KINGDOM OF SAUDI ARABIA

GENERAL AUTHORITY OF CIVIL AVIATION

CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

PAINTING PROCEDURE

Project Quality Manager: Project Manager:

ENGR. Amr Ibrahim Metwally ENGR. HADI OMAR HARB

 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

Table of Contents
1.0 Objective ………………………………………………………………………………… 03
2.0 Scope …………………………………………………………………………………….. 03
3.0 References ………………………………………………………………………………. 03
4.0 Abbreviations …………………………………………………………………………… 03
5.0 Responsibilities …………………………………………………………………………04
6.0 Alignment and Fit-up ………………………………………………………………….. 04
7.0 Welding ……........................................................................................................... 04
8.0 Manpower ……………………………………………………………………………….. 06
9.0 Inspection and Production of Welds ……………………………………………….. 06
10.0 Welding Consumables …………………………………………………..................... 12
11.0 Safety Precautions …………………………………………………………………….. 12

Appendix ………………………………………………………………………………….19
 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

1.0 SCOPE

This specification covers the minimum requirements for receiving, storing, coating
application, inspection and testing and transportation to be carried out during the
application of painting to the external surface of the station/terminal pipes for
above ground installation for Ras Az Zawr Riyadh Water Transmission System.

2.0 CODES AND STANDARDS

The Applicator shall control the quality of items and services to meet the
requirements of this procedure, applicable codes and standards, and other
procurement documents.
 RAL German Institute for Quality Assurance and Certification
RAL Ral Colours

 American Society for Testing and Materials (ASTM)

D 4285 Indicating Oil or Water in Compressed Air

D 4417 Field Measurement of Surface Profile of Blast Cleaned
Steel
ASTM G12 Mod Measurement of Dry Film Thickness

 Steel Structures Painting Council (SSPC)

PA 1 Shop, Field and Maintenance Painting

SP 1 Solvent Cleaning
SP 7 Brush-off Blast Cleaning
SP 10 Near White Blast Cleaning
SP 11 Power Tool Clean to Bare Metal

 Swedish standard ISO 8501-1/SIS

ISO 8501-1 Pictorial Surface Preparation Standards for Painting Steel

Surfaces, Swedish Standards Colour Pictorial ISO 8501-1

ISO 8502-3 Dust Contamination Visual Standard ISO 8502-3

 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

3.0 RESPONSIBILITIES

3.1 Project Manager

He has overall responsibility for the management of the project including

Quality and Safety aspects.

3.2 QA/QC Manager

 Responsible for the management of Quality System, inspection and tally

3.3 Project Engineer

 Responsible for Customer communications and scheduling

3.4 Safety Officer

 Responsible for handling of safety requirements

3.5 Production Superintendent/Painting Foreman

 Responsible for plant coating in accordance with the project specifications

and standards

4.0 MATERIALS

4.1 Only approved coating materials and/or products for the project shall be
used. Coating systems and/or products other than those listed in the
approved materials require an approved deviation prior to use. Coating
material shall meet the project requirement of adhesion, hardness and
cathodic disbondment performance.

4.2 Abrasive Materials

Abrasives for blast cleaning shall be clean and dry; furnished either in bulk
or packaged; and shall be free of oil or other contaminants. The particle
size shall be capable of producing the specified surface profile. Mineral
and slag abrasives shall meet the requirements of SSPC AB1.

4.3. Thinners, Solvents, and Cleaners

Thinners, solvents, and cleaners shall be as recommended by the coating

material manufacturer and shall be identified by the product number and
generic formulation.
 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

4.4 Touch-Up Materials

Materials for touch-up of damaged areas of surfaces shall be the

same as to those that originally applied. Touch-up finish color and
sheen shall be an exact match to the original coating.
4.5 Delivery and Storage
 Coating materials shall be delivered to the place of application in
the manufacturer’s unopened, original containers bearing a legible
product designation, batch number, expiration date, shelf life, data of
manufacture and color code. Containers which are damaged or not
bearing the manufacturer’s label, shall not be used.
 The coating material shall be handled and stored in accordance with the
manufacturer’s latest published instructions and shall be protected from
damage, moisture, direct sunlight, and temperatures below 5°C or above
60°C. Storage facility shall be well ventilated and free from open flame or
other sources of ignition.
 The coating materials shall be used within the manufacturer’s published
and guaranteed shelf life.

