DFT shall be a minimum of 100 microns.
13.9.6 Patch Repair

Transportation and erection damage shall be repaired using 80 grit sandpaper to feather the edges and to
remove loose contaminants, followed by washing with clean running water to remove salts. Allow to dry and
prime.
Apply one coat ZincFix (epoxy zinc rich paint), to areas where the galvanising has been damaged. DFT shall
be a minimum of 25% greater than the coating of the galvanising around the repair areas and not less than
60 microns – whichever is the greater.
Damage to the painting coatings shall be repaired with the respective coatings specified in paragraph 15.9.5
above. These coatings shall overlap the existing sound coating with a minimum of 50mm.
13.9.7 Total Thicknesses

The total DFT shall be a minimum of 100 microns above the minimum average specified for the galvanised
coating.
Galvanise Iron Cleaner

As recommended by the manufacturer of the selected primer
Patch Primer: Repair to Galvanising

ZincFix Speccoats.
For dark/bright colours exposed to UV rays (use should be limited):

Futura AS Jotun
Varthane 099 Varcol
REV
For pastel colours (inside and outside, exposed to UV rays and not exposed to UV rays):
Intergard 345 International Paint

Jotamastic 87 Jotun
Sigmacover Sigma Coatings
Varguard 300 Varcol
NOTE:
It is the responsibility of the applicator to assure that he can achieve the required dry film thickness (DFT)
of any and all of the required coats in a single application. If multi-coats are required, they shall be applied
within the re-coat restrictions of that particular coating and all additional labour shall be for the sole account
of the applicator.

13.10.1 Scope
This system details the corrosion protection of all electrical equipment such as control panels, switchgear
cabinets, power and lighting distribution boards.
13.10.2 General
This system details the duplex coating of all control panels, switchgear cabinets, power and lighting
distribution boards.

The panels, cabinets or boards shall be either hot-dip galvanised in accordance with NWPCS 01 (not heavy-
duty system) after fabrication or shall be fabricated from galvanised sheet.
13.10.4 Powder Coating Application

The duplex coating shall be an approved Epoxy Polyester Powder Coating system. Structured powder finish
is not acceptable.
The powder coating shall be applied in an approved proprietary electrostatic powder application plant
comprising a suitable multistage pre-cleaning process, electrostatic powder application facility and either
electrical or gas powered curing ovens.
The powder coating shall be applied in strict accordance with the coating manufacturer's recommendations
and instructions, including powder curing time and temperature programs.
The thickness of the powder shall be a minimum of 65 microns.
13.10.5 Patch Repairs

All damage to the duplex coating system caused by transport, handling, erection or site modifications shall
be carried out as described below.
Damaged galvanising shall be repaired using 80 grit sandpaper to feather the edges and to remove loose
contaminants, following by washing with clean running water to remove salts. Allow to dry and prime. Apply
one coat of ZincFix (twin pack epoxy zinc rich paint), DFT shall be a minimum of 60 microns. This coating
shall overlap the existing sound coating with a minimum of 25mm.
Damaged powder coating shall be repaired by applying, after surface preparation, one coat of polyamide
cured epoxy galvanising primer. DFT shall be a minimum of 75 microns, followed by one coat of aliphatic
acrylic polyurethane of a matching colour to the powder coating. This coating shall be applied to a minimum
DFT of 40 microns.
Areas to be patch repaired shall be suitably cleaned and abraded, feathering edges of existing coating prior
to coating application. The repairs shall overlap the existing sound coating for a minimum distance of 50 mm.
Powder Coating Repairs less than 2 500 mm² in area may be repaired by localized brush applications.
Areas of damage greater than 2 500 mm² in area must be repaired by spray applications.
REV
All repairs to panels to be performed prior to electrical apparatus installation.

