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PT Alam Tri Abadi

Specification for Overland Conveyor


Surface Protection
41-18765-M-SP-003

October 2007
Contents

1. Scope 3

2. Standards 4

3. Preparation and Application Requirements 6


3.1 General 6
3.2 Safety 6
3.3 Surfaces Not to be Coated 6
3.4 Protection of Equipment and Surfaces not requiring Surface
Treatment 7
3.5 Protection of Existing Equipment 8
3.6 Abrasives 8
3.7 Galvanised Surfaces 8
3.8 Surface Preparation 8
3.9 Coating Application 9
3.10 Application Procedures 10
3.11 Film Thickness 12
3.12 Handling of Finished Coated Items 13
3.13 Rectification and Touch-up Painting 13

4. Inspection and Testing 14

5. Application Records 15

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1. Scope

This specification covers the minimum technical requirements for the supply of materials and
workmanship for surface preparation and paint treatment.

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2. Standards

Unless otherwise approved or specified the workmanship, equipment and materials shall comply with the
latest revision (including the latest addenda prior to the date of submission of the bid) of the relevant
Indonesian, Australian Standards or the relevant ISO, DIN, US or British Standards (including parts
thereof) together with the requirements of competent Authorities having jurisdiction over all or part of the
works. Where conflict exists between different applicable codes, standards or regulations the higher
requirement shall apply. The supplier shall not deviate from the provisions of the relevant Standard
without first obtaining approval in writing.
If required, the supplier shall be responsible for obtaining at his cost, all necessary statutory approvals,
certificates and registrations. Where statutory approvals can only be obtained by the purchaser, the
supplier shall highlight such approvals and shall supply all the necessary information and documentation
to the purchaser to enable such approvals to be obtained.

Particular standards relevant to the work covered in this specification include but are not limited to the
following:
AS 1214 Hot dip galvanised coatings on threaded fasteners

AS 1345 Identification of the contents of pipes, conduits and ducts


AS 1580 Methods of Test for Paints and Related materials
AS 1627 Metal Finishing - Preparation and Pretreatment of Surfaces
AS/NZS 2310 Glossary of Paint & Painting Terms
AS 2311 The Painting of Buildings
AS/NZS 2312 Guide to the Protection of Iron and Steel Against Exterior Atmospheric Corrosion

AS 2331 Methods of Test for Metallic and Related Coatings


AS 2700 Colour Standards for General Purposes
AS 3730 Guide to Properties of Paints for Buildings

AS/NZS 3750 Paints for Steel Structures


AS 3887 Paints for Steel Structures - Coal Tar Epoxy (Two Pack)
AS 4024 Safeguarding of Machinery (Parts 1-2)
AS 4025 Paints for Equipment Including Ships
AS/NZS 4680 Hot-dip Galvanised Coatings on Fabricated Ferrous Articles
AS/NZS 4792 Hot-dip Galvanised Coatings on Ferrous Hollow Sections

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The supply of goods and services shall be in accordance with all relevant statutes, regulations and
bylaws relating to safety and with generally accepted practices including but without limiting the
generalities of:
AS 1470 (SAA Code of General Principles for Safe Working in Industry).
The following statutory requirements shall also be complied with:
Decision of Ministry of Mining and Energy No. 555 K/26/M.PE/1995 dated 25 May 1995 on Workplace
Health and Safety in Mining.

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3. Preparation and Application Requirements

3.1 General
The surface preparation and treatment shall be carried out in accordance with this specification and to
recognised standards of good practice. This specification does not remove the responsibility for quality of
workmanship.

3.2 Safety
All equipment including, but not necessarily limited to, ladders, scaffolds, compressors, electrical and
pneumatic equipment shall conform to the requirements in force by the appropriate statutory regulations
and bylaws and shall be properly maintained and used in strict accordance with any additional safety
regulations pertaining to it.
All caution notices on the manufacturer's coating and material labels shall be strictly observed and every
necessary precaution taken to prevent accidents.

Transport, storage and handling of coating products shall be strictly in accordance with the requirements
of the relevant statutory authority and proper trade practices.
When working in enclosed spaces adequate ventilation shall be provided to remove and disperse solvent
vapours, avoid explosion and ensure safety of personnel and safe working conditions.
Where air operated equipment is used the operator's hood or headgear shall be ventilated by clean, cool,
oil free air served through a regulator filter to prevent blasting residue from being inhaled by the operator.
Breathing masks shall be worn when painting inside enclosed spaces.
Forced ventilation sufficient to keep fume concentration at a safe level shall be provided for all enclosed
spaces.
Spraying from a bosun chair or swinging basket shall be performed only with approval.

