Protective Coating Standard Pcs 100 Acp0166

7/31/2019 Protective Coating Standard Pcs 100 Acp0166

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WARNING Document current at time of printing or downloading

BMIS Document Number: ACP0166 Issue: 01 Date: 23 December 2010Document Owner: Policy Standards & Materials Manager Page 1 of 80

Standard Specification

PCS 100

PROTECTIVE COATING STANDARD


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SYDNEY WATER



Table of Contents

A. INTRODUCTION.................................................................................................................5A.1. Purpose and Scope......................................................................................................5A.2. Disclaimer.....................................................................................................................5 A.3. Document Structure .....................................................................................................5A.4. Mandatory and Informative...........................................................................................5A.5. Use of the Document....................................................................................................6

A.5.1. Design ...................................................................................................................6A.5.2. Construction ..........................................................................................................6A.5.3. Testing ..................................................................................................................6

A.6. Referenced Documents................................................................................................6A.7. Definitions.....................................................................................................................7

B. GENERAL REQUIREMENTS..............................................................................................9B.1. Quality Assurance ........................................................................................................9

B.1.1.

Quality System......................................................................................................9

B.1.2. Suppliers Specification .........................................................................................9B.1.3. Approved Applicators ............................................................................................9B.1.4. Materials................................................................................................................9

B.2. Surface Preparation ...................................................................................................12B.2.1. General ...............................................................................................................12B.2.2. Mild Steel, Cast Iron and Ductile Iron..................................................................12B.2.3. Galvanized Steel, Stainless Steel, Aluminium, and Copper ................................ 12B.2.4. Plastics and FRP.................................................................................................13B.2.5. Concrete and Masonry........................................................................................13B.2.6. Existing Coatings ................................................................................................14B.2.7. Pre-coated Proprietary Equipment ......................................................................15B.2.8. Rectification of Metal Defects..............................................................................15B.2.9. Pre-Cleaning .......................................................................................................15B.2.10. Abrasive Blast Cleaning...................................................................................15B.2.11. Brush Blasting .................................................................................................16B.2.12. Hand or Power Tool Cleaning..........................................................................17B.2.13. Sealing for Reservoirs with Concrete Base .....................................................17

B.3. Coating Application ....................................................................................................18B.3.1. Application Constraints........................................................................................18B.3.2. Additional Constraints for Application of Concrete Surface.................................19B.3.3. Ventilation and Dehumidification.........................................................................19B.3.4. Mixing..................................................................................................................19B.3.5. Film Thickness ....................................................................................................19B.3.6. Edge Coating and Stripe Coats...........................................................................20B.3.7. Crevices and Gaps..............................................................................................20B.3.8. Repair of Defects in New Coatings .....................................................................21

B.4. Inspection and Testing ...............................................................................................22B.4.1. Inspection and Test Plan (ITP)............................................................................22B.4.2. Coating Inspector ................................................................................................22B.4.3. Quality Control Records ......................................................................................22B.4.4. Quality Control Testing........................................................................................23

B.5. Health and Safety.......................................................................................................27B.5.1. General ...............................................................................................................27B.5.2. Handling Of Chemicals........................................................................................27


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B.5.3. Pressure Equipment............................................................................................27B.5.4. Earthing...............................................................................................................27B.5.5. PPE and Ventilation ............................................................................................28B.5.6. Access.................................................................................................................28

B.6. Environmental Protection ...........................................................................................29B.6.1. General ...............................................................................................................29B.6.2. Lead Paint ...........................................................................................................29B.6.3. Containment........................................................................................................29B.6.4. External Surfaces................................................................................................30B.6.5. Internal Surfaces .................................................................................................30B.6.6. Assessing Emissions...........................................................................................30

C. PROTECTIVE COATING SYSTEM SELECTION..........................................................32C.1. Introduction.................................................................................................................32 C.2. Maintenance Painting.................................................................................................32C.3. Recommended Coating Systems............................................................................... 34

C.3.1. Water Reservoirs and Pipelines..........................................................................35C.3.2. Sewage Pumping Stations and Water Pumping Stations....................................36C.3.3. Sewage Treatment Plants and Water Filtration Plants........................................37

C.4. Environment Exposure Class.....................................................................................39C.5. Default Colours...........................................................................................................40

D. COATING SYSTEM SPECIFICATIONS........................................................................ 42D.1. Summary Descriptions ...............................................................................................42CS-01....................................................................................................................................45 CS-02....................................................................................................................................46 CS-03....................................................................................................................................47 CS-04....................................................................................................................................48 CS-05....................................................................................................................................49 CS-06....................................................................................................................................50 CS-07....................................................................................................................................51 CS-08....................................................................................................................................52 CS-09....................................................................................................................................53 CS-10....................................................................................................................................54 CS-11....................................................................................................................................55 CS-12....................................................................................................................................56 CS-13....................................................................................................................................57 CS-14....................................................................................................................................58 CS-15....................................................................................................................................59 CS-16....................................................................................................................................60

CS-17....................................................................................................................................61 CS-18....................................................................................................................................62 VES ......................................................................................................................................63NOV......................................................................................................................................64GAL ......................................................................................................................................65TSZ.......................................................................................................................................66PMB......................................................................................................................................67EPM......................................................................................................................................68CPL.......................................................................................................................................69CAC......................................................................................................................................70

E. APPROVED COATING PRODUCTS ................................................................................72F. ADDITIONAL INFORMATION (Informative)......................................................................76F.1. General guideline for selection of coatings.................................................................76


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F.2. Examples of asset types ............................................................................................78F.2.1. Assets that may require higher protection...........................................................78F.2.2. Assets that may require lower protection ............................................................78

F.3. Chemicals corrosivity .................................................................................................79


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A. INTRODUCTION

A.1. Purpose and Scope

This Document sets out the standard protective coating requirements to ensure high qualitylevel of workmanship and long-term protective coating performance is achieved. It applies toconstruction and maintenance of Sydney Waters drinking water, wastewater, stormwater, andrecycled water infrastructures and associated equipment.

This Standard shall be used in conjunction with all technical documents provided by theSupplier of the coatings to be used. This document also refers to, and shall be used inconjunction with, relevant Australian Standards (AS), Australian/New Zealand Standards(AS/NZS), and other international standards. Together they form an integrated specificationthat must be adhered to by the Applicator. If there are any contradictory recommendations orrequirements between the documents, then it shall be referred to the Principal (Sydney Water).

A.2. Disclaimer

Sydney Water develops and publishes this Document only for the purpose and scope statedabove and on the understanding that:

Sydney Water Corporation and individual contributors are not responsible for the resultsof any action taken on the basis of information in this Document, nor any errors oromissions;

Sydney Water Corporation and individual contributors disclaim all and any liability to anyperson in respect of anything, and the consequences of anything, done or omitted to be

done by a person in reliance upon the whole or any part of this Document; This Document does not purport to be a comprehensive statement and analysis of its

subjective matter, and if further advice is required, the services of a competentprofessional should be sought; and

Sydney Water Corporation reserves the right to make any changes to the content of theDocument without giving notice or explanation.

A.3. Document Structure

This Standard comprises of:

Section A: Introduction Section B: General requirements Section C: Selection of coating system Section D: Specifications of coating system Section E: Approved coating products Section F: Additional information

A.4. Mandatory and Informative

This document provides a mixture of mandatory and informative statements. They aredeliberately combined throughout the document in order to provide relevant context and enablebetter understanding of the mandatory requirements.