The total thickness of the duplex system, i.e. galvanising plus powder, shall be a minimum of 85 microns.
Primer Repair to Galvanising:

ZincFix Speccoats
Primer Coat: Repair to Power Coating

Penguard Jotun
Sigmacap Primer EP Sigma Coatings
Varguard 50 Varcol
Final Coat: Repair to Power Coating

Futura AS Jotun
Varthane 099 Varcol
Corpro 800 O’Grady Coatings

13.11.1 Scope
This system is applicable to the internal and external surfaces of air conditioning and ventilation ducting
fabricated from continuously zinc coated (galvanised) steel sheet operating at temperatures up to 80ºC.
13.11.2 Treatment
HDG in accordance to HDG Association Specification (attached).

13.12.1 Scope
This system is applicable to overhead cranes.
13.12.2 General
This system shall be applied on accordance with the general requirements of this document.
13.12.3 Application
All coatings shall be applied in accordance with the coating manufacturer’s recommendations and
instructions, including over coating times and surface preparation that may be required between coats.
REV
break free, remove all oil and grease by high pressure water washing or by using a water-soluble degreaser
13.12.5 Primer
Apply one coat of aluminium filled multipurpose epoxy. DFT shall be a minimum of 100 microns.
13.12.6 Patch Repair

clean running water to remove salts and allow to dry.
Apply one coat of aluminium filled epoxy by brush. DFT shall be a minimum of 100 microns. This coating
shall overlap the existing sound coating with a minimum of 50mm.
13.12.7 Sealant
Seal all crevices with reinforced epoxy compound. See paragraph 3.4 for the definition of crevices and
concealed surfaces.
13.12.8 Final Coat

Apply one coat of aliphatic isocyanate cured polyurethane acrylic. DFT shall be a minimum of 40 microns.

Primer
Interseal 670 HS Aluminium International Paint
Jotamastic 87 Jotun
Sigmacover Aluprimer Sigma Coatings
Varguard 349 Aluminium Varcol
Corpro 600 O’Grady’s Paints
Sealant
Varguard 46 Varcol
Final Coat
Futura AS Jotun
Carbothane 134 StonCor
Varthane 099 Varcol
NOTE:
It is the responsibility of the applicator to ensure that he can achieve the required dry film thickness
(DFT) of any and all of the required coats in a single application. If multi-coats are required, they shall
be applied within the recoat restrictions of that particular coating and all additional labour shall be for
the sole account of the applicator.
REV

13.13.1 Scope
This system is applicable to the internal and external surfaces of the E-House/s for the Stacker/Reclaimers
where manhole entrances give access to these internal surfaces.
13.13.2 General
13.13.3 Application

break free, remove all oil and grease by high pressure water washing or by using a water-soluble degreaser
Prior To Fabrication
All plate work shall be abrasive blast clean to Standard Sa 2½ as per ISO 8501:1 – 1988 to obtain a surface
profile of 40 to 70 microns, prior to assembly.
Apply zinc filled inorganic coating (weldable primer). DFT shall be a minimum of 15 microns.
After Fabrication
Remove all oil and grease by using a water-soluble degreaser followed by rinsing with clean potable water.
All welding and grinding areas shall be abrasive blast clean to Standard Sa 2½ as per ISO 8501:1 – 1988 to
obtain a surface profile as recommended by the coating manufacturer for the primer being used.
13.13.5 Primer Coat

Apply one coat of zinc rich epoxy primer. DFT shall be a minimum of 75 microns.

Repair damaged areas using 80 grit sandpaper to remove the loose contaminants, followed by washing with
clean running water to remove salts. Allow to prime and dry.
Apply one coat of aluminium filled epoxy by brush. DFT shall be a minimum of 100microns. This coating
shall overlap the existing sound coating with a minimum of 50 mm. Apply one coat of polyamide cured epoxy.
DFT shall be a minimum of 75 microns. This coating shall overlap the primer coat with a minimum of 50 mm.
13.13.7 Internal Surfaces Of Inaccessible Sections

All surfaces of inaccessible boxed sections (no manhole entrance) which are not guaranteed to be 100%
airtight shall be painted in accordance with this specification, prior to the last plate being welded in place.
Patch repair of all internal welds shall be made where possible.
REV

Total DFT of system shall be a minimum of 150 microns in accessible boxed sections (manhole entrance)
and a minimum of 75 microns (primer only) in all seal welded boxed sections without manhole entrances.