3.3 Surfaces Not to be Coated


The following surfaces and materials shall not be blasted or coated:
» Raised or flat faces on flanges or vessels, valves, pipes and pumps which shall be masked to protect
the machined raised surface during blasting and painting. (The remaining surface of the flange and
bolt holes shall be abrasive blasted and painted).
» Glass.
» Plastic including:
– Fibreglass reinforced plastic (FRP)
– Plastic pipe and fittings including:
polyethylene
PVC
ABS

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– Cables
» Instruments and fittings including:
– Gauges
– Valve stems
– Grease fittings
» Identification tags and nameplates: Surface preparation and coatings shall be continuous under
identification tags and plates if possible, otherwise they shall be edge sealed with a suitable epoxy
putty.
» Nameplates and tags shall not be painted and shall be kept clean and legible.
» Threads of bolting and adjusting screws.
» Internal surfaces of tanks, bins, chutes and hoppers unless specifically indicated on the relevant
drawings or specifications.
» Liner plates
» Machined surfaces
» Non ferrous, galvanised or stainless steel surfaces unless specified otherwise
» Hydraulic or pneumatic hoses and fittings.
» Field weld margins: Areas to be field welded shall be masked after blasting to leave a 50 mm
unprimed margin. A further 50 mm of primer shall be masked before overcoating to facilitate final
touch up of field welds.
» Friction grip surfaces and other fully tensioned bolted joints specifically nominated on the drawings:
Inorganic zinc silicate may be applied to the contact surfaces of friction grip joints provided that the
coating allows for the development of a slip factor of at least 0.35 - refer Section 9.3.3 AS 4100.
Where other coatings are specified, the contact surfaces shall be cleaned and left uncoated and given
the appropriate touch-up treatment after erection.

3.4 Protection of Equipment and Surfaces not requiring Surface Treatment


All items including but not necessarily limited to hardware, instrument gauges and dials, machined
surfaces, nameplates, lighting fixtures that are on or in contact with surfaces to be painted shall be
removed, masked or otherwise protected prior to surface preparation and coating operations.
Removal of items and subsequent reinstallation after completion of coating work shall be carried out by
workmen skilled in the trades involved.

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3.5 Protection of Existing Equipment
All cleaning, preparation and coating shall be scheduled so that dust, contaminants and overspray will
not fall on previously coated surfaces, surfaces, which are to be left uncoated, or surfaces coated by a
different material or product.

3.6 Abrasives
Blasting abrasive shall be dry, clean, free from contaminants and contain no more than 20 ppm total
soluble salts.
Abrasives shall be sized to achieve the specified surface profile.
All abrasives shall be NATA approved with certificates and batch numbers available at all times.
Abrasives shall be subject to retest on request.
Abrasive shall not be reused unless cleaned, resized and tested for contamination.

3.7 Galvanised Surfaces


Where galvanised surfaces are specified the surface shall be pickled in accordance with AS 1627.
Zinc shall be deposited by the hot-dip process. The minimum acceptable coating shall be 450 g/m 2 for
steel thickness ≤3 mm and 600 g/m2 for steel thickness >3 mm unless otherwise approved.

3.8 Surface Preparation

3.8.1 Metal Surfaces


The surface shall be free from fabrication irregularities. All traces of undercut, weld spatter and sudden
changes in section shall be relieved by grinding. All sharp corners shall be broken.
All surface contamination shall be removed in accordance with AS 1627.
The item shall be abrasive blast cleaned to AS 1627.4 Class 2.5 unless specified otherwise in the data
sheet. Blasted surfaces shall not remain unprimed for more than 4 hours. In instances where materials
are supplied pre-painted abrasive blast cleaning of damaged areas shall be sufficient.
Blasting shall not proceed when the metal surface temperature is less than 3°C above the dew point or
when the relative humidity exceeds 90%.
If the surface becomes contaminated or rust bloom is evident then the abrasive cleaning process shall be
repeated. Blast cleaned surfaces left overnight shall be re-blasted.

3.8.2 Architectural Surfaces


Substrates shall be prepared to receive the system as specified. Procedures shall include but not
necessarily be limited to the following:

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Cleaning
Cleaning down and removing oil, grease and loose foreign matter including laitance, efflorescence,
moss, lichen, mould, mildew, dirt and corrosion products, in a manner which causes neither undue
damage to the substrate nor damage to, or contamination of, the surroundings.
Glossy Surfaces
Adequately scuffing and/or solvent or chemically etching as appropriate to provide satisfactory adhesion
for subsequent paint coats.
Filling
Filling cracks and holes with filler, sealants or grouting cements as appropriate for the finishing system
and substrate and sanding smooth.
Drying

Unless otherwise specified, ensuring that surfaces are cured and dry before painting commences.
Recontamination
Applying the first coat of paint immediately after cleaning and before contamination of the substrate can
occur. Where contamination of intermediate coat occurs, cleaning in accordance with the coating
manufacturer's recommendations shall be completed immediately prior to over-coating.

