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XSTRATA TECHNOLOGY PTY LTD

TECHNICAL SPECIFICATION PMA-XT-SP0012

SURFACE PREPARATION & PROTECTIVE COATING GENERAL REQUIREMENTS


Revision Date Revised 25-Jan-10 Description/Comment Originator Approved for Use C. Hanna Signatures Checked B. Boucher Approved H. Joubert

Xstrata Technology Pty Ltd ABN 65 118 727 870 Level 4, 307 Queen Street, Brisbane, Queensland 4000 Telephone: +61 7 3833 8500. Facsimile: +61 7 3833 8555 www.xstratatech.com

TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

TABLE OF CONTENTS
1 2 3 4 5 6 7 8 9 10 11 SCOPE AND CONTENT OF GUIDELINES................................................................................................. 3 STANDARDS........................................................................................................................................... 3 DEFINITIONS........................................................................................................................................... 4 ABBREVIATIONS .................................................................................................................................... 5 CONTRACTORS RESPONSIBILITIES ........................................................................................................ 6 SAFETY REQUIREMENTS........................................................................................................................ 6 PLANNING REQUIREMENTS................................................................................................................... 7 QUALITY ASSURANCE ........................................................................................................................... 7 GENERAL SURFACE PREPARATION ....................................................................................................... 9 SURFACE PREPARATION CASES ...................................................................................................... 12 SURFACE PREPARARTION OF CONCRETE AND MASONRY SURFACES .......................................... 13

12 CLEANING, PROCESSING, SURFACE TREATMENT, TESTING, AND HANDLING OF PIPEWORK USED FOR CONVEYING OXYGEN ENRICHED COMBUSTION AIR OR HIGH PURITY OXYGEN............................. 14 13 14 15 16 17 18 CLEANING OF HYDRAULIC AND FUEL PIPE-WORK AFTER FABRICATION...................................... 17 PROTECTIVE COATING APPLICATION.............................................................................................. 18 REPAIRS TO NEW COATINGS........................................................................................................... 21 GALVANISED COATING FOR STEEL ................................................................................................. 22 IDENTIFICATION ............................................................................................................................... 24 HANDLING, PACKING AND TRANSPORT OF FINISHED COATED ITEMS......................................... 25

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SCOPE AND CONTENT OF GUIDELINES


1.1 This specification defines the requirements for industrial protective coatings systems for substrates on equipment, structures and civil works for use in Xstrata Technology (XT) Projects. This specification does not include information on the following coating and lining systems: Metal spraying Rubber lining Anodising Colorbond or Pre-coated Metal Sheeting Manufacturers standard coatings systems applicable to propriety equipment such as electrical motors, valves, actuators and instrumentation.

STANDARDS
2.1 All coating materials, surface preparation and application activities shall comply with the current issue of the relevant standards including the following. AS 1318 AS 1319 AS 1345 AS 1580 AS 1627 AS 1940 AS 2105 AS 2310 AS 2312 AS 2700 AS 3750 AS 3894 AS 3990 AS 4100 AS/NZS ISO 9002 SIS 055900 NACE SAA Industrial Safety Colour Code Safety Signs for the Occupational Environment Identification of the Contents of Pipes, Conduits and Ducts Paints and Related Materials Method of Test Metal finishing Preparation and Pre-treatment of Surfaces, Parts 0 to 9 Storage and Handling of Flammable and Combustible Liquids Inorganic Zinc Silicate Paint Glossary of Paint and Paint Terms Guide to the Protection of Iron and Steel Against Exterior Atmospheric Corrosion Colour Standards for General Purposes Paints for Steel structures Site testing of Protective Coatings Mechanical Equipment (Steelwork) Steel Structures (Appendix C) Quality Systems Model for Quality Assurance in Production, Installation and Servicing Pictorial Surface Preparation Standards for Painting Steel Surfaces (Swedish Standard) NACE International Joint surface Preparation Standard NACE No 5/SSPC-SP 12 Surface Preparation and Cleaning of Steel and Other Hard Materials by High and Ultra High Water Jetting Prior to Recoating International Protective Coatings Hydroblasting Standards. International Protective Coatings Slurry Blasting standard. International Protective Coatings Abrasive sweep Blasting.

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Rev No. 0

DEFINITIONS
XT: Client: Engineer: XT Inspector: Contractor: Painting Contractor: Xstrata Technology Pty Ltd Person or company to whom XT reports to. (Also known as the Principal) Person or company appointed by XT to oversee the Contract between the Contractor and XT. (Also known as Superintendent for the Contract) Person or company appointed by XT to inspect the work carried our by the Contractor and or Painting Contractor Person or company that reports to XT. In certain circumstances the Painting Contractor and the Contractor may be one and the same. Person or company responsible for carrying out surface treatment work. The Painting Contractor usually reports to the Contractor, however, in certain circumstances the Painting Contractor and the Contractor may be one and the same. Approval, in writing, by a statutory authority, XT, the Engineer or a recognised governing body (i.e. NATA, Standards Australia). In the event of conflict, that conflict shall be resolved by giving precedence in the order as stated. A detailed account of methods and procedures used in surface preparation and protective coatings application. Preliminary blasting operations carried out to remove old, contaminated coatings prior to profile blasting. Blasting operations carried out to achieve a desired profile, usually the final blast prior to coating, or surface treatment. Blasting operations carried out to remove localised corrosion, or damage, to otherwise sound coatings. Brush applied coating, usually to edges, welds and other areas susceptible to coating breakdown. Base material over which a protective coating is applied. Light blasting carried out to abrade a surface, with minimal removal of the substrate. A site other than the Painting Contractors works

Approved:

Method Statement: Pre-blast: Profile blast: Spot blast: Stripe coat: Substrate: Whip blast: Site:

