Specification For Painting & External Coating of Metal Pipes & Structures

SPECIFICATION FOR PAINTING &
EXTERNAL COATING OF METAL PIPES
& STRUCTURES
0 02-02-2002 Approved Issue

rev. date Description/issued for prepared authorised
client: ADWEA
project: STANDARD SPECIFICATIONS FOR WATER WORKS
title: SPECIFICATION FOR PAINTING & EXTERNAL COATING OF METAL PIPES &
STRUCTURES
tender: project: document: W-C-SS-014 rev: 0 sheet: 1 of: 23

TABLE OF CONTENTS PAGE
1. SCOPE...................................................................................................3
2. APPLICABLE STANDARDS AND CODES ..........................................3
3. SITE CONDITIONS................................................................................5
4. TECHNICAL REQUIREMENTS.............................................................5
4.1 Surface Preparation....................................................................5
4.2 Environmental Conditions/Safety.................................................8
4.3 Painting .......................................................................................9
4.4 Repair of Defects.......................................................................12
5. SAFETY REQUIREMENTS .................................................................12
6. INSPECTION AND TESTING ..............................................................13

6.1 General......................................................................................13
6.2 Environment ..............................................................................13
6.3 Surface Preparation...................................................................13
6.4 Coating Film Thickness .............................................................13
6.5 Calibration .................................................................................14
6.6 Inspection Report ......................................................................14
6.7 Testing Instruments/Tools .........................................................14
7. MARKING, HANDLING AND STORAGE............................................15
8. APPROVALS .......................................................................................15
9. QUALITY ASSURANCE/QUALITY CONTROL...................................16
10. PERFORMANCE GUARANTEE..........................................................17
11. ANNEXURES.......................................................................................17
Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR PAINTING & EXTERNAL COATING OF METAL PIPES &
STRUCTURES

1. SCOPE
This specification covers the minimum requirements for the surface preparation, and painting,
of the following:
1. : External Coating System for Carbon Steel Above Ground Piping.
2. : External Coating System for Stainless Steel Above Ground Piping.
3. : External Coating System for Galvanized Steel Above Ground Piping.
4. : Coating System for Structural Steel (Non Galvanised).
5. : Coating System for Galvanized Structural Steel Parts.
6. : Coating System for Stainless Steel Structural Parts
Coating system on submarine pipeline, wood, concrete structures and metal fittings are not
covered under this specification.
No deviations or exceptions from this specification shall be permitted without the written
approval of the ADWEA/ENGINEER.
Intended deviations shall be listed by the manufacturer on a separate sheet of paper as an

alternative at the time of bids and supported with reasons by the CONTRACTOR for
consideration by ADWEA/ENGINEER.
Compliance with this specification shall not relieve the CONTRACTOR of the responsibility of
furnishing specified material.
The CONTRACTOR shall co-ordinate, expedite and resolve any problems with the
manufacturer/ supplier. The CONTRACTOR shall be responsible for ensuring that all relevant
information and documentation is passed on to the manufacturer/ supplier, to complete the
work to the satisfaction of ADWEA/ENGINEER.
The final responsibility for the satisfactory completion of the work shall lie with the
CONTRACTOR.
2. APPLICABLE STANDARDS AND CODES
Swedish Standard SIS 05 59 00 Pictorial Surface Preparation Standards Steel

Surfaces for Painting
SSPC - SP1 Solvent cleaning

SSPC - SP2 Hand tool cleaning
SSPC - SP3 Power tool cleaning
SSPC - SP10 Near-white blast cleaning
SSPC - PA1 Shop, field and maintenance painting
SSPC - PA2 Measurement of dry film thickness with magnetic
gauges
Client ADWEA
STRUCTURES

ASTM B117 Salt spray (fog) testing.
ASTM D4060 Abrasion resistance of organic coatings by the Taber Abraser.
ASTM D4541 Pull off strength of coatings using portable adhesion tester.
ASTM D 5162 Dissimilarity (Holiday) testing of non conductive protective coating

on metallic substrates.
RAL 840 HR Standard Colours.
ISO 2409 Paints and varnishes cross of test for adhesion.
ISO 2808 Paints and varnishes – Determination of film thickness.
ISO 4624 Paints and varnishes – Pull off test for adhesion.
ISO 4628 Paints and varnishes – Evaluation of degradation of paint coatings
ISO 8501 Preparation of steel surfaces before application of paints and related
products.
ISO 9001 Quality Systems – Model for Quality Assurance in Design,

Development, Production, Installation and Servicing.
ISO 9003 Quality Systems - Model for Quality Assurance in Final Inspection
and Test.
ISO 9004 Quality Management and Quality System Elements – Guidelines.
BS 245 Specification for mineral solvents (white spirit and related

hydrocarbon solvents) for paints and other purposes.
BS 3900 Methods of test for paints.
BS 5411 Methods of test for metallic and related coatings.
BS 6949 Specification for bitumen based coatings for cold application

excluding use in contact with potable water.
BS 7079 Preparation of steel substrates before application of paints and

related products.
BS 4164 Specification for Coal tar based hot applied coating materials for
protecting iron and steel, including a suitable primer.
BS 476 Fire tests on building materials and structures.
Client ADWEA
STRUCTURES

