Technical SpecificationTS4 – Project and Maintenance Coating CBH Engineering Pty Ltd P | (08) 9236 5350 F | (08) 9236 5370 www.cbh.com.au TS4 – Project and Maintenance Coating Document Control Document owner: Manager Coatings Change Control Policy Any amendment to this standard must be recorded in the table below. If substantial changes are made a new version of the document shall be created to preserve an audit trail. Review Date Author Description of amendments A 21/05/2009 T. Tyler Reformatting, CBH changed to BWE, updating reference codes and Standards B 20/7/2009 T. Tyler Previously TS 8 & 9 C 07/10/2009 T. Tyler Change BWE back to CBH D 30/04/2010 T. Tyler Rebranding E 29/07/2011 S. Bracegirdle Note added to 6.8 Colour Schedule F 30/11/2012 J. Watson General updates G 13/08/2013 J. Watson Addition of coating system PC10 H 18/11/2014 J. McMiles Updates styling and formatting. DOCS 826860v6 2 ....................... Intention of Specification.......................................................................... Contractor Responsibilities ............................................................ 4 2..................................................................................... 8 6......... Quality Control & Inspection ........................................................................................ 10 DOCS 826860v6 3 ..TS4 – Project and Maintenance Coating Contents 1....................................................................................................................... 7 5............................................... Reference Codes & Standards ....................................................................................................................... 4 3.............. Approved Coatings & Coating Specifications .................... 5 4................................................... Scope ............... the Contractor shall refer to the Principal (CBH Group) or its nominated representative. In the event of conflict. whose decision shall prevail and be binding. codes and Standards referenced in this Specification or any other documents. including CBH Engineering Pty Ltd. Generally and as far as practicable. Where reference is made within this specification to Co-Operative Bulk Handling (CBH) this shall include any nominated representative of the CBH Group. Inspection and Testing Approved coatings. inconsistency or ambiguity between the Contract. Contractor responsibilities Quality Control. DOCS 826860v6 4 .TS4 – Project and Maintenance Coating 1. all steelwork shall be prepared for painting and have the coating system applied and inspected to ensure compliance with this specification and/or applicable standards. Statutory requirements. this Specification. Scope This Specification covers the minimum requirements for: • • • • • • • 2. is performed in accordance with the Coating Manufacturer’s Product Data Sheets and to the highest possible industry standards. The aim of this specification is to provide project and maintenance coating systems that shall provide a minimum Design/Service Life as per AS/NZS 2312 irrespective of the service environment and/or location and also have a minimum of 10 years before first maintenance. coating systems and colour coding Surface preparation Application of coatings Acceptance criteria and treatment of defective work Safe work practices on site Intention of Specification It is the intention of this Specification to ensure all Project (new Shop and Site touch-up) and Maintenance surface treatment work. 408.TS4 – Project and Maintenance Coating 3.1 Site Testing of Protective Coatings – Non-conductive Coatings – Continuity Testing .11 Site Testing of Protective Coatings – Equipment Report AS 3894.8 Site Testing of Protective Coatings – Visual Determination of Gloss AS 3894.1 Metal Finishing – Preparation and Pretreatment of Surfaces – Removal of Oil. Reference Codes & Standards All works shall conform to the latest edition of the following standards or their approved equivalent.408.5 Site Testing of Protective Coatings – Determination of Surface Profile AS 3894.6 Site Testing of Protective Coatings – Determination of Residual Contaminants AS 3894.5 Paints and Related Materials – Method of Test .Adhesion – Pull-Off Test AS 1627.2 Paints and Related Materials – Method of Test .High Voltage (Brush) Method AS 3894. Conduits and Ducts AS 1580.408.4 Paints and Related Materials – Method of Test .4 Metal Finishing – Preparation and Pretreatment of Surfaces – Abrasive Blast Cleaning of Steel AS 1627.0 Site Testing of Protective Coatings – Introduction and List of Test Methods AS 3894.9 Metal Finishing – Preparation and Pretreatment of Surfaces – Pictorial Surface Preparation Standards for Painting Steel Surfaces AS 2700 Colour Standards for General Purposes AS 3894.2 Metal Finishing – Preparation and Pretreatment of Surfaces – Power Tool Cleaning AS 1627. Grease and Related Contamination AS 1627.7 Site Testing of Protective coatings – Determination of Surface Temperature AS 3894.4 Site Testing of Protective Coatings – Assessment of Degree of Cure AS 3894.9 Site Testing of Protective Coatings – Determination of Adhesion AS 3894.Adhesion (Cross Cut) AS 1580. the relevant new standard shall be read in lieu of the superseded standard.2 Site Testing of Protective Coatings – Non-conductive coatings – Continuity testing – Wet Sponge Method AS 3894.10 Site Testing of Protective Coatings – Inspection Report – Daily Surface and Ambient Conditions AS 3894.3 Site Testing of Protective Coatings – Determination of Dry Film Thickness AS 3894.0 Metal Finishing – Preparation and Pretreatment of Surfaces – Method Selection Guide AS 1627. If any standard listed below has been superseded. AS 