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ABBREVIATIONS
ACA: AS: BS: DFT: EPA: ITP: kPa: MSDS: NACE: ppm: QA: QC: RH: TDS: m: Australasian Corrosion Association Australian Standard British Standard Dry Film Thickness Environment Protection Authority Inspection and Test Plan kilo Pascals Material Safety Data Sheets National Association of Corrosion Engineers, Houston Texas Parts per million Quality Assurance Quality Control Relative Humidity Total Dissolved Solids Microns (0.001 mm)

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CONTRACTORS RESPONSIBILITIES
The Contractor shall supply all tools, equipment, scaffolding, weather protection, abrasives, coating materials and thinners, labour, supervision, and all other things necessary to apply the nominated coatings to structures and/or equipment as specified. All surface preparation work and application of coatings shall be performed by personnel with a minimum of three years' experience with heavy-duty industrial coating application, particularly using solvent free epoxy systems. The Painting Contractor shall be accredited under lS0 9002 or equivalent. All work may be subject to inspection by XT. The Contractor shall conduct their inspections and quality control responsibilities in accordance with their approved Quality Plan including their Inspection and Testing Plan (ITP). Inspection by the XT shall not imply acceptance for any defective work subsequently found. The Contractor shall employ a coating inspector certified by ACA, NACE, ICQRR, or an approved equivalent body to verify that coatings are applied in accordance with this specification and with the coating manufacturer's recommendations. The identity and qualifications of the appointed inspector shall be nominated to the XT Engineer prior to the commencement of work. Inspection of the work shall be in accordance but not limited to the requirements of Section 8 of this specification. The Contractor shall ensure that all surface preparation and coating work is performed in accordance with the coating manufacturer's recommendations and the provisions of this specification.

5.1.1

5.1.2

5.1.3 5.1.4

5.1.5 5.1.6

5.1.7 5.1.8 5.1.9

5.1.10 If the work does not comply with these instructions, it may be deemed to be defective. Such defective work shall be made good by re-preparation and/or re-coating, in accordance with the applicable specifications, at no additional cost to XT. 5.1.11 The Contractor shall maintain detailed records and prepare documentation in accordance with Section 8 of this specification, as well as the Quality Assurance Requirement Specification, and shall submit such documentation to the XT Engineer as required in the Contract.

SAFETY REQUIREMENTS
All appropriate SH&E procedures and requirements shall be complied with. Coating materials thinners etc are classified as hazardous materials. The use and storage shall comply with AS 1940, Coating Manufacturers Recommendations and the Dangerous goods act. Health and safety instructions as described on the Manufacturers Safety Data Sheets (MSDS) and warning labels on containers relating to the use of coatings, thinners and cleaning operations such as fume exposure, confined ventilation storage issues etc. shall be fully understood by the workers before commencement of protective coating activities.

6.1.1 6.1.2

6.1.3

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PLANNING REQUIREMENTS
All surface preparations and coatings shall be shop applied wherever possible Unless otherwise specified, no steel components shall be installed without all of their surfaces having at least been prepared and a primer coat applied. This is of special importance where subsequent blast cleaning would be harmful to installed equipment or other coated surfaces. It is essential that the environmental conditions applicable at the time and place of the intended work, including ambient temperature, relative humidity, substrate temperature and wind conditions, are within the manufacturer's limits for the nominated preparation process or coating application. The limits of these environmental conditions are given in section 13 of this specification. Under no circumstances, shall coatings be applied if environmental conditions are outside of those listed. The Contractor shall ensure that adequate allowance is made in the schedule for poor coating conditions or that other provisions are made to ensure that the specified application conditions are attained.

7.1.1 7.1.2

7.1.3

7.1.4

8
o o

QUALITY ASSURANCE
Full quality assurance requirements are detailed in the Quality Assurance Requirement Specification for Procured Items. The Contractor shall carry out the work in accordance with the requirements of this Specification. All work shall conform to the relevant Australian Standards and to XTs requirements. It is the responsibility of the Contractor to demonstrate at any stage of the work his conformance to the requirements of this Specification to the satisfaction of the XT Engineer. The contractor shall appoint a certified coating supervisor (ACA, NACE or approved equivalent) for the inspection and testing of the coating system. The Contractor shall perform all necessary inspections to assure that the work is meeting all requirements of this Specification. The Contractor shall provide at least three days notice to the Engineer prior to the commencement of any protective coating work. QUALITY ASSURANCE AND TRACEABILITY Preference shall be given to the manufacturers and applicators of protective coatings, which are certified to ISO 9002 or equivalent, or in the process of gaining certification or holding approval from the Paint Contractors' Certification Program (Class 4).

o o o 8.1

8.1.1

8.2

INSPECTION AND TEST WORK PLANS (ITPs) The Quality Plan shall contain an Inspection and Test Plan (ITP) nominating approved daily inspection reports (to AS 3894.10) and Equipment Inspection reports (to 3894.11) reflecting the required quality control points and activities over each phase of the protective coating system, e.g. surface preparation, application, acceptance testing, transport, coatings repairs etc. Approval from the XT Engineer must be gained before commencement of protective coating preparation and application.

8.2.1

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8.3

PAINTING CONTRACTOR RECORDS The Painting Contractor shall maintain written records of the work so that complete traceability of all work and materials provided under this Specification is maintained. The three Australian Standards 3894-10, -11, & -12 QA report forms shall be used as a minimum record keeping format. These reports shall be maintained on a daily basis and submitted to the XT Engineer when requested, or if not specifically requested, at the completion of the Works.