BS 1070 Specification for black paint (Tar based)
BS 2523 Specification for Lead Based Priming Paints.
BS 4800 Schedule of paint colours for building purposes.
BS 5252 Framework for colour co-ordination for building purposes.
BS 6150 Code of practice for painting for buildings.
BS 7664 Specification for undercoat and finishing paints.
BS 8202 Coating for fire protection of building elements.
BS EN ISO 12944 Code of practice for protective coating of iron and steel structures
against corrosion.
AWWA C203 Water protective coating and lining for steel water pipelines enamel
and tape hot applied.
3. SITE CONDITIONS
For site and climate conditions refer General Technical Requirements document
4. TECHNICAL REQUIREMENTS
4.1 Surface Preparation
Surface preparation and technical requirements are applicable for the pipes and structural
items are as under.
4.1.1 Pipes
Surface preparation shall be carried out by dry blast cleaning to a visual standard in
accordance with Swedish standard SIS 05 59 00, Sa 2.1/2 (equivalent to U.S. Standard
SSPC-SP10), unless other wise specified.
Sand shall be not used as a blast cleaning material.
The abrasive shall be dry and free from oil, grease, dust, salts, and other impurities, and shall
not contain any sand or silica component.
The average profiles height shall be in the range of 50 - 80 microns . Rough peaks are
acceptable up to a maximum of 100 microns.
Alternative surface preparation techniques shall only be applied when dry blast cleaning is
unsafe, not feasible or impractical.
Client ADWEA
STRUCTURES

Carbon Steel Piping shall be thoroughly cleaned of all dirt, grease, rust and scale by means of
chipping, scraping wire brushing and/or solvent cleaning in accordance with SSPC-SP1.
Particular attention should be given to the cleaning of welded, brazed and soldered joints.
The surface shall be blast cleaned to near white metal finish in accordance with SSPC-SP10.
Apply one coat of metal primer immediately on the cleaned surfaces as approved by the
ADWEA/ENGINEER.
Galvanised piping for painting shall be thoroughly cleaned of dirt, grease, dusted and washed
down with fresh water and/or suitable solvent. Any minor areas of rust shall be removed by
wire brushing and spot primed with a zinc rich primer. For weld repair and minor damage,
clean the damage area per SSPC SP3. Touch up with a high zinc dust content cold
galvanising paint.
If the priming coat of pre-primed metal work has suffered damage in transit, or during erection
on site, the affected areas shall be cleaned off by wire brushing, abrading and dusting off, the
bared patches touched up with a primer of a similar type to that already applied.
Priming shall follow manual preparation as quickly as possible and not later than on the same
day with blast cleaned surfaces. Priming should follow with in 1 hour and under no
circumstance later than after 3 hours after blasting.
All surface finish requirements shall be met at the time of commencing painting/coating
operations.
4.1.2 For Structural Steel Items
Bare metal work shall be thoroughly cleaned of all dirt, grease, rust and scale by means of
chipping, scraping and wire brushing, particular attention should be given to the cleaning of
welded, brazed and soldered joints. Wash down with white spirit and wipe dry with clean
rags. Apply one coat of metal primer immediately the cleaned surfaces have been approved
by the ADWEA/ENGINEER. Iron and steel surfaces shall receive two coats of primer of 50
microns thickness.
Galvanised metalwork scheduled for painting shall be thoroughly cleaned of dirt, grease,
dusted and washed down with white spirit and wiped dry with clean rag. Any minor areas of
rust shall be removed by wire brushing and spot primed with a zinc rich primer. Apply at least
one coat of a two pack high build epoxy undercoat, pigmented with zinc phosphate to all
surfaces subsequently to be painted.
If the priming coat of pre-primed metal work has suffered damage in transit, or during erection
on site, the affected areas shall be cleaned off by wire brushing, abrading and dusting off, the
bared patches touched up with a primer of a similar type to that already applied.
Copper scheduled for painting shall be lightly abraded with emery cloth, washed with white
spirit and wiped dry with clean rag. When the cleaned surfaces have been approved apply.
One coat of etch primer of copper pigmented primer and one coat of alkyd gloss paint or other
approved coating system
Client ADWEA
STRUCTURES