1345 Identification of the contents of Pipes.12 Site Testing of Protective Coatings – Inspection Report – Coating DOCS 826860v6 5 .Adhesion – Knife Test AS 1580. TS4 – Project and Maintenance Coating AS/NZS 2310 Glossary of Paint and Painting Terms AS/NZS 2312 Guide to the Protection of Structural Steel against Atmospheric Corrosion by the Use of Protective Coatings AS/NZS 3750.1 High Pressure Water (Hydro) Jetting Systems – Guidelines for Safe Operation and Maintenance AS/NZS 4680 Hot Dipped Galvanised (Zinc) Coatings on Fabricated Ferrous Articles SSPC Painting Manual Volume 1: Good Painting Practice SSPC Painting Manual Volume 2: Systems and Specifications DOCS 826860v6 6 .Organic Zinc-Rich Primer AS/NZS 3750.9 Paints for Steel Structures .15 Paints for Steel Structures .Inorganic Zinc Silicate Paint AS/NZS 4233. and Work Instructions for each procedure. consumables. and be available onsite. abrasives. The project management structure. labour. and provide a detailed Gantt chart of the proposed work schedule. transport. 4. as per manufacturers recommendations or applicable Australian standards listed in section 3.7 Ensure the availability of technical assistance from the Coating manufacturer or other authority approved by CBH. Contractor Responsibilities The Contractor shall: 4.4 Ensure all staff has a thorough understanding of all the conditions applying to this Specification. equipment. 4.3 Provide a list of those items. Inspection and Test Plan (ITP) documentation. 4.TS4 – Project and Maintenance Coating 4. activities or approvals required to be supplied or performed by CBH prior to the commencement of any work. 4. inspection and safety equipment to perform the work scope in strict accordance with this Specification and best industry standards.0 of this specification.5 Ensure that all QA/QC Staff have relevant qualifications to perform all inspections/testing in accordance with the relevant Australian standards. relevant work experience of the site supervisor/inspector. 4.8 Protect CBH product. safe storage facilities. damage or injury caused by the Contractor’s activities on-site. DOCS 826860v6 7 .2 Provide CBH with written details of all equipment (all test equipment must have a valid calibration certificate every 12 months from last calibration date. the contents of Coating manufacturer’s Product Data Sheets and Material Safety Data Sheets.6 Be responsible for co-ordinating all on-site work activities with other Contractors or CBH activities in the general work area. 4. 4.1 Supply all coating materials. equipment and personnel from contamination. HV Holiday Tester LV Holiday Tester Where requested. equipment for the measurement of soluble salt concentrations).1 Maintain quality records in accordance with the AS3894 series .e.5 Provide CBH with access to the work area while work is in progress or on completion. such as.3 Provide inspection equipment. provide CBH with details of the proposed daily work schedule and the approximate timing for the following inspection stages: • • • • • high pressure pre wash or solvent cleaning to remove product and grease/oil contaminants from the area to be treated on completion of the abrasive blast cleaning on completion of brush stripe coating. Quality Control & Inspection The Contractor is required to: 5. DOCS 826860v6 8 .Site Testing of Protective Coatings.7 Accept that where there is conflict with any provisions of this Specification and the Coating manufacturer’s product Data Sheet or recommended coating systems.TS4 – Project and Maintenance Coating 5.Inspection Report . 5. but not limited to: • • • • • • • • • 5. 5.Coating Copies of all records shall be submitted to CBH at the completion of work or as requested by CBH or its representative.6 Work not conforming to this Specification shall be reinstated at no cost to CBH.4 Surface temperature gauge Ambient temperature gauge Hygrometer WFT gauge (comb type) DFT measuring instrument such as the Elcometer or approved equivalent Surface profile replica tape such as Testex tape and micrometer Residual contamination testing equipment (i. 5. • • • Part 10 . the issue shall be resolved by adopting the highest standard acceptable to the principal or its representative.Inspection Report – Daily Surface and Ambient Conditions Part 11 .2 Provide CBH with a copy of the Work Instruction (WI) and Inspection and Test Plan (ITP) documents to be used for each coating system. 5. on completion of the application of each coat in the coating system on completion of repairs 5.Equipment Report Part 12 . CBH reserve the right to request amendments (at any time though out the project) to WI or ITP documents which shall be amended as required. The Contractor shall retain one test panel or item as a quality reference for work in production.TS4 – Project and Maintenance Coating 5. DOCS 826860v6 9 . CBH may request the Contractor to prepare at no cost to CBH. or on completion of the work scope. Two test panels or Items shall be retained by CBH for use as quality references in the event of a dispute. 3 sample panels or items for each coating system. The Contractor’s nominated Coating manufacturer and or representative shall witness the surface preparation and coating application of each system and acknowledge in writing the conformance of each prepared test panel and item.8 Prior to commencement of work. The test panels and items shall be prepared in accordance with the Contractor’s proposed Work Instruction and Test Plan documents. 