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Where an obligation is given and it is not stated who is to undertake these obligations, they areto be undertaken by the Applicator. Where a submission, request or proposal is required and itis not stated who the recipient shall be, it is to be provided by the Applicator to Sydney Water(Principal) for approval.

The use of this Standard does not relieve Supplier and Applicators of any responsibility fordelivering the quality level of design, materials, workmanship, and performance, that they havebeen engaged to provide.

A.5. Use of the Document

The following scenario illustrates a typical use of the document.

A.5.1. Design

The Designer or Project Manager uses this document, in particular Section C (Selection of

coating system) and Section D (Specifications of coating system), as input for designSpecification and/or Drawings.

A.5.2. Construction

The Applicator is engaged to apply the specified protective coatings in the design Specificationand/or Drawings. The Applicator must follow the methodology specified in this document(Section B) and use approved materials and products only (Section E), and other sectionsreferred by the Designer or Project Manager.

A.5.3. TestingCoating inspector(s) work under Applicator or Project Manager should refer to Clause B.4.

A.6. Referenced Documents

AS/NZS 1345 Identification of the contents of pipingAS 1627.1 Surface Preparation DegreasingAS 1627.4 Surface Preparation - Abrasive Blast CleaningAS 1627.9 Pictorial surface preparation standards for painting steel

surfaces

AS/NZS 1715 Selection, use and maintenance of respiratory protectiveequipmentAS/NZS 1716 Respiratory protective devicesAS/NZS 2310 Glossary of paint and painting termsAS 2700 Australian Standard Colour CodeAS 3894.1 Site Testing of Protective Coatings

Continuity Testing - High Voltage (brush) MethodAS 3894.3 Site Testing of Protective Coatings

Determination of film thicknessAS 3894.4 Site Testing of Protective Coatings

Degree of cure

AS 3894.5 Site Testing of Protective CoatingsDetermination of surface profile


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AS 3894.6 Site Testing of Protective CoatingsContamination

AS 3894.7 Site Testing of Protective CoatingsDetermination of Surface Temperature

AS 3894.9 Site Testing of Protective Coatings

Determination of AdhesionAS 3894.10 Site Testing of Protective Coatings

Inspection Report - Daily surface and ambient conditionsAS 3894.11 Site Testing of Protective Coatings

Inspection Report EquipmentAS 3894.12 Site Testing of Protective Coatings

Inspection Report CoatingAS/NZS 4020 Testing of products for use in contact with drinking waterAS/NZS 4158 Thermal-bonded polymeric coatings on valves and fittings

for water industry purposesAS 4361.1 Guide to lead paint management - Industrial applications

AS/NZS 4680 Hot dip galvanised (zinc) coatings on fabricated ferrousarticles

ASTM D4263 Standard Test Method for Indicating Moisture in Concrete bythe Plastic Sheet Method

A.7. Definitions

Refer to AS/NZS 2310 for a glossary of paint and painting terms which may be used in thisdocument.

The following definitions apply to this Specification:

Steel or steelwork Refers to all ferrous-based components includingcarbon steel, wrought-iron, cast iron and galvanizedcomponents.

Dry film thickness (DFT) The dry film thickness of a coating remaining on thesurface and above the peaks of the surface profilewhen the coating or system has hardened and cured.

Nominal dry film thickness (NDFT) The dry film thickness specified for each coating layeror for the whole coating system.

Minimum dry film thickness The minimum acceptable dry film thickness for eachcoating layer or for the whole coating system.

Maximum dry film thickness The highest acceptable dry film thickness for eachcoating layer or for the whole coating system abovewhich the performance of the coating layer or systemcould be impaired.

Gauge reading A single DFT reading taken at one point.


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Spot measurement The arithmetic average of three gauge readings madewithin a circle of approximately 40 mm diameter.


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B. GENERAL REQUIREMENTSThis section contains general requirements covering methods of surface preparation andcoating application, inspection and testing, quality control, quality assurance, health and safetyand environment protection.

B.1. Quality Assurance

B.1.1. Quality System

The Applicator shall develop and implement a Quality Management System for the works. In allcases, this is to involve preparing ITPs (Inspection and Test Plans) for each coating system tobe used and the provision of a suitable system of Quality Control (QC) records.

B.1.2. Suppliers Specification

A written specification or coating schedule from the Supplier prior to the commencement of thework shall be submitted for each coating system. It must contain the requirements for thesupply, storage, mixing, equipment, surface preparation, application, recoat times, curing,inspection, testing and repair of defects.

B.1.3. Approved Applicators

Surface preparation and coating application shall be undertaken by a pre-qualified paintingcontractor (Applicator). The Applicator shall be accredited by the Painting ContractorsCertification Program (PCCP) to the class relevant to the work to be undertaken. Where the

work involves the maintenance or removal of coatings which contain or may contain leadcompounds or other toxic substances, such work shall only be undertaken by a pre-qualifiedApplicator holding a PCCP Class 5 certificate.

It should be noted that there are some products specified herein that may be applied by a non-PCCP accredited Applicator. These products are typically linings for concrete and masonrystructures. They include polymer modified mortars and bitumen, aluminate cements, andgeosynthetics. For this work, the Applicator shall demonstrate that its personnel havesuccessful track records in applying the nominated product.

If the Supplier requires that the application of its products be undertaken only by an applicator

that has been approved by the Supplier, then the Applicator shall be a Supplier-approved one.

B.1.4. Materials

a) Protective Coatings

A list of approved protective coating products can be found in Appendix E. These coatingshave been assessed to:

have satisfactory long-term track records;

originate from quality assured manufacturers and/or suppliers;

be part of a global product range; and

have relevant certifications issued by Australian Paint Approval Scheme (APAS), whereavailable. Note that preference should be given to coatings approved by APAS.


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APAS approved coating products are preferred by Sydney Water. If the listed APAS approvedproducts are not available, then non-APAS approved products may be used.

In the case of all listed products are not available, other products that can be demonstrated tohave at least equal performance to the ones specified in the list may be used, subject to prior

approval from the Sydney Water.

Where available, all products used within a selected coating system should originate from asingle supplier. Importantly, they must be compatible with each other and applied strictly inaccordance with this Standard and the Suppliers specification.

Sydney Water reserves the right to make any changes to the content of the list without givingnotice or explanation.

b) Thinners

For each of the coating products, use only the specific thinner recommended by the Supplierfor thinning of coating. Thinners shall not be decanted into previously used containers and alldrums and cans are to have their original and traceable batch number.

Solvents that are specified only for the cleaning of equipment shall not be used to thin anycoating material. Prior to application of coating, all cleaning solvents shall be removed andflushed from the equipment.

c) Transportation and Storage

All products brought to site must be in their original unopened containers, bearing themanufacturers label, batch number, product code(s), coating colour, mix ratio information andexpiry date where applicable. Products that have exceeded their expiry date or havedeteriorated during storage shall not be used.

All products are to be stored under cover and in a manner that ensures protection fromextremes of temperature, contact with moisture or other conditions that could lead todeterioration of the material. Lids on solvent drums or cans must be kept closed when not inuse to prevent contamination with water or other materials. Coatings about to be used shall bewithin a temperature range that meets the Suppliers recommendations. If no recommendationsare provided, the temperature of all components shall be between 15C and 25C at the time ofmixing.

d) Coatings in Contact with Drinking Water

Any coating in contact with drinking water shall be certified to comply with AS/NZS 4020 by aNATA accredited laboratory. Overseas products that have ANSI/NSF 61 or BS 6920certificates may be approved for use, if it can be demonstrated that the Supplier is in theprocess of obtaining AS/NZS 4020 certification.