Shop Primer
Interplate 11 International Paint
Shopprimer Jotun
Sigmaweld Sigma Coatings
CarboWeld 11 StonCor
Varzinc 137 Varcol
Aquazinga Zinga Industries
Primer Coat
Barrier Plus Jotun
Varguard 30 Varcol
Final Coat
Intergard 345 HS International Paint
Jotamastic 87 Jotun
Varguard 349 Varcol
NOTE:
be applied within the recoat restrictions of that particular coating and all the additional labour shall be
for the sole account of the applicator.

13.14.1 Scope
This system details the painting of 3CR12 deck plates.

Not to be painted.

13.15.1 Scope
This system is applicable to all electrical control panels, switchgear cabinets, power and lighting distribution
boards manufactured from mild steel.
13.15.2 General
REV
each specified coating, consult with the technical division of the paint manufacturer. (It is strongly
recommended that the main Contractor establish the maximum allowed DFTs from the chosen paint
manufacturer at the commencement of a contract and prescribe such limitations on each of their Sub-
Contractors to establish consistent requirements).
13.15.3 Application

Abrasive blast clean to Standard Sa 2½ as per ISO 8501/1-1988 to obtain the surface profile of 40 to 70
microns or as recommended by the primer manufacturer. Air pressure should be reduced to 3½ bar.
13.15.5 Primer
13.15.6 Final Coat

Apply one coat of aliphatic isocyanate cured acrylic polyurethane. DFT shall be a minimum of 40 microns.

Primer
Barrier Plus Jotun
Varguard 30 Varcol
Final Coat
Futura AS Jotun
Carbothane 134 StonCor
Varthane 099 Varcol
NOTE:
REV

13.16.1 Scope
This system is applicable to the temporary protection of machined surfaces e.g. shafts and subsequent
painting after installation.
13.16.2 General
13.16.3 Surface Preparation And Application Of Tempory Protection

Dry off, immediately with clean dry compressed air and solvent wipe all surfaces with white spirits and allow
the solvent to flash off. Apply, immediately, VPCI-368 wax coating by brush and allow to stand for
approximately 30 min. Care must be taken to avoid direct contact to these machined surfaces here after.
This coating shall be removed prior to blast cleaning, on adjacent surfaces to surfaces, which are to be blast
cleaned, by wiping these surfaces with “White Spirits” and then protecting these surfaces by applying the
PVC blast tape to completely cover these surfaces. After blast cleaning the relevant primer coat should be
applied as soon as possible. Once the primer coat has been applied, the PVC blast tape must be removed
and VPCI-368 immediately re-applied as prescribed above.
Prior to assembly, the VPCI-368 must be removed using “White Spirits”.
13.16.4 Surface Preparation And Application Of Coatings On Exposed Machined Surfaces After Installation
This coating shall be removed using “White Spirits” followed by degreasing using a water soluble degreaser
and rinsing with clean potable water to achieve a water break free surface.
Abrade surfaces thoroughly with 80 grit sand paper.
Apply the specified coating system.
Temporary protection
Cortec VPCI-368 Cortec (PTY) LTD

Or other temporary protector approved by the Project Engineer.
REV

13.17.1 Scope
This system is applicable to Propriety Equipment as stipulated by Kumba.
The painting Quality Control Plans will be submitted to Kumba for approval, along with the supplier’s /
manufacturer’s specification.
13.17.2 General
This system shall be applied in accordance with the requirements of the coating manufacturer’s
recommendations and instructions and with the general requirements of this document.
13.17.3 Surface Preparation And Application

This will then be painted according to the Kumba approved supplier’s / manufacturer’s specification.