1 Only coatings approved by CBH shall be used. Mixed systems. Non-specified coating systems or procedures shall not be used without the written approval of CBH. unless stated otherwise. damage free. All paint materials shall be delivered to the shop or site in the coating manufacturer’s original containers with labels and seals unbroken.3 All coating materials shall be supplied in their original containers and are to be sealed. uniquely marked for Identification giving the following information as a minimum. 6. the coating Manufacturer's representative shall be required to inspect the proposed work scope and supply a specific coating specification and written endorsement for the suitability of their proposed coating system.TS4 – Project and Maintenance Coating 6.5 Contractors are responsible for selecting coating products from the approved Manufacturers whose products best suit the Contractor’s commercial and practical requirements. • Type and identification • Batch number • Expiry Date 6. 6. shall be rejected and reworked in accordance with this Specification at no cost to CBH. Approved coating Manufacturers are: • • • • • • • DOCS 826860v6 Akzo Nobel Pty Ltd (International) Ameron Coatings (Australia)(PPG) Pty Ltd Jotun Australia Pty Ltd Dulux Protective Coatings Resene Paints (Australia) Ltd (Altex) Wattyl Australia Pty Ltd Hempel Paints 10 .4 For areas and coating systems not specifically mentioned in this Specification. • Manufacturers name.2 All coatings and thinners used within a coating system shall be sourced from one Coating manufacturer. 6. Approved Coatings & Coating Specifications 6. Other coating materials may be considered for use provided such a request is made in writing and supported by relevant case histories. TS4 – Project and Maintenance Coating 6.Strength 45540 Surface Tolerant Epoxy Carboguard 690 Amerlock 400/2K Durebild STE Interzone 954 Jotamastic 87/90 Epinamel DTM 985 Hempadur mastic 45880/1 Epoxy High Build MIO Carboguard 690 MIO Amerlock 400 /2K MIO Ferreko no 3 Interplus 1180 MIO Jotamastic 87 MIO 50 Epinamel DTM 985 MIO Hempadur mastic 45880/1 1243 E-Line 929IF Amercoat Iso-Free 977 Acrathane IF Interfine 629 Hardtop CA Paracryl 540 IF Hempel’s Pro-Acrylic 55880 Duraprime Amercoat 185K Luxaprime ZP Interprime 198 Pilot QD Duranamel PR10 Hempaquick Primer 13640 Isotal Enamel Styralux 220 Metal Shield Premium UV Resistant Enamel Topcoat Interlac 665 Pilot 11 Kill Rust Enamel Hempaquick Enamel 53840 N/A Amercoat 288 955 Acrashield Intercryl 988 N/A Sunfast Gloss/Low Sheen N/A N/A Amercoat 471 (75µm) Zincanode 402 (75µm) Amerlock 400 MIO (200µm) Duramax GPE MIO (200µm) Intershield 300 (175 µm) Barrier 77 (65µm) PSX 700 (125µm) Weathermax HBR (100µm) Interthane 300 (175µm) Jotamastic 80/87MIO (350 µm) (80% content MIO) Gloss Acrylic (Two pack) Zinc Phosphate Primer (1 pack) Gloss Finish (1 pack) Water Borne Gloss Acrylic (1 pack) HB Marine coating System (classified as E-M as per AS2312) All DFT’s are in accordance with manufacturers recommendations DOCS 826860v6 Interthane 990 (60µm) Hardtop XP (75 µm) Galvit EP100 (75µm) Epinamel DTM 985 MIO (300µm) Paracryl IF540 (50µm) Hempadure Zinc 17360 (75µm) Hempadure Mastic 45881 (125µm) Hempathane HS 55610 (125µm) 11 .6 Approved Coating Products Generic Type Altex PPG/Ameron Dulux International Jotun Wattyl Hempel Inorganic Zinc Rich Ethyl Silicate Carbozinc 11 Amercoat D9 Zincanode 304 Interzinc 215 Resist 86 AU Galvit ES 600 Galvosil 15700 Epoxy Zinc Rich Primer – Friction Grip Certified Carbozinc 858 Amercoat 471 Pending Certification Interzinc 315 Pending Certification Pending Certification Pending Certification Epoxy Zinc Rich Primer Carbozinc 858 Amercoat 471 Zincanode 402 Interzinc 52 Barrier Galvit EP 100 Hempadur Zinc 17360 Zinc Phosphate Epoxy Primer (2 Pack) Altra-Prime 504 Amercoat 182 ZPK Durepon P14 Intergard 251 Penguard Express ZP Epinamel PR 250 Hempadur Fast Dry 15560 High Build / High Solids Epoxy (CP Compatible) Carboguard 690 Amerlock 400/2K Durebild HSE Interzone 954 Jotamastic 87/90 Epinamel DTM 985 Hempadur Multi. elevator casings.Section 2. motors. Buried. stringers.TS4 – Project and Maintenance Coating 6. tanks and piping. Friction grip bolted faces * See Notes.7 Item. Vendor-supplied. gear boxes.3) Coating System Category E: Very High (Coastal) PC3/PC10* Category B: Low (Inland) PC2 Category E: Very High (Coastal) PC1/PC10* Category B: Low (Inland) PC5 Category E: Very High (Coastal) PC3/PC10* Category B: Low (Inland) PC6 Galvanised steel – field welds ONLY All environments PC7 Galvanised steel (colour coded) All environments PC8 All environments PC4 All environments PC8 All environments PC9 Category E: Very High (Coastal) Category B: Low (Inland) PC1* PC5* Storage cells and supporting structure Structural steelwork Conveyors. chutes. Propriety equipment colour coding over manufacturers standard finish. Environment and Coating Systems Item or Area to be coated Environment Atmospheric Corrosivity Category (Based on AS 2312 . immersed or in conjunction with Cathodic Protection Equipment. supports. garner bins. internal surfaces of boot pits Structural steel. page 13 DOCS 826860v6 12 . hoppers. 4 class 2.6 DOCS 826860v6 13 .4 class 3 Abrasive blast clean to AS1627.8 Project Coating Systems Coating System # PC1* PC2 PC3 PC4 PC5* PC6 PC7 PC8 PC9 PC10 Surface Preparation Method and Standard Abrasive blast clean to AS1627. 