For the purposes of this specification, drinking water is assumed to include water at any stageof the treatment and delivery processes, and not just the final product. These coatings includethose that are immersed in drinking water, frequently splashed, and where condensation

occurs, hence subsequently the water enters the drinking water system.


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Attention must be given to the ratio of surface area to volume. The specified ratio of surfacearea to volume in the test certificate must be equal or greater than the actual structure ratio ofsurface area to volume.

e) Cathodic Protection System Compatibility

Where the coatings are nominated for structures that have cathodic protection (CP) system, acertificate of suitability from the Supplier shall be provided.


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B.2. Surface Preparation

The following clauses in this section contain requirements for surface preparation according tosubstrate materials and approved methods.

B.2.1. General

The surface preparation method or combination of methods shall be selected taking intoaccount the condition of the structure, the potential contaminants present, access to performthe work, and the required surface cleanliness and profile.

Where possible for new construction, all preparation and the application of the first coat shouldbe performed off site in a suitable enclosed workshop or otherwise in controlled conditions.

To avoid excessive damage and repair to pre-primed or pre-coated surfaces, wherever

possible, rolling, forming and fabrication operations shall be completed prior to the surfacepreparation and coating application.

Prior to blast cleaning in order to achieve the required surface cleanliness and profile, anydefects shall be repaired and all surfaces shall be pre-cleaned.

B.2.2. Mild Steel, Cast Iron and Ductile Iron

All mild steel, cast iron and ductile iron surfaces shall have an angular surface profile of 30 60 microns and a minimum Class 2 (Sa 2) finish in accordance with AS 1627.4, unlessotherwise stated in the relevant coating table in Section D.

All systems for immersion shall have a Class 3 (Sa 3) cleanliness standard, also with anangular surface profile of 30 60 microns. Where hot metal spray (aluminium, zinc/aluminiumor zinc) is to be used, the surface shall be blast cleaned to a Class 3 (Sa 3) standard with asharp, angular surface profile of 75 125 microns.

B.2.3. Galvanized Steel, Stainless Steel, Aluminium, and Copper

The surface of these non-ferrous metals shall be lightly abraded using hand or power tools, orbrush blasted at low pressure in order to achieve a surface finish equivalent to Class 2. Whilethe descriptions in AS 1627.4 and AS 1627.9 refer specifically to mild steel surfaces, and as

such, will not be directly indicative of the appearance of other metallic surfaces, efforts shall bemade to achieve a similar visual degree of surface cleanliness.

The surface profile of the non-ferrous substrate shall be 20 microns or less. This is typicallyvisually indicated in the form of a matte finish (not glossy).

Galvanized steel shall not be blasted back to the steel surface, rather, the thickness of theremaining zinc layer shall be maximised, while still achieving the required level of surfacepreparation. Where galvanizing has been damaged or corroded back to bare steel, it shall berepaired using appropriate system.


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B.2.4. Plastics and FRP

The surface shall be lightly hand or power tool abraded, or low pressure brush blasted toremove all visible gloss from the surface. The surface profile shall not exceed 20 microns.

B.2.5. Concrete and Masonrya) New Concrete

All new concrete works shall be cured to a minimum 28 days before application of coatings,unless otherwise approved. Any foreign materials such as oils, grease, waxes, form releaseagents, curing compounds, efflorescence, sealers, salts, laitance, or other contaminants shallbe effectively removed.

Abrasive blasting should be used to prepare the surfaces. All debris shall be removed followingthe cleaning and disposed of in an appropriate waste facility. Acid etching may only be used forhorizontal surfaces only. The concentration of HCl solution used for acid etching shall not

exceed 10%. The etched surface shall be adequately washed with fresh water to remove anyresidual acid. This is indicated when the water used for washing has reached around pH 7. Theconcrete surface finish shall be sufficiently rough to receive the coating. Typically it isequivalent to sandpaper with grit 80 or coarser.

Level or grind concrete substrates to manufacturer's recommended tolerances and to producea textured but uniform installation, including removal of all sharp edges, ridges or depressions.New concrete voids and depressions shall be filled with render/filler material, re-establishingplan finished grades and surface profiles

Cementitious rendering products shall be used for surface levelling, filling voids, large

bugholes, and for general concrete patching and shall be installed and cured according tomanufacturers guidelines. Polymer modified filler and repair products shall be used for fillingand repairing small bugholes, static cracks and joints, and for general concrete patching inorder to provide uniform and void free surface for coating application.

b) Old Concrete

Any drummy or delaminated concrete sections, or concrete deteriorated by corrosion or othermeans, shall be broken out and removed so that sound substrate remains. Sound concreteshall have pH 10 or greater. This may be indicated using a phenolphthalein solution spray.

All oil, grease and chemical contaminants must be removed from the surface of concrete.Concrete surrounding any corroded reinforcement bars shall be broken out beyond the limits ofcorrosion until clean bar is evident, and at least 20 mm behind the bar. Where there is apotential for excessive removal of substrate material, or the reinforcement bar has more thansurface corrosion, a direction from the Principal shall be sought. Any exposed reinforcementshall be primed with zinc rich coating, and fully embedded without any air pockets beingentrapped. The surface shall be steel trowelled, and its profile shall be made to achieveoptimum bond with the protective coating.

The broken out voids and lost concrete sections shall be restored back to the original surfacelevel using a suitable patch repair mortar. Feathered edges shall be avoided by saw cutting to

a minimum depth of 10 mm at the edges of the area to be patched.


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Static cracks wider than 0.3 mm shall be repaired. The path along the crack shall be chasedforming a wedge-shaped slot of 20 mm wide x 20 mm deep. The slot is then filled with polymermodified repair mortar. The surface shall be struck flush with the cleaned concrete adjacent tothe crack. Any active crack shall be treated as a joint, and repaired using a waterproof jointsealant system. Any infiltration at the crack shall be stopped first prior to undertaking crack

repair.

c) Masonry

All oil, grease and chemical contaminants must be removed from the brick by chemicalcleaning, hydroblast or abrasive blast to provide anchor profile on brickwork and to remove allexisting paints, protective coatings, foreign particles, chemically attacked or unsound mortar.Loose brickwork and voids in the mortar joints should be re-pointed. All active hydrostatic leaksmust be stopped prior to protective coating application.

B.2.6. Existing Coatings

All existing coatings shall be first visually inspected for damage and tested for adhesion usingAS 3894.9 Method A (Knife Test). A result of 0 to 2 on the scale provided in the standard isrequired. In areas where damage is present, or test results indicate an adhesion rating ofgreater than 2, the existing coating shall be fully removed to bare substrate and the surfaceshall be prepared for the application of new coating using the requirements detailed herein.

If a large proportion of the existing coating is unsound, then removal of the entire existingcoating shall be considered. In addition, it may be necessary to remove the existing coatingwhen the combined system of existing and new coatings is not compatible with each other, orwould become too thick.

Where existing coating is in an exterior environment and is intended to be left principally intactby being either spot repaired, spot repaired and fully coated, or fully recoated; all surfaces areto be jetwashed clean using fresh water at a nozzle pressure of greater than 14 MPa (2000 psi)and less than 34 MPa (5000 psi).