8.3.1

8.3.2

8.4

FILM THICKNESS TESTING The film thickness is the minimum dry film thickness, including primer coats specified in the painting system. Final acceptance of each increment of work will not be made until the dry film thickness meets or exceeds the specified thickness. Regardless of the number of coats specified, such additional coats shall be applied as may be necessary to achieve the specified thickness, at the Painting Contractor's expense. The Painting Contractor shall provide and operate wet film and dry film thickness gauges of an approved type to ensure the correct thickness of each coat and the full system is achieved. Total dry film thickness on metallic substrates shall be determined by means of a properly calibrated electronic thickness inspection gauge in accordance with AS 3894 & AS/NZ 1580.108.1. The results of these measurements shall recorded by the Contractor. Each nominated coat shall not be less than the specified minimum DFT (as described in AS 3894.3). The average of any 5 readings on each 10m of surface area shall be equal to or greater than the specified DFT and no single point reading shall be less than 80% of the specified DFT. The DFT shall not exceed the maximum DFT nominated in the manufacturers data sheet. DFT readings shall be taken in a manner and location that is representative of the entire area. Calibration of the DFT gauge shall be performed prior to each batch of measurements using a series of known standards. Calibration methods are detailed in the Australian Standard 3894. During application of the coating system the wet film thickness of each coat shall be regularly checked with an appropriate gauge to ensure that the required wet film thicknesses are being applied.

8.4.1

8.4.2 8.4.3

8.4.4

8.4.5 8.4.6

8.4.7

8.5

FILM CONTINUITY Coated surfaces requiring film continuity inspection such as the coatings on the inside of tanks and internal surfaces of launders shall be tested for holidays, pinholes, scratches and other coating discontinuities by means of an approved pinhole or holiday detector (Spark Tester). Testing shall be conducted in accordance with AS 3894. The final continuity tests shall be a hold point in the Contractors ITP and may be performed and or witnessed by the Xstrata Technology Inspector.

8.5.1

8.5.2 8.5.3

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8.6

CORRECTION OF DEFECTS AND DEFICIENCIES All deficiencies and defects revealed by the above inspection and test methods shall be promptly repaired or corrected.

8.6.1

8.7

XSTRATA TECHNOLOGY INSPECTOR A certified inspector of coatings, ACA (Australian), NACE (United States), Icorr (U.K), or approved equivalent may be appointed by the / Engineer for the Contact for inspection and testing of protective coating systems to be applied by the Painting Contractor. All work may be subject to inspection by the Xstrata Technology Inspector. However, this shall not relieve the Painting Contractor of his own Quality Assurance/Quality Control responsibilities nor prevent the Contractor from appointing his own inspector.

8.7.1

8.7.2

8.8

INSPECTION & TESTING Testing shall include but not limited to: Surface contaminant test. Surface profile measurement testing Coating Dry Film Thickness Test (DFT) to AS 3894.3. Adhesion test to BS 3990 Continuity Testing (holiday detection) to AS 3894.1 Testing for cure of coatings to AS 3894.4

8.8.1

9
o

GENERAL SURFACE PREPARATION


The performance of any paint coating system is directly dependent upon the correct and thorough preparation of the surface prior to coating. The most expensive and technological advanced coating system will fail if the surface preparation is incorrect or incomplete. The importance of removing oil, grease, old coatings and surface contaminants such as mill scale, corrosion product on steel, laitance on concrete and zinc salts on galvanised surfaces cannot be over emphasised. The principal factors affecting performance are: Soluble surface contamination including salts, sulphides, oils, grease, drilling and cutting compounds, Integral surface contamination including rust, mill scale and surface profiles (roughness).

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9.1

SURFACE DECONTAMINATION Surface decontamination is required prior to the application of protective coatings, when preparing previously coated or uncoated steel that has been exposed to a corrosive environment. Before abrasive blasting is carried out, all soluble surface contaminants shall be removed in accordance with AS 1627.1. This can be achieved by the use of: Proprietary emulsions Degreasing compounds Steam cleaning

9.1.1

9.1.2

9.1.3

Solvent washing shall be followed by wiping with clean rags. The wiping clean is essential, because if this is not carried out thoroughly the result of solvent washing will simply spread the contaminants. Once abrasive blasting has been completed, all surfaces shall be tested for the presence of chlorides, soluble metal salts and alkaline/acidic contaminants with a SCAT Kit or similar approved tests, such as: Using ferrous ion (Eisen) indicator strips. Titrations analysis e.g. Quantab Chloride Titrator No 1174 indicator test strips. PH indicator strips

9.1.4

9.1.5

No steel may be coated until the contaminants are below the following maximum ranges for contamination: Soluble iron salts < 3mg/l. Sodium Chloride less than 30 ppm PH between 6 and 8

9.1.6

When these ranges are exceeded, use a high-pressure potable water spray (hydro blast) using a minimum nozzle pressure of 25,000 kPa to remove any contaminants from the surface. Hydro blasting shall only be used on steel, which has previously been abrasive blasted, UNO. After each hydro blast, the surfaces shall be retested and if contamination values are still found to exceed the maximum values, the surfaces must be hydro blasted again and retested. The frequency of testing shall not be less than once every 10m2. Hydro blasting must be used until any contamination falls below the maximum range for each contaminant. The testing shall be recorded on a suitable approved quality control sheet.

9.1.7

9.1.8 9.1.9

9.1.10 Hydro blasting shall comply with NACE Standard 5/SSPC-SP12 Surface Preparation and Cleaning of Steel and Other Hard materials by High and Ultra High Pressure Water Jetting Prior to Recoating.

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9.2

SURFACE DEFECTS Surface defects likely to be detrimental to the protective coating system shall be brought to the attention of the XT Engineer for evaluation. Defects deemed to be structurally deleterious shall be removed and/or repaired and the area re-blasted in accordance with the relevant XT Coating System. Defects such as voids crevices gaps etc. that are deemed not to be structurally deleterious shall be filled with an approved solvent-less epoxy filler after prime coat and before top coat. Flash rusting shall be re-blasted in accordance with AS 1627.4 and the specified XT coating system.

9.2.1 9.2.2

9.2.3

9.3

ABRASIVE BLASTING Abrasives shall comply with AS 1627.4 and shall be dry and free from contamination. Abrasives shall be tested for chlorides or other contaminants before first time use. Chlorides shall not exceed 30 ppm. The abrasive medium shall be new and unused. Recycled abrasive shall only be used for preblasting. The use of silica sand or other potentially harmful abrasive material shall not be used. Blast cleaned surfaces left uncoated for more than four (4) hours shall be re-blasted to the specified class before priming. Abrasive blasting shall not be carried out (except for pre-blasting) when: The relative humidity is above 85%. The metal temperature is less than 3C above dew point.