Aluminium scheduled for painting shall be lightly abraded with emery cloth, washed with white
spirit and wiped dry with clean rag. Apply a coat of each primer and zinc chromate primer
immediately the cleaned surfaces have been approved.
All surfaces finish requirements shall be met at the time of commencing painting/coating
operations.
4.1.3 Techniques and Restriction
4.1.3.1 Dry Blast Cleaning
Blast cleaning shall be done to a visual standard in accordance with Swedish standard SIS 05
59 00, Sa 2.1/2 (equivalent to U.S. Standard SSPC-SP10), unless other wise specified. Sand
shall be not used as a blast cleaning material. The abrasive shall be dry and free from oil,
grease, dust, salts, and other impurities, and not contain any sand or silica component. The
average profiles height shall be in the range of 50 - 80 microns . Rough peaks are acceptable
up to a maximum of 100 microns.
Blast cleaning shall only be conducted when the steel surface temperatures are minimum 3°C
above dew point, and when the relative humidity is less than 85%, so as to avoid the risk of
condensation. Blast cleaning shall also not to be carried out during blowing winds or dust
storms .
Blast cleaning shall not be done where adjacent areas or equipment are insufficiently
protected from contamination by abrasive or debris.
Blast cleaning shall not be done in areas close to painting operations to prevent
contamination of wet paint films by dust and grit.
Factory coated equipment like pumps, compressors, motors, valves, electrical,

instrumentation and fire fighting items etc., shall be adequately protected prior to
commencing blasting operations.
All gasket surfaces, valve stems, name plates, pressure gauges, instrument cases, gauge
glasses, and all windows, previously coated or galvanized surfaces shall be adequately
protected prior to commencing any blasting operations (or these components shall be
carefully removed after proper marking and reinstalled at appropriate places after the blast
cleaning). All open piping, louvres, access fittings, nozzles, etc. shall be plugged or sealed to
prevent ingress of the abrasive material.
All welded areas shall be cleaned to remove weld slag and deposits in crevices. Welded
areas shall be freed from alkaline residues by rinsing with water. Weld splatter, slivers,
lamination and underlying mill scale, not removed during fabrication and exposed before and
during blast cleaning, shall be removed and the edges shall be ground flush.
Any blast cleaned areas not yet coated, which become rusty due to rain or condensation,
shall be reblasted to the specified grade of surface finish.
Client ADWEA
STRUCTURES

4.1.3.2 Power Tool Cleaning
Power tool cleaning shall be to a visual standard in accordance with SIS 05 59 00 - St3
(equivalent to U.S. Standard SSPC-SP3). Power cleaning shall be done utilizing abrasive or
wire type power discs.
Where welds occur or when areas cannot accommodate a power disc, power impact tools
(needle guns, chisels) shall be applied followed up by wire brush cleaning.
4.1.3.3 Hand Tool Cleaning
Hand tool cleaning is the least effective of the surface preparation methods, but it may be
used for touch up/repair with certain surface tolerant coating systems. Handtool cleaning shall
be to a visual standard in accordance with SIS 05 59 00 -St2 (equivalent to U.S. Standard
SSPC-SP2). Cleaning shall be done with brushes, scrapers, sanders or other hand impact
tools.
4.1.3.4 Solvent Cleaning
Solvent cleaning shall be in accordance with U.S. Standard SSPC-SP1"Solvent Cleaning".

Before blast cleaning or power tool cleaning, and again before painting/coating, all surfaces
shall be examined for the presence of oil or grease. If present, it shall be removed by solvent
cleaning and the relevant areas shall be reblasted or power tool cleaned to the specified
standard.
All metal surfaces to be coated which do not require blast cleaning or power tool cleaning
shall be thoroughly cleaned to remove all mud, oil, grease or other foreign matter.
All bolt-holes shall be solvent cleaned before blast cleaning or power tool cleaning to remove
any oil/grease residues.
Note that solvent cleaning may incorporate the use of detergents or emulsifying agents. This
shall then be followed by fresh water washing.
No acid washes or other cleaning solutions or solvents shall be used on metal surface after
final surface preparation.
4.1.3.5 Surface Cleaning
Immediately after blasting stops, all grit, dirt and dust shall be removed from the area to be
coated by blowing -off with clean and dry compressed air or vacuum cleaning.
4.2 Environmental Conditions/Safety
Storage, handling, mixing, and application of the paints and materials shall be done strictly in
accordance with the manufacturer/supplier recommended procedures and hardware for
assurance of personal safety. Safety precautions shall be clearly written on the containers.
Client ADWEA
STRUCTURES

Facilities shall be available for effective removal of spillage, collection and disposal of paints,
brushes, scaffolding, equipment, waste, etc., upon completion of painting activities.
All necessary precautions shall be taken to safeguard the environment.
The CONTRACTOR shall maintain all the blasting and painting equipment, airlines, etc., in
good working condition and shall place them in an orderly manner to avoid any obstruction
possible.
4.3 Painting
4.3.1 Materials
4.3.1.1 Preparatory Materials
Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping,
knotting, fillers and other commodities shall be of the types recommended by the
manufacturer of the coating to be applied.
White spirit shall comply with BS 245.
Knotting shall comply with BS 1336.
4.3.1.2 Primers, Paints and Coatings
All brands of primers, paints and coating shall be approved and shall comply with the relevant
BS where one exists.
Undercoats on metal surfaces shall be of the drying-oil/resin binder type pigmented with
titanium dioxide and/or coloured pigments providing a matt or low-sheen finish suitable for
subsequent application of a drying-oil finish.
Water thinned priming paints and undercoats shall only be used with the specific approval of
the ADWEA/ENGINEER and compliance with BS 5082 will need to be demonstrated in order
to obtain such approval.
Finish coats on metal surfaces shall be of the drying-oil/alkyd resin binder type pigmented
with titanium dioxide and/or light fast, coloured pigments, marine environment type paint or
any other coating system approved by the ADWEA/ENGINEER.
4.3.2 Workmanship
Before painting commences all floors shall be washed over and every possible precaution
taken to keep down dust. No paint shall be applied to surfaces structurally or superficially
damp and all surfaces damp and all surfaces must be ascertained to be free from
condensation, efflorescence, etc., before the application of each coat.
No primed or undercoated metalwork shall be left in an exposed or unsuitable situation for