50-75 microns of Inorganic Zinc Rich Ethyl Silicate *For coating systems marked PC10 please refer to manufacturers recommended coating thicknesses stated in table 6.5 Abrasive blast clean to AS1627.5 Coat 1 Generic Type Epoxy Zinc Rich Primer DFT (µm) 75 Inorganic Zinc Rich Ethyl Silicate 75 Epoxy Zinc Rich Primer 75 HB/HS Epoxy (CP Compatible) Inorganic Zinc Rich Ethyl Silicate 200 Zinc Phosphate Epoxy Primer (two pack) Epoxy Zinc Rich Primer 75 Coat 2 Generic Type High Build MIO Epoxy Zinc Rich (weld areas) High Build Epoxy HB/HS Epoxy (CP Compatible) DFT (µm) 150 Coat 3 Generic Type High Build MIO DFT (µm) 150 Total DFT in µm 375 75 WB –Acrylic HB 150 300 200 Gloss Acrylic (two pack) 50 325 200 400 75 75 Gloss Acrylic (two pack) 50 125 100 100 Zinc Phosphate Epoxy Primer (two pack) 75 Gloss Acrylic (two pack) 75 150 Zinc Phosphate Primer (one pack) Epoxy Zinc/Surface tolerant Epoxy (dependant on manufacturer chosen) 75 Gloss Enamel (one pack) 40 Gloss Enamel (one pack) 40 155 See belo w* High Build MIO/Surface tolerant Epoxy See belo w* Gloss Polyurethane – Acrylic or Polysiloxane See below * See below* *For friction grip joints apply Certified for Friction Grip Joints Epoxy Zinc Rich Primer 50-75 microns for PC1 and for PC5.4 class 2.4 class 2.2 class 2 Acid etch or whip blast or power tool class 2 AS1627.4 class 2.4 class 2.5 Power tool clean to AS1627.5 Abrasive blast clean to AS1627.4 class 2.2 Solvent wipe and abrade Abrasive blast clean to AS1627.TS4 – Project and Maintenance Coating 6.5 Abrasive blast clean to AS1627.5 Abrasive blast clean to AS1627. Signal Red Dust Ducting X42 .Blue Grey Zinc Silicate finish (Natural Zinc) N45 . hand wheels. Y35 .Koala Grey X15 .9 Colour Schedule* Items to be painted AS2700 Colour Number and Name Storage cells and supporting structure.Jade Galvanised (Where safety colour coding required finish in Y14) Y14 .Golden Yellow B21 .Orange G44 .Raffia Fresh water B15 . unless otherwise stated by the Principal or its representative. Kick Plates ladders and cages shall be colour coded to Y14 – Golden Yellow.TS4 – Project and Maintenance Coating 6.Off White Internal surfaces of boot pits Compressed Air Line Electric Motors Gearboxes Conveyors.Mid Blue Pre-cast concrete panels As nominated by the Principal * Colour schedule is a guide only. colour changes made during the planning stage of manufacturing new equipment is at the discretion of the Engineering Services and Senior Projects Managers of Network and Engineering.Ultramarine N 53 . DOCS 826860v6 14 . stringers.Palm Green White R13 . levers. *All hand rails including Stanchions.Golden Tan Gas X31 .Biscuit Engine Fuel Hydraulic Lines X53 . couplings) Machine guards (interior and exterior) Inspection door (dust) Grain treatment lines CLS Stacker Boom J Pit CLS Stacker Chassis Structural Steelwork Woodwork (interior and exterior) Conduits Cable ducting Cable trays Switches Switch boxes (exterior) Switch boxes (interior) Fire Service Emergency Valves Hazardous items B25 – Aqua G21 . supports and take up frames Elevator casings Spouts and chutes Garner bins and hoppers *Hand Rails *Ladder Cages All moving parts (pulleys. 1 General This section details the approved surface preparation methods. dirt. 7.4 Metal Finishing – Preparation and Pretreatment of Surfaces – Abrasive Blast Cleaning of Steel 1627.3 Prior to the commencement of any abrasive blasting. any oil and grease on the surfaces to be treated shall be removed using suitable solvents or non-ionic detergents in accordance with the requirements of AS1627. equipment and materials. all surfaces shall be inspected by the Contractor’s representative for compliance with this Specification. Surface Preparation 7. Grease and Related Contamination 1627. loose millscale and other foreign particles or residues which are likely to effect the performance of any subsequent protective coating system.5 Prior to the application of coatings. grit. corrosion product.4 Prior to commencing surface preparation. Other methods such as hand or power tool cleaning shall only be used for small or repair areas with the approval of CBH. CBH shall be given the opportunity to inspect prepared surfaces prior to the application of coatings. DOCS 826860v6 15 . 7. abrasive blast cleaning is the only acceptable surface preparation method.1 Metal Finishing – Preparation and Pretreatment of Surfaces – Removal of Oil. dust. salt residues. 7.1. Surface preparation by high pressure water jetting may also be acceptable however only with the approval of CBH. These checks shall be conducted daily at the start of each shift or any time there is a change of air supply lines or equipment.2 Surface preparation shall be performed in accordance with the current editions of the following Australian Standards: 1627. weldscale. In general steel shall be cleaned of all grease. fingerprints. all compressed air shall be free of oil.2 Metal Finishing – Preparation and Pretreatment of Surfaces – Power Tool cleaning 1627.9 Metal Finishing – Preparation and Pretreatment of Surfaces – Pictorial Surface Preparation Standards for Painting Steel Surfaces 7. As a general rule.TS4 – Project and Maintenance Coating 7.0 Metal Finishing – Preparation and Pretreatment of Surfaces – Method Selection Guide 1627. condensed moisture or any other contaminates and shall conform to the requirements of ASTM D 4285. Nevertheless. o Shop blasting shall be performed using steel grit or other approved materials to provide a conforming surface profile. Spent abrasive shall not be re-used. 7. All steelwork shall then be abrasive blast cleaned to the specified standard of the nominated protective coating system. which cannot be treated in accordance with the Specification. or the relative humidity exceeds 85%. ilmenite or aluminium oxide) shall only be used for Site work. garnet. must be brought to the attention of the Principal or its representative (these defective areas will be assessed on a case by case situation).TS4 – Project and Maintenance Coating 7. shall be brought to the attention of CBH. 7. Surface profile shall be appropriate for the coating system.e. Abrasives shall be free of oil. Coatings shall only be applied to surfaces that meet the minimum specified standard as detailed in Section 7 of this Specification. any other defects not already mentioned which may be detrimental to the coatings.4 class 2.12 DOCS 826860v6 Surface profiles of 35 to 65 microns (average 50 microns) shall be consistently produced.10 Areas to be spot blasted shall have the surrounding coating “feathered” over a minimum width of 50mm. Abrasive Blast Cleaning Heavily corroded and pitted steelwork shall be initially abrasive blast cleaned to AS1627.9 Abrasive blast cleaning shall cease if the steel surface temperature drops to within 3 C of the dew point temperature.8 Abrasive blast cleaning shall be performed during daylight hours only. 16 . Any other welding defects that may be detrimental to the subsequent coating processes. All blasted steel surfaces must be prime coated within 4 hours of blasting or before “flash rusting” occurs. For sake of completeness. salts. 