13.18.1 Scope
This system is applicable to all painted walkway sections not constructed out of chequer plate or grating of
sorts where a non-slip surface is needed. This system shall be applied over existing sound epoxy or
polyurethane coatings.
13.18.2 General
13.18.3 Application

break free, remove all oil and grease by using a water-soluble degreaser followed by rinsing with clean
potable water. A water break free surface shall be achieved and a clearance certificate issued prior to further
REV
Thoroughly abrade painted surface, using 80 grit sandpaper to break the gloss finish and to roughen up the
surface.
13.18.5 First Coat

Apply one coat polyamide cured epoxy. DFT shall be a minimum of 100 microns.
Coating thickness shall be measured by means of Wet Film Thickness
Immediately after applying the coating, sprinkle 16/20 Aluminium Oxide Grit over coated section/s, totally
covering the paint coating so as to embed the aluminium oxide in the wet coating. Leave the paint to dry.
After the recommended over coating time, remove all excess and loose grit particles by lightly sweeping the
surface/s with soft brooms.
13.18.6 Second Coat

Apply a second coat of polyamide cured epoxy of sufficient thickness to encase the aluminium oxide grit
particles embedded in the first coat.

clean running water to remove salts.
Allow to dry and paint as per the relevant specification previously applied and then followed by paragraph
(15.18.5) and (15.18.6) above.
First Coat
Interseal 670 H/S International Paint
Jotamastic 87 Jotun
Varguard 349 Varcol
16/20 Aluminium Oxide Grit Blastrite (Pty) Ltd
Second Coat
Interseal 670 H/S International Paint
Jotamastic 87 Jotun
Varguard 349
NOTE:

13.19.1 Scope
REV
This system details the new works coating of column bases in wet and spillage areas. This system has been
designed to coat the bottom section of steel bases and continue down over the concrete base and extend
onto the floor area.
The system to be used is that specified under MCPS 03.
Hot dip galvanised columns should not be column base protected except for crevice filling between the
baseplate and the concrete foundation.

13.20.1 Scope
This system details the corrosion protection of cable racking.
13.20.2 General

Hot dip galvanising of fabricated items shall be in accordance with SANS 121 (SABS ISO 1461) and as per
NWPCS 01.

13.21.1 Scope
This system is applicable to all hand and knee-railing including stanchions and fittings.
13.21.2 General
This system details the duplex coating of all assembled hot-dip galvanised handrails, stanchions and fittings.
This system shall be applied in accordance with the general requirements of this document, and as detailed
under NWPCS 9.

13.22.1 Scope
This system details the painting of all new structural steelwork, conveyor structures, plate work, external
surfaces of piping, chutes, hoppers, tanks, boxes, screen frames, equipment and the external surfaces of E-
houses, Stackers and Drum Reclaimers in a mining or plant environment in a less aggressive dry
environment.
13.22.2 General
The patch primer must have a minimum of 80% zinc in the dry film.
13.22.3 Application
REV
13.22.4 Surface Preparation In The Shops
If surfaces are not water break free, remove all oil and grease by high pressure water washing or by using a
13.22.5 Primer
Apply one coat of Inorganic Zinc Ethyl / Alkyl Silicate to a DFT of 75 to 110 micron. MEK test to be done.
13.22.6 Patch Repair On Site

clean running water to remove salts and allow to dry.
Re-instate the damaged primer or intermediate coat or both as required. Small areas of damage may be
coated by brush. Repairs shall be neat and shall overlap the adjacent sound coating for a minimum distance
of 25 mm.
13.22.7 Sealant
All crevices must be prepared and filled as described in the Kumba Specification.
Apply one coat of sealing compound to seal all crevices.

Total DFT of system shall be 75 to 110 microns.
Primer
Resist 86 Jotun
Patch Primer
Barrier Plus Jotun
Sealant
Varguard 46 Varcol
Corpo 900 O’Grady’s Paint
NOTE:
REV
be applied within the recoat restrictions of that particular coating and all additional labour shall be for
14 MAINTENANCE PROTECTIVE COATING SYSTEMS (MPCS)

14.1 PROTECTIVE COATING SYSTEM MPCS 01
14.1.1 Scope
This system details the maintenance recoating of structural steelwork, plate work and mechanical equipment
situated in a general heavy-duty mining or plant environment.
14.1.2 General
In each case, only the minimum coating thickness has been specified.
each of their Sub-Contractors to establish consistent requirements)
14.1.3 Application
including re-coat times and surface preparation, which may be required between coats.
The surface of the crevice shall be primed prior to the application of the sealing compound.
Edges, corners, bolt holes, bolts and cut ends shall be stripe coated by brush application with an additional
coat of polyamide cured epoxy. The stripe coat shall overlap the sharp edge in either side with a minimum
of 15mm. The stripe coating will be applied to the same thickness specified for the primer coat. The colour
of the stripe coat shall contrast with the primer and final coat.