any undue period before completion of the painting process. No exterior or exposed painting
shall be carried out under adverse weather conditions, such as rain, extreme humidity, etc.
Client ADWEA
STRUCTURES

All items not required to be painted (e.g. ironmongery) shall first be fitted and then removed
before any painting preparation commences. The fittings shall be refixed in position when all
painting is completed.
Brushes, pails, kettles, etc., used in carrying out the work shall be clean and free from foreign
matter. They shall be thoroughly cleaned before being used for different types or classes of
material.
All materials shall be used strictly in accordance with the manufacturer's printed instructions
and paints of different brands shall not be mixed or used in the same coating system. No
dilution of painting material shall be allowed except strictly as detailed by the manufacturers
and as approved by the ADWEA/ENGINEER.
The specified surface finish shall exist at the time of applying the first coat. If required,
surfaces shall be re-prepared to the specified finish. Refer the Annexures 1 to 6 for the
applicable coating system.
All surfaces shall be rendered dust free and dry before painting.
Surfaces shall be cleaned by high pressure water to remove any dust, grease etc.; after the
first coat. The surfaces shall be rendered dry before applying the subsequent coats.
Storage, mixing to an even consistency, thinning and application of paints and coating
materials and the type of application equipment shall meet the instructions and
recommendations of the paint MANUFACTURER/SUPPLIER. Mixing by high speed shakers
or rotary mixers with flat blade and speed control, shall be done in a well ventilated and dust
free area.
Paint MANUFACTURER/SUPPLIER instructions and recommendations regarding pot life,

drying/curing intervals between successive coats and final curing periods shall be followed.
Such instructions and recommendations shall be mentioned on paint

MANUFACTURER/SUPPLIER data sheets and be appropriate for prevailing environmental
conditions.
The type, brand name, number of coats, colour and coating thickness shall be strictly in
accordance with this specifications and to the ADWEA/ENGINEER.
Paints shall not used beyond the date of expiry, where indicated on the container, or
alternatively as stated by the MANUFACTURER/SUPPLIER for given batches. All paint shall
be used in order of its successive manufacture and/or delivery.
Paint shall not be applied within 50 mm of edges prepared for field welds, except when a zinc-
rich epoxy or equivalent is used.
No coating shall be applied when steel surface temperatures are less than 3°C above dew
point, and when the relative humidity is more than 85% so as to avoid the risk of
condensation during painting.
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No coating shall be applied to surfaces which have a surface temperature above 45°C at the
time of coating.
Precautions shall be taken to prevent the coating from being applied to name plates,
couplings, shafts, valve stems, bearings, linkages, vent openings, gauge glasses, pressure
gauges, instruments, windows, louvres, etc. Masking tape, plastic film, or some other suitably
impervious material shall be used, and all materials shall be removed after the painting has
been completed and accepted.
All coating surfaces shall be kept clean and dry until the coating has reached a hard set.
All coatings shall be applied under favourable conditions by highly skilled applicators. Coating
shall not be applied to wet or damp surfaces.
Over spray and drip shall kept to an absolute minimum, consistent with good painting
workmanship practices. All unavoidable over spray and drip shall be removed or covered by
an additional finish coat.
Special attention shall be given to painter safety, ventilation, the use of non-explosive lights
and other safety equipment.
4.3.3 Application Methods
4.3.3.1 Spray Application
Application by spraying shall be the preferred process.
Spraying equipment, guns, nozzle sizes and pressure ranges shall meet the paint
MANUFACTURER/ SUPPLIER recommendations for the material to be applied.
The equipment used shall be provided with adequate air and oil vapour traps, regulators and
gauges to achieve proper paint application. Traps or separators shall be periodically drained.
The air caps, nozzles and needles shall be those recommended by the Manufacturer of the
equipment for the material being sprayed.
The air pressure shall be adjusted to obtain optimum effectiveness that will cause no
excessive fogging of coating, excessive evaporation of solvent, or loss by over spray.
Ingredients shall be kept properly in agitation by mechanical means to maintain consistency in