7. followed by High Pressure fresh water to remove water-soluble corrosive compounds from the pitted steel surface. moisture and any other contaminants likely to be detrimental to the treated steel surface. 7.7 Sharp edges shall be ground to a minimum 3mm radius Weld spatter and weld slag shall be removed prior to abrasive blasting Laminations shall be ground out and the affected area re-treated Inaccessible areas. Refer coating manufacturer’s Product Data Sheet. the surface profile height of the blasted surface shall be within the range to suit the manufacturer’s protective coating system to be applied. grease. 7.6 Surface Defects to be Removed Prior to Abrasive Blast Cleaning • • • • • • 7.11 Non-silica abrasives (i. 16 Areas which cannot be properly prepared by abrasive blasting. 7. All abrasive blasting residue shall be collected. Care must be taken to only “sweep blast” the surface. DOCS 826860v6 17 . curing compounds and release agents. voids and inaccessible areas.TS4 – Project and Maintenance Coating 7. The Contractor may nominate alternative preparation methodologies such as highpressure water washing or acid etching but must provide performance parameters for the nominated surface preparation technique and confirmation from the coating manufacturer of suitability of the surface preparation for the selected coating system. Other Specifications and Methodology etc. The Contractor shall request from the Principal all information relating to curing compounds.g. identification tags. 7.13 Compressors used for abrasive blasting shall have effective moisture and oil separators fitted. electrical equipment. and the use of a lower nozzle pressure is recommended.) is to be sourced and approved by CBH before commencement of any related new or remedial works.17 New Concrete Surfaces e. Tanks etc. New concrete must be well cured and dry prior to coating. 7. painted surfaces. removed from site and disposed of by the Contractor in accordance with the appropriate statutory requirements. Air lines shall be fitted with oil and water filters which shall be drained off or cleaned daily. from damage caused by abrasive blast cleaning or painting. laitance. All surfaces shall be abrasive blast cleaned to remove loose material.15 Only filtered air shall be used to blow off spent abrasive from the prepared surfaces. 7. form release oils and the like applied to the concrete surface to be coated in order to provide a suitable surface preparation methodology. bond breakers. Bund Walls. gauge faces. shall be brought to the attention of CBH. etc. All concrete shall be suitably prepared prior to coating application to ensure a suitable surface that will provide sound adhesion between the applied coating and the concrete substrate. such as gaps. The section 7.14 The Contractor shall be responsible for protecting all rotating equipment. Allow all concrete to cure a minimum of 28 days prior to any coating application works. Removal of items and subsequent reinstallation after completion of painting works shall be carried out by tradesman competent in the relevant activity.17 “New Concrete Surfaces” above is intended as a guide only and additional information (Inspection Test Plans. the o steel surface temperature exceeds 50 C or exceeds the product Coating manufacturer’s maximum allowable steel surface temperature. Application of Coatings 8.1 Standard of Workmanship Competent and experienced personnel shall perform all coating preparation and application.5 Sealing of crevices Inaccessible areas such as crevices and bolted member joints which cannot be coated in accordance with this specification shall be sealed with a flexible sealant material that is compatible with the substrate and applied coating system. Conventional Spray.TS4 – Project and Maintenance Coating 8. dry compressed air prior to application of coating material. rolling or brush application shall only be used with the approval of CBH. All such locations shall be approved by CBH prior to application. Batch numbers and shelf life expiry dates shall be clearly visible.6 Application of Coating Airless spray is the preferred application methods. Two pack epoxy coatings shall be allowed the Coating manufacturer’s specified induction period before application. 8. Coatings which have settled excessively or gelled shall not be used. Steel surfaces to be coated shall be clean and dry. 8.3 Mixing of Coatings • • • 8.2 Storage of Coatings • • • • 8. Coating manufacturer’s mixing and thinning directions shall be strictly observed. 18 . Caution: Electric power tools can be an ignition source for solvent vapours. spent abrasive and dust shall be removed with clean. Grain dust fallout. 8. Use air driven power stirrers to mix liquid coating. erecting tarpaulins or barrier screens around work areas. Precautions such as stopping spray application in adverse conditions. 