9.3.1 9.3.2 9.3.3

9.3.4 9.3.5

9.4

WHIP BLASTING Whip blasting is an abrasive blast of a previously blast cleaned surface, to restore a class of surface preparation which has deteriorated with time. Whip blasting shall be carried out when specified. It is typically used when: Recoating old epoxy coatings The re-coating interval for a two-pack system is exceeded. Applying new coating over a glossy substrate. Coating galvanised steel or Aluminium.

9.4.1 9.4.2

9.4.3

The following conditions must be met when whip blasting unless otherwise approved by the XT Engineer: Compressor air not exceeding 300 kPa. Abrasive grades between 0.2 0.5mm. Abrasive material is clean & dry. Minimum nozzle size 10mm. Blast nozzle held at about 45 to the substrate at a distance of approximately 400mm from the surface.
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9.5

SWEEP BLASTING Sweep blasting is a light abrasive blast cleaning to roughen a surface or remove light rust, foreign particles and outer surface coatings. It shall be carried out in accordance with Appendix D of AS1627.4.

9.5.1

9.6

WET ABRASIVE BLASTING Wet abrasive blasting uses slurry consisting of water and abrasive. This process eliminates hazardous dust that may be generated by abrasive blasting heavily contaminated steel. Furthermore, when wet blasting old, extensively corroded steel many of the soluble corrosion products and/or chlorides in the pits of the steel will be washed out. This greatly improves the performance of the applied coating. However a disadvantage is that the wet steel will corrode rapidly. Wet Abrasive blasting and any measures required to prevent flash rusting shall be in accordance with AS1627.4 Where wet blasting is used and shows signs of corrosion the surface must be dry abrasive sweep blasted before the application of the protective coating.

9.6.1

9.6.2 9.6.3

10 SURFACE PREPARATION CASES


10.1 PREPARATION OF PRE-TREATED SURFACES 10.1.1 Galvanised steel surfaces shall be degreased by solvent cleaning or other approved method in accordance to AS 1627.1. The surface shall then be whip blasted to remove the oxide film and surface contamination with minimal reduction in the galvanised coating thickness. The blasted surface shall exhibit a dull grey finish and a surface profile suitable for proper adhesion of the specified protective coating. 10.1.2 Pre-painted surfaces shall be degreased in accordance with AS 1627.1, and then whip blasted removing gloss, chalking, loose material and peeling, or laminated paint. 10.2 PREPARATION OF MAINTENANCE COATINGS 10.2.1 The pre-painted surfaces shall be degreased in accordance with AS 1627.1, and then whip blasted to remove gloss, chalking, loose material and peeling, or laminated paint, prior to maintenance coating. 10.2.2 The contractor shall ensure that old coatings are tested and deemed lead free before surface preparation. 10.2.3 Repair and maintenance coating of existing coatings shall be determined according AS2312 section 10.2. 10.2.4 Compatibility between existing and new coatings systems shall be ensured using existing records, use of test patches or analytical testing e.g. Infrared Spectroscopy, to identify the original coating.

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10.3 SPOT CLEANING 10.3.1 The cleaning of localised corrosion or coating breakdown areas shall be carried out prior to protective coating maintenance activities. This shall require the removal of decomposing protective coating and/or corrosion product, by either abrasive blasting, power tool cleaning or hand cleaning. The specified cleaning method must provide a suitable substrate for the coating being applied. The perimeter of the sound existing coating to bare steel interface shall be feathered for 50mm to provide a smooth finish surface. The sound coating shall be dry abrasive sweep blasted to provide a suitable key for the protective coating. 10.3.2 Before application of a protective coating, the surface profile of the shall be measured in accordance with AS 1627.4 and conformed as complying to the specified XT coating system. 10.3.3 Hand cleaning, where specified, shall be in accordance with AS 1627 Part 7. 10.3.4 Power tool cleaning, where specified, shall be in accordance with AS 1627, Part 2.

11 SURFACE PREPARARTION OF CONCRETE AND MASONRY SURFACES


11.1 EXISTING PAINTED SURFACE 11.1.1 The surface shall be clean, dry and free from grease (see clause 6.2 degreasing). Any corrosion salts shall be removed by light abrading and water washing. The cleaned surface shall then be abraded or very lightly blasted using low pressure and non-metallic abrasive and primed with a coat of etch primer prior to painting. For lead-based existing coating, thoroughly abrade surface and omit etch primer. 11.2 NEW CONCRETE 11.2.1 The surface should be clean, dry and free from oil, grease and other contaminants such as forming lubricants and curing components, which would affect adhesion of a coating. The moisture content of the concrete or masonry should be less than 6%, measured by a Protimeter Survey Master or similar. 11.2.2 Laitance and loose surface powder formed on new concrete must be removed. The alkalinity and porosity of the surface must be considered when painting concrete or masonry. The preferred surface treatment is Sweep blasting using recoverable abrasive blasting media. Wire brushing. A proprietary acid etch treatment followed by thorough water washing