5.0 APPLICATIONS

 The Applicator shall not blast or apply coatings unless the temperature of the
substrate is always a minimum of 3°C above the dew point. The substrate
temperature during coating application and curing shall be maintained between a
minimum of 10°C and a maximum of 60°C.
 Equipment air supply lines shall be equipped with traps to remove moisture and
oil as close to the application point as possible.
 All coating details (Painting materials, coating systems, required thickness,
inspection and testing requirements) shall be determined in Inspection and Test
Plan.
 Masking or compounds used to protect non-painted surface must be removed
prior to completion of the job.

5.1 Surface Preparation

5.1.1 General Requirements

 Prior to the start of work, the Applicator shall examine all surfaces
to be coated to determine their acceptability for the specified
work. If the surfaces are found to be unacceptable, the
Applicator shall immediately notify Client’s Representative in
 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

writing and shall not commence work until corrective action has
been taken.
 Unless approved otherwise by Client, surfaces to be coated shall
be abrasive blast cleaned to “near white” condition SA 2.5 as
defined in ISO 8501-1.
 The surface profile of the steel cleaned by blasting shall be
between 40 μm minimum and 80 μm maximum depth.
 The abrasive mixture and the compressed air shall be clean, dry
and oil-free. Traps, in addition to oil and water extractors
mounted on the compressor, shall be used in compressed air
lines to remove oil and moisture from air close to the point of use.
 Prior to blast cleaning, contamination shall be removed from the
steel surfaces. Oil and grease shall be removed by solvent
cleaning in accordance with SSPC SP-1.
 All surfaces and which are not to be coated, shall be suitably
protected from blast cleaning.
 Burrs, slivers, scabs, sharp edges, and weld spatter, which
become visible after blasting, shall be removed.
 If visible rusting occurs or if the cleaned surface become wet or
otherwise contaminated, these surfaces shall be re-cleaned to
the degree specified. Cleaned surfaces remaining uncoated
overnight shall be re-blasted to remove rust.
 After cleaning and immediately before coating, dust shall be
removed with compressed air, free of oil and moisture.

5.2. Mixing and Applying Coatings

5.2.1 General Requirements

 Mixing, thinning, applying, and curing of the coating material shall

be in accordance with the manufacturer's latest published
instruction, SSPC PA-1, and the requirements specified herein.
When multiple component units are mixed, each component shall
be mixed separately prior to the mixing of the combined
materials. Only complete kits shall be mixed, no partial kits will be
allowed anytime. Improper thinning can result in increased
emissions of volatile organic compounds (VOC).
 Coating materials shall be thoroughly mixed until they are smooth
and free from lumps. Material shall be agitated to maintain a
homogeneous mixture if necessary. Inorganic zinc coatings must
be mechanically agitated at all times. The pot life of any paint
 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