All sharp edges of the remaining sound coating shall be feathered, tapered or smoothed-off toan appropriate degree based on the accessibility and visibility of the coated surface. Excessiveeffort and input to feathered zones should be avoided. They could compromise the integrity ofthe existing coating system in the transition zone due to heating during sanding or grinding.Any bare areas shall be spot primed.

All coated surfaces with intact, glossy and sound coating shall be lightly abraded to remove allvisible gloss before overcoating, unless the subsequent coating layer is tolerant of thiscondition.

The paint manufacturer shall be consulted when choosing a suitable primer product for any application

onto previous coatings. Where the compatibility between the old and new coating system isunknown, the new coating system shall be applied to a small area, and allowed to fully cure. Amethod for performing and evaluating a patch test to assess coating compatibility is detailed inASTM 5064. The adhesion of the new coating system shall then be determined as described inClause 4.4(2).


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B.2.7. Pre-coated Proprietary Equipment

Equipment supplied pre-coated with the manufacturers factory coating system may beaccepted providing the performance of the existing coating system and the level of surfacepreparation can be demonstrated as being equal to or greater than the relevant systemspecified in this document. If the existing coating does not meet the requirements of thisspecification, the existing coating system on the item shall be fully replaced or upgraded by therelevant system.

Care shall be exercised to protect bearings, windings and all operational parts fromcontamination and damage when applying new paint system.

Where the compatibility between the existing and new coating system is unknown, the newcoating system shall be applied to a small area, and allowed to fully cure. A method forperforming and evaluating a patch test to assess coating compatibility is detailed inASTM 5064. The adhesion of the new coating system shall then be determined as described in

Clause 4.4(2).

B.2.8. Rectification of Metal Defects

Prior to preparing the surface to the specified degree of cleanliness and surface profilerequired, the Applicator shall ensure the surface is free of all metal defects including but notrestricted to

Cracks Porosity Deep pitting

Burrs Weld splatter Undercuts

Sharp edges Fins Slag

Coarse welds Laminations Weld roughness

Sharp edges, bolt holes and corners, including sharp edges resulting from loss of section shallbe ground to a minimum radius of 2 mm to meet the requirements of Preparation Grade P2 asdefined in ISO 8501.3. Welds shall be ground to a smooth surface free of peaks and sharpedges to a degree where they are paintable.

Where galvanizing has been welded or otherwise damaged, the damaged areas should beground down, taking care to feather or taper edges.

B.2.9. Pre-Cleaning

All pre-cleaning processes shall be carried out in accordance with AS 1627.1 to remove oil,grease, dirt, bird droppings, algae, moss, etc.

For heavy deposits of contaminants, it may be necessary to repeat pre-cleaning processes toachieve the required level of cleanliness or use a combination of processes.

B.2.10. Abrasive Blast Cleaning

The abrasive blast cleaning process shall be performed in accordance with AS1627.4.

For all on-site work, use either almandine garnet or staurolite abrasive for the final blast,regardless of whether the work is carried out in a weatherproof containment or not.


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Do not use copper slag and other mineral slag abrasives that may contain various forms ofheavy metals. Slag abrasives that are demonstrated to be free from heavy metals (less than100 ppm lead) may be used as an abrasive for initial blasting of heavy coating films, but in allcases, the final blast cleaning shall be performed using new (not recycled) garnet or staurolite.

Remove all inspirable dust, contaminants, surface preparation debris and toxic contaminantsfrom abrasives used as a blasting medium prior to their re-use in the blasting process. ThePrincipals approval must be sought before the re-use of any non-metallic abrasive.

Abrasives are to be analysed before first use or re-use and must comply with the following:

(a) Moisture content: Maximum 0.2% as determined in accordance with ANZECCMethod 102.

(b) Soluble salt: Maximum conductivity of aqueous extract, 250S/cm tested as per ISO11127-6.

(c) Water soluble chlorides: Maximum of 50 ppm tested as per ISO 11127-7.

(d) Total lead (Pb) content: Maximum of 100 mg/kg (ppm) tested as per US EPA Method6010B.

(e) Free crystalline silica: Maximum of 1% as determined by infrared spectroscopy orXRD analysis.

(f) Free clay or fine silt: Maximum of 1% when tested to AS 1141.33.

Blasting abrasive shall be non-metallic, dry, clean, sharp and angular, free from contaminants,and of a type and size adequate to give the relevant surface profile amplitude and an angular

profile shape. Recycling of abrasives contaminated with bitumen, coal tars, oil or grease is notpermitted.

A suitable containment must be used to prevent the spread of emissions. A vacuum blastingsystem may be used as an alternative to prevent the spread of emissions. Dust and spoil shallbe removed from the surface immediately prior to coating or recoating by blowing with clean,dry air followed by either vacuum cleaning or careful brushing. All horizontal surfaces, e.g.,tank bottom plates, ledges, etc., must be vacuum cleaned before coating. Vertical or overheadsurfaces can be blown down with compressed air. Where nominated in the specification or theITP, tests for the presence of dust on the prepared steel surface shall be conducted inaccordance with AS 3894.6, Method C, Determination of surface dust. A rating of 2 or better is

required for atmospheric service, and a Rating 1 or better for immersion service.

The prepared surface must be coated before any contamination or corrosion occurs. Flashrusting typically occurs within four hours of blasting, unless dehumidification is provided. In allcases, the specified standard of surface cleanliness and surface profile height and shape, mustexist at the time the primer is applied to any surface area.

B.2.11. Brush Blasting

Abrasive brush blasting (sweep blasting) shall be carried out in accordance with AS 1627.4 Appendix D, as well as all of the requirements for abrasive blast cleaning listed above.


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B.2.12. Hand or Power Tool Cleaning

In the event that abrasive blast cleaning is impractical and at the sole discretion of thePrincipal, surfaces may be mechanically cleaned using hand or power tools such as needleguns. All hand or power tool cleaning shall be carried out in accordance with AS 1627.2.

A suitable containment must be used to prevent the spread of emissions, such as drop sheetsand/or side tarps. Dust and spoil shall be removed from the surface immediately prior torecoating by blowing with clean, dry air followed by either vacuum cleaning or careful brushing.

The prepared surface shall be coated with primer before any contamination or corrosionoccurs.

B.2.13. Sealing for Reservoirs with Concrete Base

Where a reservoir has a concrete floor and is fitted with a haunch joint at the junction of thewall and the floor, a bitumen seal is to be prepared in the following manner:

1. Cut a Vee groove into the bitumen seal so as to remove sufficient seal to expose notless than 20 mm of the embedded wall surface.

2. Prepare and coat the newly exposed steel using the coating system specified for thewalls.

3. When the coating system has fully cured, reinstate the joint by refilling the Vee groovewith a hot applied bitumen sealant


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B.3. Coating Application

The section contains the requirements for application of coatings, and repair of damage to newcoatings.

Coating application shall be performed by competent and experienced personnel under closesupervision to ensure that coatings are not applied until the specified standard of surfacepreparation has been achieved, weather conditions are suitable for coating application andcuring, and the coating application and film thickness requirements are strictly followed.

The applied coating shall be uniform in thickness and appearance and shall be free of defectssuch as runs, blisters, pinholes, holidays, overspray, inclusions, etc.; using applicationequipment (or a combination of equipment), a sequence of coating various surfaces andtechniques that produce the required coverage, DFT, standard of finish and film integrity

implied by this Specification and the product data sheets for the coating products employed. Alloverspray shall be removed by sanding from the surface of primer or intermediate coats beforeovercoating commences.