11.2.3 Any cracks shall be filled with an approved epoxy sealant prior to painting.

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12 CLEANING, PROCESSING, SURFACE TREATMENT, TESTING, AND HANDLING OF PIPEWORK USED FOR CONVEYING OXYGEN ENRICHED COMBUSTION AIR OR HIGH PURITY OXYGEN
12.1 GENERAL 12.1.1 Very stringent handling, cleaning and testing procedures will apply to the internal surfaces of all equipment and pipe-work associated with the conveyance and distribution of oxygen and/or highly oxygen enriched air. The Supplier shall comply with the requirements set out in the following sections relating to handling and execution of surface treatment, cleaning procedures, inspection and approval of cleaned items, protective sealing against recontamination after completion of cleaning and clear marking for identification and protection against installation of non-approved items. 12.1.2 Care shall be taken during cleaning operations to avoid personal injury from toxic vapours generated from some cleaning chemicals. Special attention shall be given to the handling of these products, and to the protective measures required for personnel using them including suitable clothing or other special protective body cover and work area ventilation. 12.1.3 The cleaning areas shall be clean and completely protected from intrusion of contaminating materials including dusts, grinding cuttings, etc. 12.1.4 Equipment and tools used in the cleaning areas shall be cleaned so as to be free of oil, grease, hydrocarbons or any other prescribed contaminants, and dedicated to the work described herein. Personnel engaged in the work shall not have oil, grease or other contaminating substances on hands or clothing. 12.1.5 Equipment supplied free-issue to the supplier, such as valves, bellows and instrumentation items, and designated as cleaned for oxygen service shall be stored and protected against contamination and only removed from their sealed packaging immediately prior to incorporation into an assembly with fully processed pipe spools or other components. 12.1.6 All blasting, chemical cleaning/washing and final assembly activities relating to oxygen conveyance and distribution pipe work shall have client (Xstrata) hold points on the relevant ITP. 12.1.7 CAUTION!! The dried residues of all degreasing solutions are flammable. These residues must therefore be completely removed during processing by rinsing. For stainless steel equipment, clean potable water can be used to rinse any residues away. If the equipment is manufactured from plain carbon steel, a rust inhibitor must be added to the clean potable water before it can be used for rinsing purposes. 12.2 SPECIAL EQUIPMENT 12.2.1 Applied Australia Pty Ltd Degreasing Agent No. 4480 (or XT approved equivalent) 12.2.2 Applied Australia Pty Ltd Rust Inhibiter Agent No. 4-320 (or XT approved equivalent) 12.2.3 Ultra-violet (UV or black-light) light source. The light source is required to emit a wavelength of between 2500-3700 Angstrom units with a minimum power output of 800W/cm2. 12.2.4 Paper suitable to test for the presence of hydrocarbons. Cigarette paper (e.g. Tally-Ho, Zigzag) or Xstrata approved equivalent. 12.2.5 Dry, oil-free compressed air to ISO 8573.1:2001 Class 2.2.1.

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Document No.: PMA-XT-SP0012

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12.3 INTERNAL CLEANING FOR OXYGEN ENRICHED AIR PIPING 12.3.1 Inspect all piping material prior to fabrication and degrease as necessary in order to prevent any contamination of the piping material during fabrication. 12.3.2 Inspect piping immediately following fabrication. Any slag, or welding residues should be removed. 12.3.3 Degrease, flush, and dry. (Refer to Section 12.5 for details regarding degreasing and use of rust inhibitor agents). 12.3.4 Further inspection of the bore of the piping, using a ultra-violet light source, should be carried out. Should the piping be found to contain any amounts of hydrocarbon materials, it is recommended the piping be degreased, flushed, and dried. (Refer to Section 12.5 for details regarding degreasing and use of rust inhibitor agents). This cleaning procedure may help prevent the impregnating of unwanted material during the grit-blasting procedure. 12.3.5 Grit blast the entire inner surfaces of the plain, carbon steel fabricated pipe assemblies using clean, new garnet grit medium and dry, oil-free compressed air. Clean to AS1627.4 Class SA21/2. Upon completion, remove unwanted dust and grit using dry, oil-free compressed air or nitrogen. 12.3.6 Rinse using clean, high pressure potable water until all traces of grit medium has been removed. If the piping is fabricated from plain carbon steel, a rust inhibitor must be added to the potable water prior to it being used for rinsing. The degreasing, flushing and drying must then immediately follow the rinsing process. 12.3.7 Degrease, flush, and dry. (Refer to Section 12.5 for details regarding degreasing and use of rust inhibitor agents). This procedure is to be performed immediately following the rinse procedure. 12.3.8 Inspect piping using a ultra-violet light source. Areas that are inaccessible and cannot be inspected with the UV light (Refer Section 12.2) are to be inspected using paper (Refer Section 12.2). Acceptability of cleaning shall be determined by Xstrata Technology or its nominated representative. Should unacceptable levels of trace hydrocarbons be found during inspection, then, repeat the previous degreasing, flushing and drying step as necessary. 12.3.9 Immediately following inspection and approval of the state of cleanliness by the XT Engineer, or XT representative, all piping must be sealed. Prior to sealing, desiccants should be packed in the piping to prevent any moisture from condensing in the pipe. The Contractor can then securely seal all screwed ports with caps or plugs and install blank flanges with gaskets on all flanged openings. 12.3.10 Apply the protective coatings to the external surfaces of any plain carbon steel piping in accordance to the specified protective coating system. 12.3.11 Each item can then be included in its designated pipe section, or sub-assembly, as per the assembly drawing, with care being taken to prevent the ingress of any agents of contamination. The assembly shall incorporate, without further treatment, all necessary freeissue equipment (valves, bellows etc) provided to the Supplier.