8.4 Coatings shall be delivered to site in the original and unopened containers.7 DOCS 826860v6 The Contractor is responsible for all damage caused by over-spray. Ambient and Surface Conditions Coating shall not be applied when the relative humidity exceeds 85% steel surface o o temperature at or lower than 10 C and/or not falls below 3 C above dew point. Coatings shall be stored in dry and cool environments at a temperature not o exceeding 30 C or as specified by the manufacturer. and masking shall be taken. planning work areas and schedules around the prevailing wind strength and directions. Care shall be exercised to ensure that coating materials are not unduly brushed out as this will reduce the dry film thickness. 8. it shall be added during the initial mixing process.8 Stripe Coating Before Each Coat.10 The Coating manufacturer’s pot life and re-coat intervals (min and max) shall be strictly observed. blooming. spent abrasive and foreign matter. pinholes.13 Coatings shall be applied in an even and consistent finish.14 DOCS 826860v6 Where possible. amine blush/bloom. minimum re-coat and maximum re-coat intervals. touch dry. studding materials and welds shall be coated by brush in an even and consistent film with each coat in the coating system prior to spray application of the same coating. blistering. unless otherwise stated on the coating manufacturers product data sheet. It is not permissible to add additional thinner after the coatings have been thinned to the proper consistency. entrapped air or solvent. free of defects such as. each coating within a multi-coat coating system shall be top coated within 24 hours of application to avoid contamination. 8. 8. loss of adhesion/cohesion. any damage or defects to previous coats shall be touched up with the specified coating before further coats are applied within a specified system. Any repairs to the finished coatings for any of the above defects (or any defects not listed) that may be detrimental to the design life (minimum 10 years to first maintenance) shall be repaired at no extra cost to the principal. inadequate cure. 8. Solvent-Borne Inorganic Zinc Silicate coatings are exempted from this requirement.TS4 – Project and Maintenance Coating 8. 8. mud cracks. Natural surface tension forces causes the coating to retreat from any edge type formation. Each coat within a system shall be of a contrasting colour to the subsequent coats. The Contractor shall reference the Coating manufacturer’s coating cure information detailing the pot life. All edges.9 All known field weld areas shall be given the specified abrasive blast preparation but left uncoated for a distance of 50mm from the weld line. 19 . nor shall the coating material be applied in excessive quantities. Failure to adequately stripe coat will cause premature failure of the coating in the areas that are required to be stripe coated. Care must also be taken to ensure the correct type and size of brush is used for the shape and size of the structure and or area to be stripe coated.11 Prior to the application of any coat of material. Such areas shall be given the appropriate touch-up treatment after site erection. 8. sags. Thinning shall not exceed limitations established with the coating manufacturer’s product data sheet.12 No thinner shall be added unless necessary for proper application. When the use of thinner is permissible. overspray. but not limited to. deeply pitted steel. holidays. runs. 18 Hot Dip Galvanising All galvanising shall be carried out by the hot dipping process and conform to the requirements of AS/NZS 4680 – Hot Dipped Galvanised (Zinc) Coating on Fabricated Ferrous Articles. All Galvanising vent relief holes on rectangular hollow sections.TS4 – Project and Maintenance Coating 8. continuous. Particular attention must be paid to the removal of excess zinc in and around bolt holes. 8.Hot Dipped Galvanised (Zinc) Coating on Fabricated Ferrous Articles. Dross and flux must not be adhered to or be an inclusion in the galvanised coating. Any repair of the galvanising must be strictly in accordance with AS/NZS 4680 . 8. circular hollow sections.15 Contaminated coating surfaces shall be cleaned using a suitable solvent or non-ionic detergent and High Pressure Fresh Water.16 Rollers shall not be used for applying inorganic zinc primer coating. smooth and totally free of any defects which could be detrimental to the intended end use. Particular attention must be paid to the removal of excess zinc in and around bolt holes. square hollow sections or box beam members are to be plugged (with an approved metal composite putty) and sealed unless noted otherwise on the drawings or approved in writing by the principal or its representative. runs and lumps. DOCS 826860v6 20 . 8.17 Protection of Existing Finishes All cleaning. surfaces that are to be left unpainted or surfaces painted by a different material or product. Use of rollers for other coatings. refer coating manufacturer’s PDS. Once vent holes have been plugged all vent holes must be sanded flush and coated as per AS/NZS 4680. contaminates and overspray will not be deposited onto previously painted surfaces. surface preparation and coating works shall be scheduled so that dust. Zinc coatings must be free of spikes. The finished galvanised coating must be adherent. The Contractor shall take records of typical daily surface profile values using replica tape such as Testex Press-O-Film Replication Tape in accordance with the procedure detailed in AS/NZS 3894. Surface treatment found to be defective shall be re-instated in accordance with this Specification at no cost to CBH.10. Contaminants shall be clearly seen when the tape is removed and placed against a dark/light background.1. 9. If contamination is still present. 