The Contractor shall record all details of surface preparation, paint application, ambientweather conditions, and film thickness measurements on Daily Inspection Reports. As a guide,suitable forms are available in AS 3894.10 to 14.

Airborne dust, insects and other foreign matter that settles onto and is protruding from theprimer or intermediate coat surface shall be removed by sanding once the coating hassufficiently hardened.

Where more than one coating layer is to be applied, the colour of successive coats (includingstripe coats) shall be different to aid application and inspection.

B.3.1. Application Constraints

Unless overruled by the coating manufacturers product data sheet(s) or written instructions,the following limits of application and curing conditions are to apply:

Final surface preparation, coating application or initial coating curing (at least 12 hours) shallnot take place when:

(a) The relative humidity is above 85 percent; or

(b) The substrate temperature is less than 3C above the dewpoint; or

(c) The ambient air temperature is below 10C or above 30C; or

(d) The substrate temperature is below 10C or above 35C; or

(e) The surface to be coated is wet or damp; or

(f) Where the full prime coat application cannot be carried out before the specifiedcleanliness of the surface deteriorates.

Proper and effective control of the environment and conditions during the curing stage of allcoating layers are to be maintained.


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B.3.2. Additional Constraints for Application of Concrete Surface

Application in direct sunlight and/or with rising surface temperatures is strongly notrecommended, as this may result in blistering of the materials due to expansion of entrappedair or moisture (out-gassing) in the concrete. In such cases, it will be necessary to postpone theapplication until later in the day when the temperature of the substrate is falling. Concretesurfaces that have been in direct sunlight must be shaded for at least 24 hours prior toapplication and remain shaded until the initial set has taken place. Consult Manufacturer forapplication schedule guidelines specific to temperature conditions and possible sealerapplication recommendations to reduce out-gassing.

B.3.3. Ventilation and Dehumidification

If surface preparation and coating application is performed inside containments or on theinteriors of enclosed areas, a mechanical ventilation system must operate during all applicationto improve visibility, lower the OH&S risk to operators, and assist in removing the desorbedsolvent. After application and during the curing phase (typically overnight), a mechanicalventilation system will still be required to ventilate the containment for a period up to at least 24hours after the end of application, although this could operate at a lesser number of airchanges per hour during the curing period.

Dehumidification units and/or heaters that vary the relative humidity and control thetemperature may be required to prevent flash rusting and create optimum environmentalconditions during coating application and curing. All heaters must be indirectly fired, i.e., nocombustion products are to come into contact with the coating system or the ambient air in thecontainment. When using such equipment to vary coating application conditions, theequipment must be used during the whole time that work is being performed including the

recommended curing period after the last application of the coating.

B.3.4. Mixing

Two-pack coatings shall be thoroughly mixed using the whole contents of each container toensure the correct proportioning ratio has been maintained. Split or part packs shall not beused unless a reliable and repeatable method of proportioning the components is used.

Coating materials containing heavy or metallic pigments that have a tendency to settle shall bekept in suspension in the fluid pot by a power driven mechanical agitator. Other coatingmaterials shall be agitated as frequently as workability requires.

If the coating material requires the addition of a catalyst, the pot life for the prevailingconditions must not be exceeded. When the pot life limit is reached, the materials must bediscarded and all equipment cleaned.

B.3.5. Film Thickness

The Supplier should be consulted to determine if the dry film thickness (DFT) for a single coatcalled for by this specification is achievable. If the dry film thickness cannot be achieved in asingle coat, then multiple coats may be used, so long as the specified dry film thickness for thatcoating system is achieved. In all cases, the DFT specified is to prevail, not the number of

coats.

Where multi-coat systems are specified in this document, the condition of the coated surfaceshall be in accordance with this Specification and the Suppliers requirements prior to


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application of subsequent coats. The specified time between coats shall be calculated from theproduct data sheets at the prevailing temperatures, and strictly adhered to.

Application shall be carried out such that a smooth, uniformly coat within the correct filmthickness range is obtained. There shall be no deep or detrimental brush marks or adverse

spray patterns that could compromise the performance of the coating. Paint shall be workedinto all crevices and corners without causing overbuild.

The cured coatings shall be free of pinholes, voids, inclusions, bubbles, runs and sags.

B.3.6. Edge Coating and Stripe Coats

All areas such as external corners and edges, welds, bolts, nuts and interstices shall receive astripe coat prior to application of the specified film thickness and to ensure continuity of thecoating, except for the primer, which shall be stripe coated after the full coat has been applied.The stripe coat shall be allowed to touch dry prior to the next coating application.

Where specified, a separate additional stripe coat, having a colour distinctly different to theunderlying and subsequent coatings, is to be applied.

The purpose of the stripe coat is to ensure that the final DFT achieved on difficult-to-sprayareas will be between the minimum and maximum limits, but having excessive film build thatcould in itself be detrimental.

Where stripe coats are specified, they shall be applied to all shadowed and other difficult-to-spray areas such as:

edges,

welds, bolt heads,

nuts,

washers,

rivets,

unsealed and filled lap joints,

crevices formed by plates; exposed edges,

holes, and

heavily pitted areas,

before the application of each full coat, except for primers, where the stripe coat is to beapplied after the full coat is sprayed. Inorganic zinc silicate primers are generally not to bebrush-applied as stripe coats. Stripe coats shall be applied by brush, roller, spray or otherapplication method as applicable to the nature of the surface or structure.

If the combination of a prior-applied stripe coat and then a spray-applied full coat does notachieve the correct coverage and film build in all areas, additional touch-up effort will berequired to complete each layer to achieve the specified acceptance criteria before anysubsequent coating layers commence.

B.3.7. Crevices and Gaps

Unless specified otherwise, fill any crevices and gaps that are not filled following application ofthe primer and intermediate coats. The filler material shall be compatible two-pack, marine-grade solventless epoxy filler, approved by the Supplier.

As there is minimal corrosion protection afforded by the epoxy filler, it is not to be applied tobare or primed steel. The epoxy filler is to be applied after the first coat of epoxy high build, andis then to be sealed with a stripe coat of epoxy high build prior to the application of the balanceof the coating system.


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Fill gaps between back to back angles or other sections with an epoxy filler only at upwardfacing locations that have the potential to hold water and/or dirt such as at points of intersectionof slats in latticed members. Apply a stripe coat of the epoxy build coat paint and other paintsin the coating system to filled crevices and gaps prior to the application of the topcoat.

Unsealed joints without any principal gap in atmospheric service only, such as on crossedlattice slats, shall be filled using compatible caulking gun-grade polyurethane. This filler shallbe applied after the first coat of epoxy high build, be stripe coated and then topcoated.

B.3.8. Repair of Defects in New Coatings

Areas where inadequate coating thickness or pinholes have been detected, shall be repairedwith the following methodology.

1. Remove all loose and flaking coatings until a sound, tightly adhering edge is achieved;

2. Pre-clean the surface to ensure the surface is clean and free of oil, grease, dirt and allcontaminants;

3. Grind out or sand pinholes or minor faults sufficiently to ensure the repair coating willpenetrate and eliminate the defect;

4. Feather, taper or smooth-off all sharp edges of the remaining sound coating to anappropriate degree;

5. Lightly abrade the damaged surface with a hand or power tool, or sweep blast toremove visible gloss;

6. Remove all dust using a slightly solvent-wet rag; and

7. Reinstate the surface by re-applying the coating system over the affected area.


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B.4. Inspection and Testing

B.4.1. Inspection and Test Plan (ITP)Prior to commencement of the work, an ITP similar to the informative example in section E.3shall be prepared for each coating system and submitted for approval. The ITP must also showthe type, sequence, and number of tests to be taken in a given area and how the pass or rejectcriteria are determined.