Tightly adhering rust and rust scale must be removed by using needle-pin descalers.
Abrasive blast clean to Standard SA 2½ per International Standard ISO 8501/1-1988 to obtain a surface
profile of 40 to 70 microns.
14.1.5 Primer
14.1.6 Sealant
REV
Apply one coat of sealing compound to seal all crevices and concealed surfaces. See paragraph 3.4 for the
definition of a crevice.
14.1.7 Final Coat

Apply one coat of polyamide cured epoxy. DFT shall be a minimum of 100 microns.

Total DFT shall be a minimum of 200 microns and a minimum of 300 microns on all sharp edges.
Primer
Interseal 670 H/S AL International Paint
Jotamastic 87 Jotun
Sealant
Varguard 46 Varcol
Final Coat
Jotamastic 87 Jotun
Varguard 349 Varcol
Corpro200 O’Grady’s Paint
NOTE:
It is the responsibility of the applicator to assure that he can achieve the required dry film thickness
be applied within the re-coat restrictions of that particular coating and all additional labour shall be for
For the application of coating by brush or roller every painter will have a WET FILM (WFT) GAUGE.
They must have a good understanding regarding the use of the WFT gauge. The WFT gauge will be
used throughout the application period. In the case of spray painting the spray painter, the team leader
and the supervisor will have a WFT gauge to monitor the wet film throughout the application period.

14.2.1 Scope
This system details the maintenance patch repair to the coating of structural steelwork, plate work and
mechanical equipment situated in a general heavy-duty mining or plant environment.
14.2.2 General
This system can be applied over existing sound epoxy / polyurethane systems. Sound coatings of other
generic types, i.e. chlorinated rubber, vinyls etc. may be recoated with this system, but a test patch shall first
be applied to evaluate compatibility with the new system. It is recommended, however, whenever practical
to remove aged coating of other generic types.
REV
14.2.3 Application
Edges, corners, bolt holes, bolts and cut ends shall be stripe coated by brush application with an additional
coat of polyamide cured epoxy. The stripe coat shall overlap the sharp edge in either side with a minimum
of 15mm. The stripe coating will be applied to the same thickness specified for the primer coat. The colour
of the stripe coat shall contrast with the primer and final coat.

Remove all existing loose rust, rust scale and loose or flaking paint by using pneumatic power tools, fitted
with 140mm cup wire brushes. Tightly adhering scale must be removed by using needle-pin descalers.
Clean damaged areas to standard ST3 of the Swedish Specification SIS 05 59 00, followed by brushing of
the existing coating to feather edges remove chalking and to provide a key. 80 Grit sandpaper may only be
used in areas inaccessible to the machines.
Thoroughly wash all cleaned steel with running water and scrubbing brushes to remove dust and salts. Dry
with clean dry compressed air and allow to dry for a further 30 minutes and prime.
14.2.5 Patch Primer

All areas where existing coating has been removed shall receive one coat of aluminium filled epoxy applied
as a patch primer by brush or spray. This coating shall overlap the existing sound coating by 50mm minimum.
DFT shall be a minimum of 100 microns.
14.2.6 Sealant
Apply one coat of sealing compound to seal all crevices and concealed surfaces. See paragraph 6.4 for the
definition of a crevice.
14.2.7 Final Coat

Apply one coat of polyamide cured epoxy. DFT shall be a minimum of 100 microns.

Total DFT shall be a minimum of 100 microns above existing coating thickness, and a minimum of 200
microns over areas of bare metal and a minimum of 200 microns above existing coating thickness on all
sharp edges.