9.3 Surface Profile Surface profile shall be within the range of 35-65 microns (average 50 microns). A 2 chloride result higher than 50mg/m (or figure determined by the applicable paint manufacturer) shall have further high pressure fresh water washing (with potable 2 water) of the affected surface and re-blasting until the result is less than 50mg/m . shall be blown down using filtered compressed air and retested using the tape.6. 9. Blasted steel with non-conforming profile values shall be re-blasted with suitably graded abrasive to ensure compliance with this Specification (surface profiles within the coating manufacturer’s data sheets recommendations may also be accepted at the discretion of the Principal or its representative). Other tests as determined by CBH may be performed as required.5 Method A. the surfaces shall be high pressure fresh water washed until clean. by pressing a wide. Frequent monitoring of the WFT shall be done by the contractor to achieve the specified DFT. to remove “flash rusting” corrosion products prior to coating. clear adhesive “1580” tape onto the upper surfaces of suspect areas. Affected surfaces with a rating of above 0 . Replica tape records shall be affixed to the Daily Inspection Report form as detailed in AS/NZS 3894.TS4 – Project and Maintenance Coating 9. Coating to be over coated shall be tested for dust and spent abrasive as determined in accordance with the procedure detailed in AS/NZS 3894.2 Surface Contaminants The presence of soluble salts on the surface of freshly blasted steel shall be determined in accordance with the procedure(s) detailed in AS/NZS 3894.4 Wet Film Thickness (WFT) Measurements Contractors shall be capable of calculating the % volume solids reduction for different thinning ratios.6. DOCS 826860v6 21 .1 General The field testing/inspection procedures detailed in this section shall be used by the Contractor to establish compliance with this Specification. Acceptance Criteria & Treatment of Defective Work 9. 7 Adhesion Testing Each coat within a System may be tested for adhesion at CBH’s discretion and by the Contractor’s Quality Control representative.408.SB-IZS Primer and Topcoats (one pack) – 2MPa (290PSI) • System of . All completed coatings or disputed results. For coatings 125 microns and above.e. Minimum acceptable adhesion values shall be: • System of . Any readings found to be below the specified minimum are to be repaired at no cost to CBH.2 shall be used for field testing within the coating process (i. The minimum thickness stated in this specification is the absolute minimum. Coating which does not exhibit a cure trend consistent with the Coating manufacturers cure information.3 High DFT readings (above 150% of maximum specified DFT per coat) shall require complete removal at the discretion of CBH.HB/HS Epoxy – 4 MPa (580 PSI) The Contractor shall spot repair all areas subject to adhesion testing at no cost to CBH.2 Table 1. 9. daily or before the application of subsequent coats) at the discretion of CBH or its nominated representative.4 Method C – Rub Test. 9.HB Epoxy Primers. For coatings 50-125 microns. (allow for temperature differences) shall be removed and re-instated in accordance with this Specification at no cost to CBH. shall have adhesion testing conducted with an Elcometer 106 or similar approved adhesion device in accordance with AS1580 Method 408. Coatings with unacceptable adhesion test results shall be removed and reinstated at no cost to CBH.TS4 – Project and Maintenance Coating 9. 2mm apart.5 Dry Film Thickness (DFT) Measurements DFT readings shall be taken according to AS3894.6 Cure State Solvent Borne Inorganic Zinc Silicate and appropriate Organic coatings shall be tested for cure in accordance with procedures detailed in AS/NZS 3894. this simple test requires an “X” (with the intersecting cut at approximately 30o) to be cut using a sharp Stanley blade through to the substrate. the cross hatch is 11 cuts 1mm apart.5. DOCS 826860v6 22 . The adhesive test results shall be graded and recorded as detailed in AS1580. 6 cuts. Coatings less than 50 microns. the cross hatch method is required. The adhesive test described in AS1580 Method 408. Discolouration of the test rag shall be considered evidence of insufficient cure. The areas tested shall be representative of the total coated section. HB Epoxy and Topcoats – 3MPa (435PSI) • System of . cracks. Any repairs/areas that fail a retest shall be removed and reinstated (at the discretion of the Principal or its representative) in accordance with section 10. shall be repaired and retested allowing sufficient cure periods between testing. Any discontinuity’s identified. or where the defective area is equal to 20% or more of the total coated surface. buried or marine conditions (definitions of a marine environment are a category D or E as described in AS 2312) shall be tested using an Elcometer High/Low Voltage Holiday Detector device or approved similar.0 of this specification. Defective coating shall be removed and be reinstated in accordance with this Specification at no cost to CBH. blisters. shall be rejected outright. foreign inclusions and rogue profile peaks shall be marked for repair and retested upon full cure of the repair coating. voids.2.8 Holiday Testing All coatings exposed to immersion.1/ AS/NZS 3894. DOCS 826860v6 23 . Test voltages and procedures shall be in accordance with AS/NZS 3894. Coatings with 5 or more defects per 5m2 section. Defects such as pinholes.TS4 – Project and Maintenance Coating 9. All repaired areas and repair procedures shall be clearly detailed in the Contractor’s Daily Paint Reports.1 All paint delivered to site for touch-up works shall be in the original sealed containers. Maintenance Coating Repair Procedure 10. then high pressure washing will continue until the concentrations of containments fall below the required threshold. The final DFT’s shall be included in the Contractors Daily Paint Reports. grinding. The surface shall be tested to the manufactures requirements for the new coating. All areas to be repaired shall be taken back to bare metal using abrasive blast or hand tool preparation to a standard required by the coating manufacturer of the coating being applied.5 The required coating DFT’s shall be achieved according to the manufacturer’s specification. power wire brushing.2 As a general rule. Epoxy Zinc Rich may only be used for small areas with CBH approval.3 Unless approved by CBH. Surface preparation shall extend 50 mm over each coat in the coating system to feather and expose the sub-coating. 