B.4.2. Coating Inspector

A coatings inspector shall be nominated by the Applicator as their quality control officer to carryout inspections, to undertake the required testing and to make the appropriate records for allwork performed in accordance with this document.

The Applicators Coating Inspector shall be certified by either: Australasian Corrosion Association (ACA); Painting Contractors Certification Program (PCCP); NACE International; or Society of Protective Coatings (SSPC).

The Principal may instruct a representative or an independent coatings inspector to carry outquality audits on the work from time-to-time on behalf of Principal. Access to the site for thispurpose shall be provided at no cost to the Principal.

B.4.3. Quality Control Records

Quality Control (QC) records, in a format similar to AS 3894 Parts 10, 11 and 12 or equal,shall be prepared and submitted for approval on a daily basis during the work. They shallconsist of:

1. Inspection Report Daily Surface and Ambient Conditions Report (Refer toAS3894.10)

(a) Details of prevailing weather conditions and other matters potentially influencingthe durability of the applied coatings shall be recorded at regular intervals during

the application process. These shall include, but not be restricted to: surfacetemperature (measured in accordance with AS/NZS 3894.7), air temperature,dew point, relative humidity, the difference between the surface temperature andthe dewpoint and general weather observations.

(b) Details of the final standard of surface preparation. Any defects in the surface tobe painted shall also be recorded.

2. Equipment Report (Refer to AS 3894.11)

Details of all production and test equipment used during application and inspectionshall be recorded at the commencement of the work. Records shall be updated

whenever calibration, standardisation, or replacement of equipment occurs.


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3. Inspection Report Coating (Refer to AS 3894.12)

Details of all paints, coatings and their component parts including solvents andthinners used shall be recorded. The results of QC testing shall be recorded foreach stage of the work. All defects shall be recorded and subsequently repaired.

These records shall be made available for inspection upon request at any time during the workand a copy provided daily to the Principal. Upon completion of the work, a full copy of allrecords shall be submitted to the Principal, even if these have been previously supplied.

B.4.4. Quality Control Testing

The following tests shall be carried out for the protective coating of all items and the resultsshall be recorded in accordance with the requirements detailed above.

Defective work shall be marked with school grade chalk, self-adhesive inspection labels, ormasking tape. Wax crayons or other grease-based markers shall not be used.

1. Inspection of Defects

All surfaces, including previously and newly coated surfaces, shall be visuallyinspected for defects. The coating shall be free of lumps, bubbles, inclusions, ripples,sags, runs, air holes and other film faults.

2. Adhesion of Existing Coating

Prior to the commencement of any surface preparation or coating application, areasof existing coating that have not experienced visible symptoms of deterioration shallbe tested for the level of adhesion to the substrate. For substrates other thanconcrete, adhesion shall be determined in accordance with the requirements of AS3894.9 Method A (Knife test). For concrete substrates, tests shall be in accordancewith AS 3894.9 Method C (Pull-off test) using 50 mm diameter test stubs. The testsshall be carried out at the same frequency as that described in the standard.

Where the test result indicates an adhesion rating of greater than 2 for the Knife test,or bond strength of less than 1 MPa for the Pull-off test, the area of existing coatingrepresented by the test shall be completely removed to bare substrate, and thesurface shall be prepared for the application of new coating in accordance with therequirements detailed in this document.

3. Surface Cleanliness

Following pre-cleaning, the presence of residual amounts of soluble materials, oiland water, residual dust, mill scale, and other undesirable materials shall bedetermined in accordance with the requirements of AS 3894.6. Items which arehighly unlikely to be contaminated by certain materials do not require testing forthose substances, e.g., new steel items in the factory do not require testing forchloride.

Unless otherwise instructed, inspection or testing for the level of surfacecontamination shall be at a rate equal to one test per each 50 m2 of cleaned steel upto 200 m2, then one test per each subsequent 200 m2 up to the first 1,000 m2 andone test per each 500 m2 thereafter; all per structure. Sites for surface contaminantsinspection or testing are to be selected by, or agreed with, the Principal.


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Remove any dirt or soluble materials by jet washing using fresh, potable water andtest as per AS 3894.6, Method A. The maximum level of chloride shall be 7 g/cm2(micrograms per square centimetre). Do not use proprietary chloride extractionagents. Where the surface was blast cleaned, re-blast after salt testing.

4. Surface Appearance

After surface preparation is complete, the surface shall be visually inspected usingAS 1627.4 and AS 1627.9.

Abrasive blast cleaned surfaces are to be inspected to ascertain the degree ofsurface cleanliness that has been achieved. 100% of all surfaces are to beinspected, and the specified class is to exist in each square decimetre (100 mm by100 mm), not as an average of all areas.

The class of blast cleaning surface preparation grade specified is nominated in therelevant coating system in Section D.

Determinations of the class of blast that has been achieved are to be made undernatural light (where possible), by viewing the surface at right angles to the substrateand without magnification. The written descriptions of the various classes of blastcleaning contained in Appendix B of AS 1627.4 are to prevail. The writtendescriptions can be augmented with the pictorial representation contained inAS 1627.9.

The specified surface preparation standard in cleanliness, profile height and shape

is to exist in all respects at the time the primer is being applied.

For metallic substrates, two sets of coupons of the same material as the substrateshall be prepared at the commencement of works, to show the minimum standard ofsurface preparation to be achieved. Following approval, they may be used as on-siteQC Secondary Standards for both profile and the degree of surface cleanliness. Oneset of coupons would be retained by the Applicator, and one set by the Principal.

5. Surface Profile

Following abrasive blasting of metallic substrates, the surface profile amplitude shallbe determined using Methods A or B of AS 3894.5.

The profile shape or nature is to be angular and sharp, not peened or rounded, andfree from raised or folded hackles. The profile shape is generally more important tocoating performance than amplitude. The nature of the profile is to be ascertained inrepresentative areas by inspecting with an illuminated microscope or magnifier.

The amplitude of the surface profile (the average peak to valley depth) is to beassessed in accordance with Method A or Method B of AS 3894.5, and reported asper the designations provided in Table 1 of AS 3894.5. The achievement of thesurface profile shape and amplitude is to be recorded on the Daily Inspection Report.


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6. Temperature and Relative Humidity

Prior to coating application, the surface temperature, dew point, ambienttemperature, and relative humidity shall be measured and recorded once every fourhours of each shift. A calibrated psychrometer or electronic climatic measuringgauge shall be used to determine these readings.

The application of coatings shall not proceed when conditions are contrary to theSuppliers technical literature.

7. Moisture Content Concrete and Masonry Structures Below Water Table

Prior to coating application, the moisture content of concrete substrates shall betested using a moisture meter or qualitatively using the method described in ASTM D4263, which involves taping down a 450 mm by 450 mm piece of 75 to 150 micronthick polyethylene film for a period of 24 hours.

Coatings shall not be applied if any moisture is found on the backside of the film, or ifthe moisture content exceeds 4%.

8. Wet Film Thickness

A gauge for measuring wet film thickness shall be used during the application tominimise the possibility of low dry film thickness. The gauge shall be used andreadings recorded in accordance with Australian Standard AS 3894.3 Appendix C:Determination of wet film thickness by comb gauge.