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

12.3.12 Unless noted otherwise, all sub-assemblies and sealed pipe sections are to be leak tested with clean, dry air, or, Nitrogen to 300kPa, hold for at least 30 minutes. If pressure falls by more than 10kPa, pipe shall be checked for leaks and made good as required. Repeat the leak test as required following leak rectification. Upon successful leak testing, slowly relieve pressure and remove leak testing equipment. Please note that the desiccants placed in the piping prior to painting need to be removed prior to leak testing. 12.3.13 Once testing has been successfully completed, the sub-assemblies and pipe sections can be totally sealed to prevent the ingress of any agents of contamination. Prior to sealing the pipe sections, or sub-assemblies, a sachet containing at least 250 grams of an approved desiccant such as Silica Gel shall be securely fixed to the inner face of the sealing membrane. Large assemblies shall be provided with multiple desiccant sachets. 12.3.14 Note: the time span between the inhibitor application and assembly/sealing shall be minimized. If the item has not been assembled and sealed within a period of 1 day from the start of chemical cleaning, then the procedure must be repeated. This is to prevent contamination of the piping. 12.4 CLEANING OF STAINLES STEEL PIPES FOR OXYGEN SERVICE PIPING 12.4.1 Inspect all piping material prior to fabrication and degrease as necessary in order to prevent any contamination of the piping material during fabrication. 12.4.2 Inspect piping immediately following fabrication. Any slag, or welding residues should be removed. 12.4.3 Pickle and passivate all the heat affected zones around all the welds using Australian Stainless Steel Development Association (ASSDA) recognized pickling and passivation liquids, typically a mix of nitric and phosphoric acid. Follow the manufacturers application instructions. Rinse and dry thoroughly (Refer to Section 11.5 for details on rinsing). 12.4.4 Degrease, flush, and dry. (Refer to Section 11.5 for details regarding degreasing). 12.4.5 Inspect piping using a ultra-violet light source. Areas that are inaccessible and cannot be inspected with the UV light (Refer Section 11.2) are to be inspected using paper (Refer Section 11.2). Acceptability of cleaning shall be determined by Xstrata Technology or its nominated representative. Should unacceptable levels of trace hydrocarbons be found during inspection, then, repeat the degreasing, flushing and drying procedure as necessary. 12.4.6 Immediately following inspection and approval of the state of cleanliness by the XT Engineer, or XT representative, securely seal all screwed ports with caps or plugs and install blank flanges with gaskets on all flanged openings. 12.4.7 Each item can then be included in its designated pipe section, or sub-assembly, as per the assembly drawing, with care being taken to prevent the ingress of any agents of contamination. The assembly shall incorporate, without further treatment, all necessary freeissue equipment (valves, bellows etc) provided to the Supplier.

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

12.5 DEGREASING AND RINSING PROCEDURES 12.5.1 Thoroughly review the Applied Australia Pty Ltd Material Safety Data Sheets for Degreasing Agent No. 4480 and Rust Inhibitor Agent No. 4-320 prior to initiating use. 12.5.2 Use the Xstrata approved Applied Australia Pty Ltd degreasing agent No. 4480 and follow the manufacturers directions for use. Use fresh water and mix to the approved manufacturers concentration. 12.5.3 The use of a brush or medium to high-pressure spray equipment combined with hot water will facilitate removal of contamination. 12.5.4 Remove and wire brush all screwed items including plugs and pipe stubs and wire brush socket areas to ensure cleanliness. 12.5.5 Rinse promptly and continually with fresh, potable water to remove all traces of the degreasing agent. The use of medium to high-pressure spray equipment combined with hot water will facilitate the rinsing process. 12.5.6 Note: Improper rinsing will cause suspended contaminants to redeposit onto the surface. Also, the surface shall not be allowed to dry between the degreasing phase and rinsing phase. The resulting film or residue will not be adequately removed during the rinsing phase. 12.5.7 In the final rinsing phase, combine the XT approved Applied Australia Pty Ltd Rust Inhibitor Agent No. 4-320 and follow the manufacturers directions for use. Use the manufacturers recommended maximum concentration to achieve maximum protection. Applied Australia Pty Ltd Rust Inhibitor Agent No. 4-320 is to be applied to plain carbon steel piping only. Note: Dry all internal surfaces using a hot air blower or with dry, oil free compressed air or gaseous nitrogen.

13 CLEANING OF HYDRAULIC AND FUEL PIPE-WORK AFTER FABRICATION


13.1.1 Inspect all piping material prior to fabrication and degrease as necessary in order to prevent any contamination of the piping material during fabrication. 13.1.2 Inspect piping immediately following fabrication. Any slag, or welding residues should be removed. 13.1.3 For stainless steel pipes, pickle and passivate all the heat affected zones around all the welds using Australian Stainless Steel Development Association (ASSDA) recognized pickling and passivation liquids, typically a mix of nitric and phosphoric acid. Follow the manufacturers application instructions. Rinse and dry thoroughly (Refer to Section 11.5 for details on rinsing). 13.1.4 Degrease, flush, and dry. (Refer to Section 11.5 for details regarding degreasing and use of rust inhibitor agents). 13.1.5 On completion of cleaning and drying, circuits for hydraulic and fuel valve racks shall be flushed with clean working fluid for the specific application. 13.1.6 Circuits shall be sealed with closing flanges or compression fitting caps and clearly labeled as follows: THIS CIRCUIT HAS BEEN CLEANED AND FLUSHED WITH THE WORKING FLUID PRIOR TO SHIPMENT.

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

14 PROTECTIVE COATING APPLICATION


o Protective coating application shall be in accordance with the requirements of Australian Standard 2313 Guide to the Protection of Iron and Steel Against Exterior Atmospheric Corrosion except as varied by this specification. Conditions during application: Paint application shall only be carried when appropriate atmospheric conditions. In order to determine whether condensation on the substrate may occur, the steel temperature must be taken and dew point shall be calculated using a hygrometer and the dew point calculator. The ambient conditions shall be taken prior to commencement of coating application and at changes of conditions. The results shall be recorded on Quality Control Daily Report and submitted to the XT Engineer. Protective coatings shall not be applied under the following climatic conditions: o When the surface temperature of the item being coated is less than 3 degrees Celsius above the dew point (see section 8 of AS 2313). When the surface temperature of the item being coated is higher than 55 degrees Celsius. When the surface temperature of the item being coated is less than 10 degrees Celsius. When the ambient temperature is below 5C. When the relative humidity is greater than 85%, unless a moisture-cured coat is being applied. When the surface being coated is in direct sunlight. If the weather is deteriorating, or is unfavourable for application or curing (such as high winds or rain). If the pot life of the paint has been exceeded.

o o

o o o

Ambient conditions likely to occur at shop and site during coating applications shall be taken into full account by the Contractor prior to commencing work. If the Contractor believes the system nominated may suffer application problems due to the ambient conditions, the Contractor shall notify the XT Engineer. The XT Engineer will advise the action to be taken. The same manufacturer shall supply all components in the painting system (primer, undercoat, finish, etc.) Painting Equipment shall comply with manufacturers recommendation for the specific coating system. Mixing: All paints shall be mixed, thinned and applied in accordance with manufacturers recommendation. Gelled or otherwise deteriorated coatings shall not be used. Paint suppliers products (paint & thinners) shall not be mixed in a protective coating system. Inorganic Zinc primers shall be continuously agitated during application by air operated stirrer or approved equivalent.