Interseal 670 H/S AL International Paint
Jotamastic 87 Jotun
REV

Sealant
Varguard 46 Varcol
Final Coat
Jotamastic 87 Jotun
Varguard 349 Varcol
Corpro200 O’Grady’s Paint
NOTE:

14.3.1 Scope
This system details the maintenance coating of column bases. This system has been designed to coat the
bottom section of steel bases and continue down over the concrete base and extend onto the floor area.
14.3.2 General
14.3.3 Application
This is a high performance heavy duty coating system with a short pot life. Make certain that all equipment
is available and access ready before mixing coating.

Tightly adhering rust and rust scale must be removed by using needle-pin descalers
by the coating manufacturer for the epoxy compound being used.
REV
Concrete: Sweep blast to remove all loose / unbound particles and laitances.
14.3.5 System
Apply one complete coat of reinforced epoxy compound to both the concrete and steel areas up to a minimum
of 500mm high from the base plate elevation. Abrasive blast cleaning shall be 450mm high from the base
plate elevation.
Hand clean using 80 grit sand paper the top 50mm to remove gloss and provide a key.
Coating shall start with an overlap of 50mm on the coating of the column and shall be extended over the
base plate at least 100mm onto the surrounding concrete plinth or preferable overlap the edge of the concrete
plinth. Coating should be a minimum of 3mm thick.
Initial application shall be by hand using a square flat sheet of Perspex or broad putty knife, followed by
finishing off and levelling the product by hand. Saturate the hands with a mixture of Sunlight liquid and water
(mixed about 1:5) to prevent the compound from sticking to the hands (take note of manufacturers safety
precautions.

Total DFT of system shall be 3mm minimum.

Varguard 46 Varcol
NOTE:
Individual coating materials as supplied, from different manufactures have their own particular build
characteristics.
(DFT) of any and all of the required coats in a single application.
If multi-coats are required, they shall be applied within the re-coat restrictions of that particular coating
and all additional labour shall be for the sole account of the applicator.

14.4.1 Scope
This system details the maintenance recoating of structural steelwork, plate work and mechanical equipment
situated in a general heavy-duty mining or plant environment.
Structures previously painted with In-organic Zinc Silicate can be re-coated or repaired with this specification.
14.4.2 General
each specified coating, consult with the technical division of the paint manufacturer. (It is strongly recommend
that the main Contractor establish the maximum allowed DFTs from the chosen paint manufacturer at the
commencement of a contract and prescribe such limitations on each of their Sub-Contractors to establish
consistent requirements).
REV
14.4.3 Application
All coatings shall be applied in accordance with the manufacturer's recommendation and instructions,
Bolt holes, bolts and cut ends shall be coated by brush prior to spray painting. The thickness on the edges,
corners, bolt holes, bolts and cut ends shall be the same as specified for the flat surfaces - 80 microns
minimum.
Coatings shall be moisture cured 1 hour after coat application and curing will continue for 3 days.

Tightly adhering rust and rust scale must be removed by using needle-pin descalers.
Abrasive blast clean to Standard SA 2 ½ per International Standard ISO 8501/1 - 1988 to obtain a surface
profile of 40 - 60 microns.
14.4.5 Zinga Metal Coating

a) Structural steel and Plate work:
Apply one coat of Zinga Metal. DFT shall be a minimum of 80 microns.
b) Column Base Protection:

Apply two coats of Zinga Metal. DFT shall be a minimum of 75 microns per coat.
14.4.6 Sealant
Apply one coat of sealing compound to seal all crevices and concealed surfaces.
See paragraph 3.4 for the definition of a crevice.

a) Structural steel and Plate work:
Total DFT shall be a minimum of 80, and the maximum is 120 microns for structural steel and plate
work including all sharp edges.
b) Column Base Protection:

Total DFT shall be a minimum of 100, and the maximum is140 microns for column bases including all
sharp edges.