the material. The spray equipment shall be kept sufficiently clean of dirt, any paint and other
foreign materials.
Each coat shall be applied uniformly and completely over the entire surface free from runs
and sags.
4.3.3.2 Brush Application
Brush application shall be done on areas which cannot be properly sprayed, and for touch-up
where spray application is not practical.
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Brushes shall be of a type and size which permits proper application of paint. Round or oval
brushes are most suitable for irregular surfaces, i.e. bolts holes, welds, pitted steel. Wide flat
brushes shall be used for large flat areas. The brushing shall be done such that a uniform
coat, with no deep or detrimental brush marks, is obtained. Paint shall be worked into all
corners and crevices. Runs and sags shall be avoided.
Surfaces not accessible to brushes shall be painted by spray or sheep skin roller.
4.4 Repair of Defects
When coating has been damaged in handling or due to any reason, all of damaged and
loosely adhering coating shall be removed and the surface shall be thoroughly cleaned. One
of the following methods shall be adopted with the approval of ADWEA/ENGINEER.
- Dry blast cleaning to standard Sa 2.1/2
- Power tool cleaning to standard St 3.
- Hand tool cleaning to standard St 2 (only in exceptional cases and only for minor touch
up/repair work).
Surfaces to be coated which become contaminated with oil, grease, salts, etc. shall be
cleaned with solvents and/or with detergent/fresh water solutions, followed by washing with
clean fresh water.
The type of coating materials used for repair shall be identical to, or in any case compatible
with the original materials. The designated coats of prime & finish coats shall be applied to the
satisfaction of ADWEA/ENGINEER.
All defects detected by spark testing (holiday detection) and any damaged coating areas
(resulting from mechanical damage or destructive testing shall be marked and repaired to the
satisfaction of ADWEA/ENGINEER.
The defective areas shall be cleaned down to bare metal and the surrounding coating edge
shall be bevelled. Repairs shall be then be effected by means of priming and coating.
The repaired coating shall meet the thickness requirements of the final coating and the
repaired sections shall be visually examined and re-inspected by spark testing.
5. SAFETY REQUIREMENTS
All necessary precautions shall be taken to ensure the safety of personnel and property. The
CONTRACTOR shall comply with applicable National, State or local codes and regulations
and safety orders and practices of the ADWEA covering working conditions, scaffolding,
clothing, fire and explosion hazards, safety equipment, solvents, lighting, venting and
grounding of tanks.
Rags and other waste material soiled with paints, thinners or solvents shall be kept in tightly
closed metal containers while on the job or not in use.
Client ADWEA
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Extreme precautions shall be used when working with paint materials, cleaning fluids, etc.
especially in close proximity to oxygen piping or oxygen equipment. Heavy concentrations of
volatile or toxic fumes shall be avoided. When working in confirmed areas, blowers or
exhaust fans shall be used.
Application of tar based paints may pose a risk to health under conditions. The
CONTRACTOR shall ensure that the health and safety data sheets provided by the
manufacturers of the product(s) are strictly observed.
6. INSPECTION AND TESTING
6.1 General
Visual inspection (by ADWEA/ENGINEER) of materials, equipment for surface preparation

and for coating application, hoses, scaffolding, protective clothing shall be carried out to
ensure conformance with the relevant technical and safety requirements of this Specification
and with manufacturer/supplier recommended practices.
6.2 Environment
Before commencing work on surface preparation and coating the atmospheric temperature
and the relative humidity shall be measured in order to determine the dew point.
Readings may have to be repeated depending on changes in prevailing weather conditions.