9. Dry Film Thickness

After the application of coating layer or system for any given area, the dry filmthickness of the applied coating shall be determined in accordance with therequirements of AS 3894.3, except as modified herein. DFT gauges shall becalibrated and verified in accordance with the procedure established in Appendix Dof AS 3894.3 or as instructed by the equipment manufacturer. In all cases, only thecoating thickness above the peaks of the surface profile will count as achieved DFT.

A DFT Inspection Plan shall be prepared for each contiguous area, establishing thenumber, frequency and distribution of DFT readings to be taken according to theguidance provided in AS 3894.3. Usually, the surfaces to be measured are to bedivided into zones of about 10 m2 each.

Thickness determinations shall be taken at representative locations in accordancewith the Inspection Plan using spot measurements (as defined above) for eachdetermination.For most coating systems, a minimum DFT and a maximum DFT will be specified foreach coating layer and for the complete coating system. If they are not stated, thespecified thickness shall be the minimum.

The average DFT of spot measurements for each 10 m shall be between theminimum and maximum DFT. No single spot measurement shall be less than 80% of

the minimum DFT and more than 120% of the maximum DFT. Non-conforming areashall be investigated, reported, and repaired according to Clause B.3.7.


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10. Adhesion of New Coatings

At the completion of coating for any given area, the level of adhesion of the coatingto the substrate shall be determined as described in Clause B.4.4(2) above. Thenumber of tests shall be minimised so as to limit damage to the coating. All testlocations shall be repaired after the test, as described in Clause B.3.2, such that theyblend in with the surrounding areas. Subject to the Principals consent, test couponsmade from the same or similar substrate and sprayed at the same time and in thesame manner as the workpiece, can be used for destructive evaluations of adhesion.

11. Film Continuity

Continuity testing to determine the presence of holidays, pinholes, cracks and otherdiscontinuities shall only be undertaken on new lining or coating systems that arecured, are intended for immersion or underground service, and have not beenexposed to water or high relative humidity since being applied. Coating systems fornormal atmospheric exposure should not be continuity tested. Coating systems

containing potentially conductive pigments, e.g., metallic zinc or aluminium, shall notbe continuity tested.

All continuity testing shall be conducted in accordance with AS 3894.1, however forhigh build systems and/or where high volume solids coating materials are used, theSupplier shall be consulted to verify that the voltage suggested by the formulae inAS 3894.1 is appropriate for that coating. If the suggested test voltage is above theSuppliers recommendation, the lower voltage is to be used.

If the number of defects is greater than five and are spread randomly over an area ofnot less than 10 m, the Applicator shall repair in accordance with Clause B.3.7.

Where several defects fall within a circle of 100 mm radius, they shall collectively bedeemed to be a single defect. The entire area within the circumference shall then berepaired in accordance with the requirements in Clause B.3.2.

Film continuity testing may be carried out on the repaired area if requested by thePrincipal.

12. Degree of Cure

The degree of cure of a coating shall be determined using AS 3894.4 Method C.Full cure shall be achieved before the coating is placed in service, subjected to

continuity testing or adhesion testing.


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B.5. Health and Safety

B.5.1. GeneralAll works shall comply with relevant Sydney Water and legislative health and safetyrequirements.

The Applicator shall implement a Safety Management System specifically for industrial coatingapplication, which addresses the requirements of the following clauses.

B.5.2. Handling Of Chemicals

Material safety data sheets (MSDSs) of all products shall always be available for review duringtransport and at all times when the product is in use. Attention shall be paid to all warning

labels attached to the coating and/or related product containers, the MSDSs and the Suppliersrelevant technical literature. Copies of MSDSs shall be made available on-site, and proceduresshall be made to comply with all MSDS directions.

The Suppliers instructions for the safe handling of products shall be followed to minimise therisk of injury or creation of health hazards to personnel.

Handling of coatings, solvents and chemicals shall be carried out with due care and diligence.Personnel not directly concerned with coating operations shall be protected against the effectsof products used during surface preparation and coating application.

The correct use of personal protective equipment shall be employed during the surfacepreparation, coating material preparation and application and site clean up.

Disposal of chemicals must be treated with due regard to environmental protection, and shallbe in accordance with manufacturers guidelines and statutory requirements.

No Smoking and Flammable Liquid signs shall be displayed, and suitable fire fightingequipment shall be readily available at the work site.

B.5.3. Pressure Equipment

Details on how to operate all pressure equipment in a safe manner shall be made available torelevant personnel. The details must include the inspection method, and frequency ofinspection of such equipment. A mechanical restraint is to be used on all hose-to-hose and allhose-to-equipment connections to prevent injurious disengagement. All blast hose connectionsare to be pinned with a safety clip.

All associated connections to pressure equipment shall be regularly inspected, and wellmaintained.

B.5.4. Earthing

All coating application equipment, particularly spray and blast cleaning equipment, shall beearthed to eliminate any electrostatic charge.


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B.5.5. PPE and Ventilation

Health and safety instructions on the use of coatings and sealants printed on the MSDS andwarning labels shall be fully understood before any work is undertaken. All necessaryprotective equipment and clothing shall be provided for all personnel.

Appropriate air-fed masks shall be used during abrasive blasting and coating operations.Compressed air for breathing shall be supplied from an oil- and water-free source and be fittedwith a comprehensive monitoring and alarm system for the key air quality parameters. All airlines conveying air for breathing shall be diver-grade, be used only for that purpose and haveconnection fittings that are not compatible with air lines for other duties. Other personnel in thevicinity shall wear suitable protective masks or respirators when necessary. Suitable respiratorsshall be worn to protect operators from dust, fumes, and vapours, in compliance withAS/NZS 1715 and AS/NZS 1716.

First aid equipment, including eye wash bottles, shall be available at the work site. Eye wash

bottles shall be located at or near the material pump, mixing area, and paint storage point.

Adequate ventilation shall be provided in confined spaces. Appropriate personal protectiveequipment shall be used when entering confined spaces. When using air-fed masks in theseareas, attention shall be paid to the possibility of explosive vapour build-up. Sufficient extractorfans shall be employed to ensure that airborne dust, rust, and vapours are withdrawn from anyconfined space during abrasive blasting, solvent cleaning, and coating operations.

B.5.6. Access

Scaffolding, platforms, lifts, or floating stages must only be erected and operated by licensed or

qualified personnel. The appropriate tagging system, as stipulated by the relevant authorities,shall be employed and clearly displayed. Adequate warning notices shall be posted whereoverhead work is in progress.

Personnel entering confined spaces shall have a valid working in confined spaces licenceissued by an authorised training body. Safety harnesses, standby personnel, and any otherappropriate safety precautions detailed in AS 2865 and/or the NSW WorkCover Code ofPractice for Confined Spaces shall be utilised. A robust written system for recording personnelentering and exiting from confined spaces must be in operation for all work in or adjacent toconfined spaces.


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B.6. Environmental Protection

This section outlines the responsible management and minimisation of all emissions and debris

generated during surface preparation and paint application processes, and the collection anddisposal of all wastes in an acceptable manner.

B.6.1. General

All works shall comply with relevant national, state, and local legislation concerning thepreparation and coating of surfaces.

The Applicator shall refer to Workcover NSW Health and Safety Guide: Spray Paintingforguidance concerning the control of paint emissions, waste management, and public safety forboth new and previously painted structures.