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

14.1 PRIMING 14.1.1 The specified dry film thickness of primer refers to the minimum thickness of primer measured above peaks. The primer shall be cured in accordance with the manufacturers published recommendations before application of any subsequent coatings. 14.1.2 The primer shall be applied so as to produce a smooth even coating and shall be double lap sprayed into all corners and crevices and on welds and seams, except for inorganic zinc silicate conforming to AS 2105 Type 3 or 4. 14.1.3 Previously cleaned surfaces, particularly where bare metal has been exposed, shall be prime coated or receive the first coat of a self-priming system within 4 hours of cleaning or before surface discoloration takes place, whichever occurs earlier. 14.1.4 Any surface showing deterioration before being primed shall be re-blasted at the Contractors expense. 14.1.5 When unacceptable flash rusting has occurred or substrate deterioration due to wet/hydro blasting, further blasting must be carried out until specified substrate condition has been achieved. 14.1.6 If the dried primed surface becomes contaminated, prior to application of a finishing coat the surface shall be washed with fresh clean water to remove any salt, sand, dust, grit, grease, cement or other contaminants and allowed to dry thoroughly. If necessary, suitable solvents shall be used to remove contaminants that are not water soluble and the areas concerned rewashed with potable water. 14.1.7 The field weld margin surfaces shall be masked after blasting to prevent contamination by protective coating. 14.1.8 The primer shall be applied by conventional or airless spray to achieve the specified minimum DFT. 14.1.9 Inorganic zinc silicate conforming to AS 2105 Type 3 or 4 shall not be recoated with the same primer under any circumstances. Zinc rich epoxy primers must be used for inorganic zinc silicate primer repair. 14.2 STRIPE COATING 14.2.1 All surface irregularities such as edges and weld seams must be stripe coated after priming with intermediate coat. 14.2.2 On shallow corroded depressions stripe airless application and wet rolling with lambs wool roller may be used. 14.2.3 On deep sharp pitting, stripe coating shall be thoroughly brushed into the pits. 14.2.4 Deep pits shall be filled with approved solvent-less epoxy filler.

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

14.3 COATING APPLICATION 14.3.1 The coating Painting Contractor shall apply the protective coating to achieve specified Dry Film Thickness (DFT). During coating application the wet film thickness shall be regularly checked for correct gauge. The required wet film thickness shall be calculated and recorded on Quality Control Check Sheet. 14.3.2 The DFT of each coating application shall be in accordance with the appropriate XT Protective Coating System Specification. 14.3.3 Recoating times shall comply with the manufacturers recommendations, taking into account the ambient conditions during the drying period. 14.3.4 Where multiple coats are specified each coating shall be of a different colour or shade to ensure consistent coverage. 14.3.5 Paintwork shall be subject to visual examination and measurement of the dry film thickness after the application of each coating. 14.3.6 The Contractor shall be responsible for carrying out all inspection and testing and reporting to the XT Engineer. 14.3.7 Visual Examination: All surfaces shall be subject to a visual examination after priming and after application of each top-coat. Each coat of paint shall be free of cracks, wrinkles, blisters, runs and lumps or any other defects. Whenever these defects occur, the whole paintwork system of the affected area shall be removed by specified blast cleaning and replaced at the Contractors expense. 14.4 PLANT ITEMS AND STRUCTURAL SURFACES NOT COATED 14.4.1 The following surface shall not be abrasive blasted and coated, UNO: Raised faces on pipe and equipment flanges Faces on pipe and equipment flat face flanges Stainless steel surfaces Non-metallic surfaces Rubber components Electrical cables Valve stems and grease fittings Instruments and gauges Shafts on running equipment Threads of adjusting screws Machined faces Name-plates Field weld margins (50 mm). The weld margins shall be abrasive blast cleaned but not coated until after installation Other surfaces nominated by the Contract

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

15 REPAIRS TO NEW COATINGS


o o o Coating damage shall be brought to the attention of the XT Engineer and shall be identified as a hold point on the ITP. Repair procedures shall conform to the specified XT protective coating system and is subject to approval by the XT Engineer. Areas damaged during transport/erection or weld margins shall be thoroughly cleaned and spot abrasive blasted or power tool cleaned to AS 1627, Part 2 (note; avoid burnishing metal) and shall be coated using specified XT Protective Coating System. Coatings contaminated by embedded dust or excessive overspray, shall be prepared by sanding or brush blasting and recoated to the specified DFT.

15.1 REPAIR OF DEFECTIVE COATING 15.1.1 All defective work, or work performed not in accordance with this specification, or any coating found defective or damaged during subsequent handling or installation, shall be repaired in accordance with this Section. The repair procedures proposed shall be submitted to the XT Engineer for review and acceptance. 15.2 INCORRECT FILM THICKNESS 15.2.1 Applied coatings that have been dry film thickness tested to AS 3864.3 and are found to be below the specified dry film thickness, shall be cleaned down as per AS 1627.1 to remove any surface contamination and chlorides and then recoated with the same material, provided the tested coating has not exceeded the recoat interval as stated on the Manufacturers Technical Data Sheets. 15.2.2 Coatings that have exceeded the maximum recoat interval shall be completely removed and recoated to the correct specified thickness. 15.3 SPOT DEFECTS AND LOCALISED DAMAGE 15.3.1 The damaged or defective areas together with a surrounding overlap area of at least 50 mm width shall be solvent-cleaned to- remove any oil, grease or dust. Any damaged coatings shall then be removed to an undamaged surface without any signs of loose or flaking paint. 15.3.2 The area shall then be sanded down or abrasive-disc ground, feathering back the abraded area onto the good coating with a 50 mm overlap. In the event that bare metal is exposed while removing damaged or flaking coating materials, spot abrasive blasting shall be applied to remove all particles of old coating and restore the design blast profile 15.3.3 The re-prepared surface shall then be cleaned to remove all abrasive dust, and re-coated using the original specified protective coating system (prime coat, intermediate coat and finish coat).