For measurements a temperature gauge and a hygrometer shall be used.
Following determination of the dew point, the steel surface temperatures shall be measured
by means of a magnetic steel thermometer, at regular intervals. The steel surface
temperature shall be at a safe margin of 3°C or more above the dew point and relative
humidity less than 85%, thus avoiding the risk of condensation during surface preparation as
well as during coating. During coating operations the steel surface temperature shall not
exceed 45°C.
Coating application shall be discontinued when the steel surface temperature becomes higher
than 45°C.
6.3 Surface Preparation
Cleaned surfaces shall be visually checked for conformance with the specified surface finish
and for absence of contaminants before coating application.
On dry blast cleaned surfaces the profile height shall be spot-checked by means of a surface
profile gauge or with replica tape and a calibrated micrometer. (Keane Tator surface profile or
similar device may be used). The profile height shall be within the range of 50 to 100 microns.
6.4 Coating Film Thickness
The wet film thickness shall be spot checked as an initial indication of the excepted dry film
thickness, using wet film thickness gauges of a relevant scale.
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The dry film thickness of individual coats and of the total coating system shall be checked at
random over areas representative of the work in hand by magnetic coating thickness gauge.
The number of selected areas needs to be assessed for each work. There shall be at least
one area each for horizontal, vertical and curved surfaces. The number of readings taken in
an area shall be decided by ADWEA/ENGINEER. However, a minimum of 5 readings shall be
taken in each area.
Additional readings shall be taken if there is any change in prevailing weather, personnel,
application equipment, spray nozzle size, thinning of the paint, etc.
The specified minimum dry film thickness shall not be exceeded by more than 50% with the
exception of areas such as welds, crevices, etc., where such a requirement is not practical.
Maximum 10% of the readings may be below the specified film thickness, but no single
reading shall be less than 90% of the specified film thickness.
Dry film thickness shall be measured with a coating thickness gauge, suitable for the given
type of coating, thickness range and substrate material (magnetic or non-magnetic).
6.5 Calibration
Profile height and film thickness gauges shall be calibrated before use, every day.
6.6 Inspection Report
A report shall be provided on completion giving details of the visual inspection carried out
together with the readings noted at the different stages when measurements were made.
Upon completion of each of the activities, listed below in each part of the work, the work shall
be suspended for the purpose of inspection and ADWEA/ENGINEER's witness.
- Preliminary cleaning.
- Fettling of welds, edges and defects in the steel.
- Surface preparation.
- Application of each coat.
- Drying of coatings.
- Cleaning between coats.
6.7 Testing Instruments/Tools
CONTRACTOR shall provide necessary testing instruments/tools at site.
Client ADWEA
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7. MARKING, HANDLING AND STORAGE
All materials for coating shall, until usage, remain in the Supplier's containers, marked with
supplier's name, brand, batch number and expiry date.
Storage conditions shall comply with supplier's data sheet recommendations.
All coated pipe joints shall be clearly marked internally near one bevelled end. The
information shall include steel grade, size and schedule as well as the date of coating.
The coated pipe joints shall at all times be handled and stacked in such a manner as to
prevent damage to the coating, due to abrasion or impact. Particular care shall be taken to
avoid damage while the coating is above ambient temperature and still soft.
No stacking or loading shall be undertaken until the coating has cooled sufficiently.
The coated pipe shall be stored free from the ground on suitable bearers. Sharp-edged
bearers shall not be used.
Temporary storage stacking shall meet the limitations as given in the relevant code of
practice.
Steel wire rope slings or end clamps shall not be used.
Non-metallic soft slings of nylon or polypropylene may be used. Specially designed lifting
hooks shall be used to avoid pipe-end and bevel damage.
Damaged/rejected pipe joints shall be marked as such and be kept separate from accepted
pipe joints during interim storage.
Colour coding and marking of coated piping shall be carried out in accordance with ADWEA
specification which shall be advised at the time of application.
Identification marks and direction of flow shall be marked on the pipe lines to the satisfaction
of ADWEA/ENGINEER.
8. APPROVALS
Before commencement of work, the CONTRACTOR shall provide complete specification of

the coatings along with certificates of approvals. The following physical and chemical
properties of the paint shall be provided with all other necessary data :
- Pigmentation.
- Thinners.
- Cleaner.
- Pot life after mixing.
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- Nominal solid contents by volume (%).
- Theoretical spread at Nominal Dry Film thickness.
- Drying time at 25°C.
- Colour available.
- Storage conditions and standard container size.
- Product weight per litre.
Approval of each of the following shall be obtained from ADWEA/ENGINEER, before

proceeding with any of the subsequent phase.
(a) Location of work.
(b) Equipment.
(c) Preparation of each batch of paint mix.
(d) Surface preparation.
(e) First Coat.
(f) Each subsequent coat.
9. QUALITY ASSURANCE/QUALITY CONTROL
CONTRACTOR's proposed quality system shall fully satisfy all the elements of ISO 9001,
9002 and 9004. The quality system shall provide for the planned and systematic control of all
quality-related activities performed during design, development, production, installation, or
servicing (as appropriate to the given system). Implementation of the system shall be in
accordance with the CONTRACTOR's Quality Manual and Project Quality Plan, which shall
both together with all related/referenced procedures, be submitted to ADWEA/ENGINEER for
review, comments and approval as required by purchase/contract documents.
The CONTRACTOR's shall submit certified reports of production tests as soon as the tests
are satisfactorily completed.
The ADWEA/ENGINEER reserves the right to inspect materials and workmanship at all
stages of manufacture and to witness any or all tests. The CONTRACTOR, 30 days after
award but prior to the pre-inspection meeting, shall provide the ADWEA/ENGINEER with a
copy of its application and inspection plan for review and inclusion of any mandatory
ADWEA/ENGINEER witness points.
Client ADWEA
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10. PERFORMANCE GUARANTEE
The CONTRACTOR shall provide a Joint Performance Guarantee (manufacturer and

CONTRACTOR) for the quality of paint and his workmanship for a period of 5 (five) years
according to level Re 3 on the European scale of Rusting Grades from the date of Provisional
Acceptance.
11. ANNEXURES
1 - External Coating System for Carbon Steel Above Ground Piping.
2 - External Coating System for Stainless Steel Above Ground Piping
3 - External Coating System for Galvanised Steel Above Ground Piping
4 - Coating System for Structural Steel (Non Galvanised).
5 - Coating System for Galvanized Structural Steel Parts.
6 - Coating System for Stainless Steel Structural Parts
Client ADWEA
STRUCTURES