Zinga Metal Coating Zinga Industries
Sealant
Varguard 46 Varcol
Corpro 900 O'Grady’s Paint
NOTE:
REV
Saturation
All Zinga Metal Coatings must be saturated with water, approximately 1 hour after application by
applying a soft clean water spray. This wetting process must be repeated at least 6 times to ensure
complete saturation. When 2 coats are applied, saturate the second coat not the first coat.
15 COLOUR CODING
All colour codes shall be in accordance with Kumba Iron Ore Equipment & Infrastructure Colour Coding
Standard ENG-GEN-ADM-STD-005.
16 REVISION HISTORY
Version No. Reason for Change Date
00 New November 2015
REV
17 ANNEXURE A – EXAMPLE FORMS - CONTRACTORS

MATERIALS TO BE USED
(Where two or more different paint suppliers are necessitated – e.g. spec PCS 01 and PCS 03 – complete one form for each paint supplier)
PROJECT: ____________________________________________________________________
CONTRACT No.: ______________________ LOCATION: ___________________________________
PROJECT ENG. _____________________________________________________________________________
CONTRACTOR: _____________________________________________________________________________
ADDRESS: _________________________________________________________________________________
TELEPHONE: ___________________________ CELL PHONE: ______________________________
FAX: ___________________________________ E-MAIL: ___________________________________
CONTACT PERSON: _________________________________________________________________________
EXPECTED STARTING DATE: _________________________________________________________________
EXPECTED COMPLETION DATE: ________________________________________________________
SPECIFICATION No./S: _______________________________________________________________________
COATING MANUFACTURER: __________________________________________________________________
TELEPHONE:__________________________ E-MAIL: _____________________________________________
FAX: _______________________________________________________________________________________
TECHNICAL REPRESENTATIVE: _________________________________________________________
CELL PHONE: ____________________ E-MAIL: _____________________________________________
PRODUCTS TO BE USED:
PRIMER COAT __________________________________________________________________
THINNER (PRIMER) ____________________________________________________________________
CREVICE SEALANT ____________________________________________________________________
STRIPE COAT ____________________________________________________________________
THINNER (STRIPE COAT) ___________________________________________________________________
INTERMEDIATE COAT ___________________________________________________________________
THINNER (INTER) ___________________________________________________________________
FINAL COAT ___________________________________________________________________
THINNER (FINAL) ___________________________________________________________________
COATING MANUFACTURER
__________________ ____________________ _________________
NAME SIGNATURE DATE
PAINTING CONTRACTOR
__________________ ____________________ _________________
NAME SIGNATURE DATE
ENGINEER
_________________ ____________________ _________________
NAME SIGNATURE DATE
REV
18 ANNEXURE B – EXAMPLE FORMS - CONTRACTORS

18.1 RELEASE CERTIFICATE – ABRASIVE BLASTING
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Grit supplier/product:
Batch certificate nr:
Items/area inspected:
The following tests were carried out:
Comments:
We, the undersigned, hereby certify and conform that the abrasive blasting has been done in accordance with
specification.
Inspector Contractor
18.2 RELEASE CERTIFICATE – PRE-CLEANING
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Method/Equipment used:
Comments:
We, the undersigned, hereby certify and conform that the pre-cleaning has been done in accordance with
specification.
REV
REV
18.4 RELEASE CERTIFICATE – CREVICE FILLING
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Paint supplier/product:
Comments:
We, the undersigned, hereby certify and conform that the crevasse filling has been applied in accordance with
specification.
18.5 RELEASE CERTIFICATE – EXISTING GRATING REPOSITIONED
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the existing grating has been repositioned as previously in
accordance with specification.
REV
18.6 RELEASE CERTIFICATE – FINAL COAT
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the final coat has been applied in accordance with specification.
18.7 RELEASE CERTIFICATE – MECHANICAL CLEANING
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the mechanical cleaning has been done in accordance with
the specification.
REV
18.8 RELEASE CERTIFICATE – NEW GRATING
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the new grating comply with specification and has been
installed in accordance with the specification.
18.9 RELEASE CERTIFICATE – NEW HANDRAILING
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the new handrailing comply with specification and has been
installed in accordance with specification.
REV
18.10 RELEASE CERTIFICATE – STEEL PREPARATION
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the preparation of the steel surfaces has been done in
accordance with specification.
REV
18.11 RELEASE CERTIFICATE – PRIMER
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the primer coat has been applied in accordance with
specification.
18.12 RELEASE CERTIFICATE – EXISTING GRATING RE-USED
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the re-used grating comply with specification and has been
installed in accordance with specification.
REV
18.13 RELEASE CERTIFICATE – RUBBER INSERTION
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Product used:
Comments:
We, the undersigned, hereby certify and conform that the rubber insertion has been applied in accordance with
specification.
18.14 RELEASE CERTIFICATE – STRIPE COAT
Project:
Date and time:
Contractor:
Supervisor:
Quality Inspector:
Comments:
We, the undersigned, hereby certify and conform that the stripe coat has been applied in accordance with
specification.
REV
18.15 PROGRESS INVOICE ACCEPTANCE CERTIFICATE
Project:
Date:
Contractor:
Quality Inspector:
Item nr: Area/items completed:
Comments:
We, the undersigned, hereby certify that the work have been completed according to the contract requirements as
measured in the schedule of quantities.