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

16 GALVANISED COATING FOR STEEL


o This Section covers the requirements for galvanising fabricated items of steelwork. 16.1 FABRICATION 16.1.1 The Contractor shall safeguard all items against embrittlement and distortion in accordance with the relevant requirements of AS 1214, AS 4680, ASTM A143 and ASTM A384. 16.1.2 All welding slag, spatter and burrs shall be removed prior to delivery to the galvaniser. Vent holes at least 10 mm diameter and if required, lifting lugs to facilitate handling, venting and draining during the galvanising process shall be provided. 16.1.3 All required bolt holes shall be punched or drilled prior to galvanising to avoid the need for the applied coating to be subsequently disturbed. 16.1.4 Unsuitable marking paints shall be avoided. 16.2 SURFACE PREPARATION 16.2.1 Surfaces shall be cleaned to remove oil, grease, mill scale, weld slag, markings and other foreign matter in accordance with AS 1627.1. Items shall be supplied free from paint. 16.2.2 Pickling of steel surfaces shall be performed in accordance with AS 1627.5. 16.2.3 Surfaces requiring abrasive blasting prior to the galvanising process shall have a maximum profile height of 65 m after blasting. 16.3 ZINC COATING 16.3.1 The items shall be zinc coated by the hot-dip galvanising process to the desired thickness in accordance with AS 4680. The coating shall be checked for continuity and uniformity of thickness, and the- coated articles shall be generally free from visible defects. The coating shall be free from voids, blisters, flux spots, inclusions, dross, acid or black spats. 16.3.2 The coating shall be adherent, so that it will not be removed by any reasonable process of handling or erection. Lumps, globules or heavy deposits of zinc which will interfere with the intended use of the material will not be accepted. 16.3.3 The mass of galvanised coating shall comply generally with the requirements of Table 8.1 of this Specification, and the applicable requirements of AS 4680. Testing procedures shall be in accordance with the relevant section of AS 2331.

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

Table 16-1 - Coating Requirements for Hot-Dip Galvanised Products

Class of Material Products Fabricated of Rolled, Pressed and Forged Steel Shapes, Plates, Bars and Strip Plate Thickness Less than 2 mm Plate Thickness 2 mm to 5 mm Plate Thickness over 5 mm Hollow Sections Hardware Class A - Castings Class B - Rolled; Pressed and Forged articles (except those included in Classes C and D) Class C - Centrifugal Work Class D - Bolts and Nuts 16.4 REPAIRS TO DAMAGED GALVANISED COATINGS

Minimum Mass of Coating (g. /m2)

350 454 600 300 600 600 300 375

16.4.1 Small areas of 'defective or damaged coating shall be repaired by the application of two 60 m DFT coats of zinc-rich organic coating (cold galvanizing) conforming to AS 3750.9. 16.4.2 Areas to be repaired shall be abrasive disc cleaned in accordance with AS 1627.2. 16.4.3 Remedial painting shall overlap the sound galvanised coating by 50 mm all round. 16.5 PACKAGING OF GALVANISED ITEMS 16.5.1 All galvanised items shall be packaged and strapped with dunnage or wooden spacer materials to prevent any contact between individual items. Smaller items may be crated. However, they must be kept dry and free from moisture. General packaging and freight forwarding specifications are provided in PMA-XT-0010 Packing and Freight Forwarding Requirements

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

17 IDENTIFICATION
17.1 RAW MATERIALS 17.1.1 All materials used, including cleaning agents, solvents, curing agents, thinners, primers, and any other coating materials shall be clearly labeled to ensure traceability. Each container or package shall be clearly labeled, at all times, with the following information: Manufacturer Product identity code Chemical or industrial name Batch Number Hazchem ID

17.1.2 The manufacturers recommendations for shelf life and storage conditions should be ascertained prior to shipping to site. Product data sheets, MSDS and other relevant information shall accompany product. 17.1.3 The Inspector may reject any materials that do not have a correctly completed identification label. 17.2 STORAGE AND SUPPLY OF PAINT MATERIALS 17.2.1 All coating materials shall be delivered to the factory (shop) or site in the Manufacturer's original containers with the labels and seals unbroken. 17.2.2 Coating materials shall be stored in the manner recommended by the coating manufacturer. 17.2.3 Transport, storage and handling of coating materials shall be strictly in accordance with the requirements of the relevant statutory authority and with current trade practices. 17.2.4 All materials which have been stored for longer than the specified shelf life or exposed to conditions outside the permissible storage conditions shall be discarded and replaced. 17.2.5 All containers shall be the original sealed containers have a clearly marked manufacturers identification label attached. The XT Engineer may reject any non-original containers or suspected out of date paints.

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TECHNICAL SPECIFICATION SURFACE PREPARATION & PROTECTIVE COATING - GENERAL REQUIREMENTS

Document No.: PMA-XT-SP0012

Rev No. 0

18 HANDLING, PACKING AND TRANSPORT OF FINISHED COATED ITEMS


o o o o All equipment that has been coated shall be handled with care to preserve the coating in the best practicable condition. Steelwork shall not be handled until the coating has completely cured and dried hard. Web slings or slings covered with a rubber hose or similar soft material shall be used for the handling of finish coated items. From completion of primer coatings to completion of loading the finished coated item on the transport, all coated items shall be protected by a soft material such as cloth, carpet or rubber sheeting on areas of contact (e.g. wooden supports and holding down chains or slings). Any damage to finished coated items, whether supplied by the Contractor or not, shall be repaired and made good in accordance with this specification. Items with excessive damage caused by insufficient care shall have the entire coating removed and be recoated in accordance with this specification. The XT Engineer for the Contract shall determine if damage is excessive.

o o

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