ANNEXURE - 1
EXTERNAL COATING SYSTEMS FOR
CARBON STEEL ABOVE GROUND PIPING
1. Scope
External coating for atmospheric protection of carbon steel above ground piping systems
(other than galvanized).
2. Surface Preparation
- Surface shall be cleaned with fresh water and / or suitable solvent water to remove
oil, grease, loose rust, loose paint etc. to SP-1.
- Dry blast cleaning to a visual standard of Sa 2.1/2 near-white metal finish SP-10
(SIS 05 59 00).
- For local touch up/repair work power tool cleaning to a visual standard of St 3 (SIS
05 59 00).
- Hand tool cleaning to a minimum visual standard of St 2 (SIS 05 59 00) only for
specific applications.
3. Coating Systems
- Primer Coat:
Inorganic zinc primer to a d.f.t. of 75 microns.
- Intermediate:
Polyamide epoxy to a d.f.t of 125 microns.
- Finish Coat:
Polyurethane high gloss finish to a d.f.t. of 75 microns.
- Total Dry film thickness:

Minimum total dry film thickness shall be 275 microns.
Client ADWEA
STRUCTURES

ANNEXURE - 2
EXTERNAL COATING SYSTEM FOR STAINLESS STEEL
ABOVE GROUND PIPING
1. Scope
External coating for atmospheric protection for above ground stainless steel piping.
- Removal of any grease and oil by solvent cleaning (Chloride free) to SP 1.
- Wash with fresh water to remove salts contamination.
- Removal of rust stains by light blast cleaning with aluminium-oxide or inert

aluminium-silicate grit, or by means of stainless steel wire brushing. Normal steel
wire brushes shall not be used.
3. Coating System
- First Coat
High build epoxy of marine environment type to a d.f.t. of 120 microns (minimum).
- Finished Coat
Polyurethane high gloss finish to a d.f.t. 50 microns.
- Total Dry film thickness

Note: Under any circumstances zinc containing paints shall not be used on stainless steel
surfaces.
Client ADWEA
STRUCTURES

ANNEXURE - 3
EXTERNAL COATING SYSTEM FOR GALVANIZED STEEL
ABOVE GROUND PIPING
1. Scope
External coating for atmospheric protection of above ground galvanized steel piping
system.
2. Surface preparation
- Surfaces shall be cleaned with fresh water and/or suitable solvent wash to remove
zinc salts, oil, grease, loose rust, loose paint etc. to SP 1.
- Dry light blast cleaning with suitable abrasive such as aluminium oxide/eqvt.
- If blast cleaning is absolutely impossible then solvent cleaning with an alkaline

detergent agent may be used as a second choice surface preparation.
3. Coating system
- Primer Coat
Polyvinyl butyral wash a d.f.t of 10 microns minimum.
- Intermediate
Polyamide MIO epoxy to a d.f.t of 40 microns minimum.
- Finish Coat
Polyurethane high gloss finish to a d.f.t of 75 microns.
- Total dry film thickness

Client ADWEA
STRUCTURES

ANNEXURE - 4
COATING SYSTEM FOR STRUCTURAL STEEL

(non-galvanised)
1. Scope
Coating for atmospheric protection of structural steelwork, (non-galvanised).
- Dry blast cleaning to a visual standard of Sa 2.1/2 near-white metal finish (SIS 05
59 00).
- For local touch up/repair work power tool cleaning to a visual standard of St 3 (SIS
05 59 00).
- Hand tool cleaning to a minimum visual standard of St 2 (SIS 05 59 00) only for
specific applications.
3. Coating System
- Prime Coat :
Inorganic zinc silicate to a d.f.t. of 75 microns minimum.
(Minimum pure Zinc content in d.f.t shall be 85%)
- Second Coat :
Polyamide cured tie coat of d.f.t 40 microns minimum.
- Third Coat :
Amine or Polyamide cured high-build epoxy of marine environment type to a d.f.t. of
125-175 microns.
- Fourth Coat :
Polyurethane high gloss finish to a d.f.t. of 50-75 microns, with finishing colour to
match the existing.
- Total dry film thickness:

Client ADWEA
STRUCTURES

ANNEXURE - 5
COATING SYSTEM FOR GALVANIZED STRUCTURAL
STEEL PARTS
1. Scope
Coating for atmospheric protection of galvanised steel structural parts.
2. Surface preparation
- Surfaces shall be cleaned with fresh water and/or suitable solvent wash to remove
zinc salts and/or oil, grease etc.
- Dry light blast cleaning with suitable abrasive such as aluminium oxide.
- If blast cleaning is absolutely impossible then solvent cleaning with an alkaline

detergent agent may be used as a second choice surface preparation.
3. Coating system
- Prime Coat :
Inorganic zinc silicate to a d.f.t of 75 microns minimum. (Minimum pure zinc content
in d.f.t shall be 85%).
- Second Coat :
Polyamide cured tie coat to a d.f.t of 40 microns minimum.
- Third Coat :
Amine or polyamide cured high build epoxy of marine environment type to a d.f.t of
125-175 microns minimum.
- Fourth Coat :
Polyurethane high gloss finish to a d.f.t of 50-75 microns minimum.
- Total dry film thickness :