B.6.2. Lead Paint

Where lead paint is present, all work shall be performed in accordance with AS 4361.1.

A dedicated specification shall be prepared. It shall include surface preparation, ventilation,encapsulation, waste disposal, and any other health and environmental protection measures.

The work shall be undertaken by a pre-qualified Applicator holding a PCCP Class 5 certificate.

B.6.3. ContainmentWhere the works are to be performed on-site, the Applicator is responsible for the design anderection of a suitable containment structure designed to prevent the escape of emissions intothe environment, soils, waterways, and for the protection of the public. Emissions include, butare not limited to: paint overspray, spills, wastewater, sludge, or dust from abrasive blastingand other site discharges associated with the work.

It is the Applicators responsibility to ensure the design of the containment system complieswith all national, state and local legislation, and that no visible emissions escape to theenvironment from the contained work area.

A containment system may include, but is not restricted to: cover panels, screens, tarpaulins,hoardings, and shrouds; supported by scaffolding or other structures which when usedseparately or in combination, will enclose the entire working area.

All necessary measures to recover any removed coating, spent abrasive, and associateddebris shall be undertaken. All collected residues and waste materials shall be disposed ofproperly in accordance with the appropriate statutory requirements.

Prior to the commencement of the works, the details of the proposed containment system to beinstalled for the control of emissions shall be submitted to the Principal. It should be notedhowever that the submission of the proposed containment details would not in any wayconstitute the approval or acceptance of responsibility for the containment by the Principal.


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B.6.4. External Surfaces

Where vacuum shrouded power tools and vacuum blast cleaning are used in conjunction withbrush or roller application of the coatings, a fully sealed structure for the containment ofemissions may not be required.

Where open power tools or vacuum shrouded power tools and/or spot abrasive blast cleaningare used in conjunction with the spray application of the coatings, a sealed containment systemis required.

B.6.5. Internal Surfaces

When treating the internal surfaces of sealable structures such as vessels and reservoirs,emissions may be controlled by utilising the walls, floor, and roof as the principal component ofthe containment. Sealing may be more complete by using rigid or flexible framing, sealedjoints, maintenance holes, hatches, re-sealable entryways, and air-locks having a negativeinternal air pressure.

A suitable dust collection unit and appropriate air flow shall be provided, and provision madefor waste management.

The minimum emission control level for an internal containment system is Level C, referred toin AS 4361.1.

The capacity of the dust extractor shall be sufficient for the volume of the contained structure,so as to produce not less than six air changes per hour.

Where six air changes per hour cannot be achieved continually, a 60 minute time interval is tobe allowed, with the dust extractor operating, between the completion of the blast cleaningactivity, and the commencement of coating operations.

B.6.6. Assessing Emissions

Surface preparation, paint removal operations, and the application of paint may each produceemissions. The potential of various activities to generate emissions is categorised in AS4361.1.

The Applicator shall estimate the potential level of emissions, and install an appropriate

containment to protect the environment, the public and other nearby personnel from anyhazard.

Visible emissions may be permitted providing the duration of the discharge does not exceedthe cumulative level listed in Table below or extend beyond the controlled area delineated by aboundary line or barrier.

Table 1 Guide to Estimating Emissions

Emission Level Description

0 No visible emission. (This level may not be achievable during abrasive blasting)

1 Random emissions having a cumulative duration of no more than 1% of the workday (e.g. five minutes in an eight hour work day).


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2 Random emissions having a cumulative duration of no more than 5% of the workday (e.g. 24 minutes in an eight hour work day).

3 Random emissions having a cumulative duration of no more than 10% of thework day (e.g. 48 minutes in an eight hour work day).

4 Emissions are unrestricted and may occur at any time.

Notes:1. The work-day activities for timing emissions encompass surface preparation and clean-

up only.

2. The maximum emission level for internal and external abrasive blast cleaning shall beLevel 2 or as required by the relevant statutory organisation, whichever is the mostrestrictive.


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C. PROTECTIVE COATING SYSTEM SELECTION

C.1. Introduction

Conditions vary for each asset site, ranging from severe marine to comparatively benign inlandenvironments. Within each site, macro and micro climates may be present, such as humidunderground conditions, aggressive chemical and sewer gas exposure, through to aboveground conditions where strong sunlight, salt spray and weather influence corrosion rates. Inaddition, different assets have different requirements for the level of protection required,depending on how critical the asset is, its exposure condition, required life, and maintenancerequirements.

This section provides a guide to choosing the most suitable coating system. It starts bydescribing the special requirements associated with maintenance works, then therecommended coating systems for new works.

Lists of default coating systems are also provided to assist specification of the most appropriatecoating systems for specific items and/or areas. The lists generally reflect a risk-basedframework that incorporates Sydney Waters experience, industry best practice (standards andspecifications), and consultation with experts. The risk model can be found in Appendix F.

C.2. Maintenance Painting

Maintenance painting is defined where patch repair is undertaken or existing coatings is notfully removed.

The selected coating system for maintenance painting should generally be similar to theexisting one. Attention must be given to the requirements stated in Clause B.2.6 and the use ofsuitable primer coat.

Where existing coatings are mostly sound, it may be possible to spot-repair any exposedsubstrate and feathered areas with the coating system specified in section C.3, without over-coating the existing coating.

There are some circumstances where maintenance painting has special requirements. Thesecircumstances, and their remedies, are listed below.

Table 2 Recommended coating systems for specific maintenance painting

Scope Coating System Additional Notes

Repair of damagedgalvanizing

CS-11 or CS-12 System CS-11 should used to spot repair hot dip galvanizing which hasbecome damaged during construction or in service. This system should beused to spot repair galvanizing which is to be used with or withoutadditional coatings.

Where a significant proportion of the zinc cover has been removed fromthe surface due to corrosion, system CS-12 should be used. Note that insome cases, it may be more economical to simply replace the item or re-galvanise.


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Scope Coating System Additional Notes

Patch repair ofalkyd coating

CS-15 A number of Sydney Water assets have in the past been coated with alkydcoatings, including above-ground pipelines, the external surfaces ofreservoirs, timber items, and some galvanized items.

Where these coatings only require repair in isolated areas, an alkyd

coating system CS-15 should be used for spot repair. This ensuresappearance match to the surrounding coatings and minimiseincompatibility potential issues.

Painting overexisting alkyd andlead basedcoatings

CS-08 or CS-09 Where an existing coating system is in a high enough state of breakdownto warrant full recoating, but it is not economical or feasible to blast back tothe substrate, then a surface tolerant epoxy system should be used.

CS-08 should be used where UV resistance and retention of gloss arerequired.

CS-09 should only be used where colour matching is crucial. For outdoorapplications, CS-09 must incorporate MIO pigments.

Painting over coaltar epoxy

CS-09 CS-09 should be used where existing coal tar epoxy are to be over coateddirectly.

Painting overbitumen coatings

CS-18 System CS-18 should be used for painting over aged bitumen coatingswithout prior removal of the bitumen.

However for bituminous coating in immersion service e.g. internal surfaceof reservoirs, it must completely removed and then coated with either CS-05 or CS-06.

Heavily pitted andriveted steelsurfaces inimmersion service(e.g. steels tanks

and reservoirs)

CS-07 or CS-05 The ultra high build epoxy system, CS-07, should be used for heavilypitted surfaces in immersion service.

For riveted tanks or complex surfaces, where gaps and crevices arepresent, solvent-based epoxy system CS-05 should be used instead.

Maintenance ofimmersion service