10. DOCS 826860v6 24 . The coating manufacturer’s specific repair procedures shall be adopted where the maximum re-coat period has expired. properly labelled with the name of the manufacturer and the description of the contents. SB Inorganic Zinc Rich Ethyl Silicate coatings shall be repaired as per manufacturer’s recommendations. sanding or needle gun shall 2 not be acceptable for the spot repair of defective surfaces exceeding 0. Should the threshold values be exceeded. The new coating shall be applied according to the manufacturer’s specification.TS4 – Project and Maintenance Coating 10. 10. 10. coating repairs shall be performed using the specified surface preparation and coating system. No hard line shall be present where the new coating meets existing coating. All surfaces in the repair area (base metal exposed. feathered areas or lightly abraded/whip blasted) shall be high pressure cleaned with potable water to remove any deposited or entrapped contaminants.5m . Paint shall be stored in accordance with the coating manufacturer’s instructions. humid (85%) or windy conditions or in the presence of water spray or any other potential contaminants.4 Surface preparation on site shall not be carried out in wet or excessively hot. All existing sound coatings shall be lightly abraded to remove any surface contamination and to provide adequate anchor for the new coating to sufficiently adhere too. 10. Personal safety equipment guidelines shall be strictly observed. 12. 12. lost time or near miss incidents shall be reported to CBH. cranage.4 Personal Protective Equipment such as protective clothing. 12. scaffolding.2 All safety.1 All steelwork and equipment that has been finished coated shall be handled with care so as to preserve the coating in the best possible condition.5 Material Safety Data Sheets for all materials used shall be readily available at the work Site for quick reference.1 All Contractor personnel performing work on Site are required to satisfactorily attend the CBH Site Safety Course and shall observe all Site safety rules while on Site (refer CBH General Safety Rules Handbook). 12. DOCS 826860v6 o 25 . 12. as appropriate.7 Work areas shall be suitably roped off or isolated and clearly marked “Abrasive Blasting in Progress” or “Painting in Progress”. 12.3 Contractor and Sub-Contractor supplied equipment or services such as. Failure to report safety incidents may. 12. 12. hearing protection. Dead-man devices shall be correctly fitted and operational on all abrasive blasting equipment used on site.TS4 – Project and Maintenance Coating 11. Handling & Transport 11. respiratory equipment and skin protection shall be supplied by the Contractor. access equipment. but not limited to. safety boots. result in the termination of the Contract.6 Abrasive blast cleaning shall be performed in accordance with the current statutory regulations and requirements. Eye wash solution must be available at the work site. including loading. safety glasses. When directed by CBH the Contractor shall provide a Job Safety Analysis (JSA) to be approved by CBH before the commencement of any work.2 All steelwork and equipment shall be adequately protected and prepared for transport. at the discretion of CBH. pressure vessels. Steelwork shall not be handled until the coating has completely cured and dried hard. electric and pneumatic equipment shall conform to all the appropriate statutory regulations. Material such as soft slings and soft protective wrapping is to be used. Safe Work Practices on site 12. 11. safety helmets. protected from securing methods and protected while unloading.8 All coatings and thinners shall be stored below 30 C in a well ventilated and safe storage container appropriately signed and away from any ignition source. All equipment used on Site shall be maintained in good working order in strict accordance with the Coating manufacturer’s guidelines and be fit for purpose. DOCS 826860v6 26 . Personnel working on elevated work platforms (EWP) or using height safety equipment shall be appropriately trained and certified. 12. Airless spray pump motors shall be fitted with an effective earthing cable. Sentries are required for all Confined Space Entry and all personnel are to be certified in Confined Space. 12.10 Safety harnesses and appropriate height safety equipment shall be utilised at all elevated work sites not scaffolded to statutory regulation standards.9 Abrasive blast hoses and airless spray lines shall be capable of conducting static electricity to earth. the Contractor shall provide and understand the use of equipment used to monitor air quality. The exhausting equipment shall be of sufficient capacity to ensure the solvent vapour/air concentration does not reach the Lower Explosive Limit value. When applying coatings in confined areas.TS4 – Project and Maintenance Coating 12.11 Effective exhaust fans shall be used when applying coatings in confined spaces.