Client ADWEA
STRUCTURES

ANNEXURE - 6
COATING SYSTEM FOR STAINLESS STEEL
STRUCTURAL PARTS
1. Scope
Coating system for atmospheric protection of stainless steel structural parts.
- Removal of any grease and oil by solvent cleaning.
- Wash with fresh water to remove salts contamination.
- Removal of rush stains by light blast cleaning with aluminium-oxide or inert

aluminium-silicate grit, or by means of stainless steel wire brushing. Normal steel
wire brushes shall not be used.
3. Coating System
- First coat:
High build epoxy of marine environment type to a d.f.t. of 120 microns (minimum).
- Top coat:
Polyurethane high gloss finish to a d.f.t. 50 microns.
- Total dry film thickness

Minimum total dry film thickness shall be 170 microns minimum.
Note: Under any circumstances zinc-containing paints shall not be used on stainless steel
surfaces.
Client ADWEA
STRUCTURES

Specification For Painting & External Coating of Metal Pipes & Structures

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Specification For Painting & External Coating of Metal Pipes & Structures

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SPECIFICATION FOR PAINTING &

EXTERNAL COATING OF METAL PIPES

0 02-02-2002 Approved Issue

tender: project: document: W-C-SS-014 rev: 0 sheet: 1 of: 23

2. APPLICABLE STANDARDS AND CODES ..........................................3

5. SAFETY REQUIREMENTS .................................................................12

6. INSPECTION AND TESTING ..............................................................13

7. MARKING, HANDLING AND STORAGE............................................15

9. QUALITY ASSURANCE/QUALITY CONTROL...................................16

10. PERFORMANCE GUARANTEE..........................................................17

tender: project: document: W-C-SS-014 rev: 0 sheet: 2 of: 23

1. : External Coating System for Carbon Steel Above Ground Piping.

2. : External Coating System for Stainless Steel Above Ground Piping.

3. : External Coating System for Galvanized Steel Above Ground Piping.

4. : Coating System for Structural Steel (Non Galvanised).

5. : Coating System for Galvanized Structural Steel Parts.

6. : Coating System for Stainless Steel Structural Parts

Intended deviations shall be listed by the manufacturer on a separate sheet of paper as an

2. APPLICABLE STANDARDS AND CODES

Swedish Standard SIS 05 59 00 Pictorial Surface Preparation Standards Steel

SSPC - SP1 Solvent cleaning

tender: project: document: W-C-SS-014 rev: 0 sheet: 3 of: 23

ASTM D4060 Abrasion resistance of organic coatings by the Taber Abraser.

ASTM D 5162 Dissimilarity (Holiday) testing of non conductive protective coating

RAL 840 HR Standard Colours.

ISO 2409 Paints and varnishes cross of test for adhesion.

ISO 2808 Paints and varnishes – Determination of film thickness.

ISO 4628 Paints and varnishes – Evaluation of degradation of paint coatings

ISO 9001 Quality Systems – Model for Quality Assurance in Design,

ISO 9004 Quality Management and Quality System Elements – Guidelines.

BS 245 Specification for mineral solvents (white spirit and related

BS 3900 Methods of test for paints.

BS 5411 Methods of test for metallic and related coatings.

BS 6949 Specification for bitumen based coatings for cold application

BS 7079 Preparation of steel substrates before application of paints and

BS 476 Fire tests on building materials and structures.

tender: project: document: W-C-SS-014 rev: 0 sheet: 4 of: 23

BS 2523 Specification for Lead Based Priming Paints.

BS 4800 Schedule of paint colours for building purposes.

BS 5252 Framework for colour co-ordination for building purposes.

BS 6150 Code of practice for painting for buildings.

BS 7664 Specification for undercoat and finishing paints.

BS 8202 Coating for fire protection of building elements.

4.1 Surface Preparation

Sand shall be not used as a blast cleaning material.

tender: project: document: W-C-SS-014 rev: 0 sheet: 5 of: 23

4.1.2 For Structural Steel Items

tender: project: document: W-C-SS-014 rev: 0 sheet: 6 of: 23

4.1.3 Techniques and Restriction

4.1.3.1 Dry Blast Cleaning

Factory coated equipment like pumps, compressors, motors, valves, electrical,

tender: project: document: W-C-SS-014 rev: 0 sheet: 7 of: 23

4.1.3.3 Hand Tool Cleaning

4.1.3.4 Solvent Cleaning

Solvent cleaning shall be in accordance with U.S. Standard SSPC-SP1"Solvent Cleaning".

4.1.3.5 Surface Cleaning

4.2 Environmental Conditions/Safety

tender: project: document: W-C-SS-014 rev: 0 sheet: 8 of: 23

All necessary precautions shall be taken to safeguard the environment.

4.3.1.1 Preparatory Materials

White spirit shall comply with BS 245.

Knotting shall comply with BS 1336.

4.3.1.2 Primers, Paints and Coatings