Surface Preparation and Paint Specification

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SISHEN MINE

IMPLEMENTATION DATE 2016-04-30

SURFACE PREPARATION AND PAINT

8.3 DRY FILM THICKNESS – (DFT) 20

13.18 PROTECTIVE COATING SYSTEM NWPCS 18 42

a) AMRS 9 Structural Integrity (GTS 19)

 NWPCS 01 - Galvanising of structural steel.

3 ABBREVIATIONS AND DEFINITIONS

4.1 QUALIFIED STAFF

Applicators: General Heavy Duty Coatings Applicator (PA1)

All test equipment shall have current calibration certificates.

4.2.2 Spray Equipment

4.2.3 Blast Cleaning Equipment

4.2.6 Power Mixers

4.3 COATING MATERIALS

4.4 MATERIAL ON SITE

5.3 MECHANICAL CLEANING

5.4 ABRASIVE BLAST CLEANING

5.4.2 Abrasive material

5.4.3 Material Certification

5.4.5 Water Soluble Salts

5.4.6 Moisture Content

The percentage of moisture is calculated as follows:

Original weight – final weight

5.4.7 Oil and Grease

10cm3 abrasive is shaken with 10 cm 3 methylene chloride for about 5 minutes.

5 Drops of the solvent are applied to a clean glass plate.

If there is a blue fluorescence the abrasive is rejected.

5.4.9 Grain Shape

5.4.10 Surface Profile

5.5 ACID PICKLING

5.6 SURFACE CLEANLINESS

The following requirements shall apply prior to coating application:

b) All surfaces to which coating is applied shall be free of moisture.

e) The surface to be coated shall be free of soluble salts.

The induction time recommended by the coating manufacturer shall be observed.

Products from different suppliers shall not be used in a given system.

6.4 CREVICES AND GAPS – CONCEALED SURFACES

6.4.1 Concealed Surfaces Or Back-To-Back Angles

The mastic epoxy compound may sag out of wide gaps.

Back-to-back angle Packing material e.g. rope

6.4.2 Discontinuous Welding

Mastic epoxy compound Welding

6.4.3 Pin Holes/ Porosity In Welding And Castings

6.4.4 Mating Surfaces

6.5 STRIPE COATING

6.5.2 One Coat System

Stripe coating of edges shall be done: wet on wet” by spray application.

6.7 AMBIENT CONDITIONS

c) When the ambient relative humidity exceeds 85%.

6.9 PRIMER COAT

6.10 PATCH REPAIR

6.11 EARTHING STRAPS

6.12 DESIGN CRITERIA

The Contractor shall provide for all necessary safety precautions.

7.2 SAFETY PLAN

7.3 FIRE HAZARDS

7.4 STORAGE OF HAZARDOUS MATERIALS

7.5 SCAFFOLDS AND RIGGING

8 INSPECTION AND TESTING

8.1 SURFACE PREPARATION

8.2 VISUAL INSPECTION

8.3 DRY FILM THICKNESS – (DFT)

8.4 WET FILM THICKNESS – (WFT)