shall be carefully noted, and any mixed paint that has exceeded
pot life shall be discarded irrespective of apparent condition.
 The application of the coating shall be performed only when
the environmental conditions meet the parameters specified in
this. Relative humidity shall be 80 percent or below.
 The coating shall be applied within 12 hour after the metal in blast
cleaned and prior to any visible rust bloom.
 Over-coats/topcoats shall be applied within the manufacturer's
minimum and maximum recoat times.
 Dry film thickness of each coating shall be as mentioned in
ITP. If a particular application does not achieve the minimum
specified coating thickness for the coat, additional material of the
same product shall be applied, observing manufacturer’s re-
coating instructions. Total Dry Film Thickness of coating shall be
240 mic minimum. Repair coating shall overlap with original
coating by minimum 50mm, and shall have a smooth transition to
the original coating without any steps.
 Coating shall be applied using clean equipment in good condition.
All welds shall be stripe coated using a compatible paint brush
before spray application.
 Majority sags, voids, drips, overspray, loss of adhesion,
blistering, peeling, mud- cracking, orange peeling, inadequate
cure, or rusting of the substrate shall not be permitted. Minority
cosmetic irregularities are acceptable as long as the total area is
less than 0.5% of the coated surface area. These irregularities
shall be screened or sand papered to remove the cosmetic
deficiency. Other defects require spot removal and replacement
of the coating.
 Where shop coating has been damaged in handling, all damaged
and loosely adhering coating shall be removed and the surface
thoroughly cleaned. Edges of the breaks shall be feathered and
the designated number of prime and finish coats applied. The
coating shall exactly match the original color and gloss.

5.3. Inspection and Testing

5.3.1 General Requirements

 Applicator grants Client's inspector free access to inspect all

work performed by Applicator.
 Applicator shall initiate blasting and/or painting operations as
soon as the Client’s inspector has been notified.
 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

 The following steps shall be subject to inspection by Client's

representative:
a) Following surface preparation and immediately prior to the
coating application.
b) Following the application and curing of each coat.
c) After final inspection and sign-off, in accordance with the
project requirements.
 The Applicator shall furnish the necessary testing and
inspection instruments (DFT gauge, surface profile gauge,
hygrometer) properly calibrated and maintained. Such equipment
shall be available for use by Client’s Representative in conducting
surveillance of the work.
 Prior to using compressed air, the quality of the air downstream
of the separator shall be tested in accordance with ASTM D
4285. The test shall be performed at the beginning of each shift.
The test shall also be made after any interruption of the
functionality of the air compressor. The air shall be used only
if the blotter test indicates no visible contamination, oil, or
moisture. If contaminants are evident, the equipment deficiencies
shall be corrected and the air stream shall be retested.
Separators shall be bled continuously. All lines shall be tested
individually prior to use. Surfaces, which are determined to have
been blasted or blown down with contaminated air, must be
cleaned of that contamination and re-blast with clean air and
abrasive.
 Any defects disclosed by inspection shall be re-inspected after
correction.

5.3.2 Surface Preparation Inspection

 The temperature, dew point, and relative humidity shall

be determined with an electronically hygrometer or an equal
equipment. Readings are required at the start of work and every
four (4) hours and at the completion of the work, or at other time
intervals approved in writing by Client.
 Degree of blast cleaned surfaces shall be determined by
comparison to ISO 8501-1/SIS. The profile depth shall be
verified with an Elcometer Profile Comparator® or Testex
Press-O-Film® in accordance with ASTM D-4417.
 A grease-free chalk shall be used to mark local areas which do
not meet specified standards for re-blasting.
 Abrasive used for cleaning shall be tested before use for the
presence of oil by immersing in water and checking for oil
 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

flotation. Tests shall be made once per shift. If oil is evident,

contaminated abrasive shall be replaced with clean abrasive and
retested before proceeding. All steel blasted since the last
satisfactory test shall be inspected and all contaminated steel
shall be re-blasted.

5.3.3. Coating Inspection

 Surface temperature and humidity readings shall be taken prior to

application of each coat. The work shall not proceed if the
ambient temperature parameters are outside the requirements of
this Procedure. The substrate temperature shall be at least 3°C
above the dew point temperature.
 The dry film thickness shall be tested with Elcometer® gauge or
an accepted equivalent. The testing method shall be in
accordance with SSPC PA-2. See the Inspection and Test Plan
for acceptance criteria
 After the application of each coat the surfaces shall be visually
inspected and repaired. The following defects are not permitted:
Pinholes Disbondments Contaminants
Bubbling Runs and Sags Mechanical Damage
Fisheyes Holidays Unmatched colors
Incomplete Cure Abrasive Inclusions Lack of Adhesion
Orange-Peel Dry Spray Blisters
 Surfaces having Over-Spray, Runs, Sags, or Drips shall be
screened or sand papered to remove the deficiency. Other
defects require spot removal and replacement of the coating.
 Work found unacceptable should be immediately corrected in
accordance with this Procedure. The Applicator shall submit
a non-conformance report within 7 days of discovery
identifying the defect and detailing the repair procedure.

5.4 Marking and Tally

Traceability shall be performed by applying the required marking or stencil

using Piping data supplied by Client to check the item identification.

5.5 Remedial Work

5.5.1 General

 The surface profile shall be restored to meet the specified

surface preparation requirements for cleanliness and profile (SP-
 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

11 for touch-up repair with size up to 0.01m2 and blast cleaning

for repair with size 0.01m2 and above). The periphery of a
damaged area shall be feathered prior to coating application.
 Power tool cleaning shall be done using requirements of SSPC
SP-11.

5.5.2 Paint Repair Procedure

Scope

This method describes the procedure to be used for coating repair

to either coating flaws or damaged areas. This repair procedure is
ONLY for painted surfaces.

Repair Materials

Materials for touch-up of damaged areas of surfaces shall be the

same as to those that originally applied. Touch up finish colour
shall be an exact match to the colour of parent paint.

Surface Preparation

The pipe surface shall be cleaned to remove all dirt and damaged
or disbonded coating using buff cleaning for areas with size up to
0.01m2 or blast cleaning for area with size 0.01m2 and above. The
edges of the original coatings shall be "feathered out"
approximately 50 mm around the specific area to be coated, and all
dust cleaned off before applying the repair coating. Number of
layers shall be the same as required in the original coating system.

Paint Repair Application

 The repair paint material must be properly mixed in the ratios

specified by the material manufacturer.

 After surface preparation, apply an even coat to the damaged

area using for application a brush or airless spray equipment.
The next layer of coating system (if necessarily) shall be applied
only on dry to touch painted surface.

 The touch-up repair shall not be applied when the steel surface
temperature is less than 3°C above the dew point.

 Freshly touch-up repaired areas shall be allowed to cure

according to the paint material Manufacturer's
recommendations prior to handling.
 KINGDOM OF SAUDI ARABIA
GENERAL AUTHORITY OF CIVIL AVIATION
CONSTRUCTION OF LOAD CENTER -3
Subject:

PAINTING PROCEDURE
Revision

First Rev. A CONTRACT #: R-15-085-BF-0

Index

Issue Date: 28.02.16 DOCUMENT #:

6.0 STORAGE AND HANDLING

 All pipes or spools shall be stored on padded elevated racks or polyethylene

sheathed sand berms until time for delivery
 Padding material shall be used for items storage
 All booms, hooks, forks, supports and skids used in handling or storing coated
pipe shall be designed and maintained in such a manner as to prevent any
damage to the pipe or to the coating.
 Handle items to storage areas shall be in accordance with H-QP-001.

7.0 SAFETY AND ENVIRONMENTAL

 All surface preparation, materials, and coating work shall comply with all
applicable environmental and safety provisions, laws, regulations, ordinances,
etc., of the city, county, state, province, or nation pertaining to the work being
performed and the coating materials be used.
 Material Safety Data Sheets (MSDS) shall be provided by the materials Supplier
for all cleaning and coating materials and available at the place of application for
review.
 The Volatile Organic Compound (VOC) content of all materials shall meet
Federal, State, and Local or other Regulatory requirements. Supplier is
responsible for proposing alternative coatings for approval if those coatings
specified herein do not comply with VOC limits imposed at the Supplier's shop
locale.
 Excess solvents, paint, and cleaning materials shall be handled in strict
accordance with approved disposal procedures and never dumped on the ground
or emptied into sewers.