3.9 Coating Application


Unless otherwise approved, surfaces shall be coated with the relevant painting system specified in the
data sheets.
The gloss definitions of `flat', `low-gloss', `semi-gloss', `gloss' and `full-gloss' shall be as set out in
AS/NZS 2310 and AS 2311, Clause 4.1.
The prime coat shall be applied only to prepared surfaces as specified. Surfaces which have been
abrasive blasted shall be primed or coated immediately after blasting and before any discolouration
occurs. The surface shall be clean and dry prior to the application of the prime coat. All corners and
changes of section shall be precoated with primer to ensure adequate coverage.
No coating shall proceed if the primed surface has been mechanically or chemically damaged. Such
damage shall be rectified as specified prior to coating.
Application of coatings shall not commence if:
» The ambient temperature is approaching the dew point.
» The relative humidity is higher than 85%.
» The surface temperature of the object to be painted is not at least 3°C above the dew point.
» The ambient temperature is below 13°C.
A moisture free condition of the surface shall apply for one hour prior to and one hour after coating.
If ambient temperatures are expected to be below 20°C during curing a `winter' catalyst may be used to
aid curing times, if approved by the paint manufacturer in writing.
Each coat shall be left to cure for the period recommended by the manufacturer.

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No overcoating shall be performed until the paint has been allowed to cure for the specified curing time.
The maximum recommended intercoat period shall not be exceeded.
The top coat shall be supplied or tinted to that specified in the paint colour scheme.
If the required thickness is not obtained in the specified number of coats, additional coats shall be
applied until the required thickness is obtained. The last coat shall be the finish coat nominated under the
appropriate coating system.
Adhesion of the coating shall be sound throughout. Coatings with poor adhesion shall be removed and
retreated.
When set up, all coatings shall be substantially free of sagging, craters, mud cracks, pinholes, dry over-
spray and other defects. If such defects occur excessively, the affected areas shall be repaired in
accordance with the paint manufacturer's recommendations or as instructed.
Immersed service coatings shall be tested for pinholes with a low voltage holiday detector and seven
days minimum cure shall be allowed before placing into service.
Inorganic zinc coatings exposed for a prolonged period shall have white stains and zinc corrosion
products removed prior to top coating.
Landing surfaces for gratings shall be completely coated prior to fixing of the gratings.
Coated surfaces containing embedded dust shall be sanded smooth prior to application of further coats.
When applying top coats to porous surfaces such as inorganic zinc and zinc rich coatings, a thin seal
coat should be first applied to displace air before building up to the specified film thickness.

3.10 Application Procedures


All paints shall be stored, thinned, applied and used strictly in accordance with the manufacturer's
recommendations. Coating materials which have deteriorated in any way shall not be used. Thinners,
diluents or clean up materials shall comply with the manufacturer's recommendations.
Spray guns, lines and pressure pots shall be kept clean and in good working order. An air source of
50 m3/h at 700 kPa minimum shall be supplied to each spray unit.
Conventional spray pressure pots shall be equipped with dual regulators and air driven agitator. All spray
equipment shall be equipped with fluid tips, needles and air caps consistent with the coating
manufacturer's recommendations. The air supply line shall be fitted with an efficient oil and moisture
separator.
For application by airless spray a hydraulic pump with a minimum pressure-compounding ratio of 30:1
should be used.
Atomising tips shall be consistent with the manufacturer's recommendation. The tip shall provide
optimum atomisation and fan width for the type of steel surface to be coated. The atomising air pressure
at the gun shall be high enough to properly atomise the paint, but not so high as to cause excessive
fogging of paint, excessive evaporation of solvent, or loss by overspray.
The length of the material hose between pressure pot and spray gun shall not exceed 15 metres.
Pressure pots, material hose and spray gun shall be kept at about the same elevation.

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The spray gun shall be held at right angles to the surface and each pass shall overlap the previous pass
by 50%. Large surfaces shall receive two passes at right angles to each other (cross hatching).
Coatings shall be wet on contacting the painted surface. Areas of dry spray shall be removed and the
correct system re-applied.
All steel with sharp edges will be stripe coated prior to applying the remainder of the protective coating.
Stripe coating the edges of beams, UBs, UCs, RSJs, channels, angles, welds, irregular or recessed
surfaces shall be sprayed repeatedly as required to ensure the correct build-up for each coat.
All coating materials shall be thoroughly mixed with a power mixer before application.
Zinc pigmented primers shall be kept in continuous agitation during application to prevent settling of
pigments.
Mixed materials shall be passed through a 30-60 mesh screen to remove undispersed pigment particles.
The pot life of catalysed materials shall not be exceeded. When the pot life limit is reached, the spray pot
shall be emptied, remaining material discarded, the equipment cleaned and new material catalysed.
Cleaning and coating work shall be scheduled so that dust and other contaminants from cleaning
processes will not fall on wet, newly coated surfaces.

All coating work shall conform to the following general conditions:


» The dry film thickness of each coat and of the entire system shall be as specified in the coating
system.
» Primers, sealers and undercoats shall be suitable for the substrate and compatible with the finish coat
and each other. Except for stains and other clear or translucent finishes each coating shall be of a
noticeable different tinting from the proceeding coat.
» The number of coats specified shall be a minimum number of coats to achieve the specified dry film
thickness. Where coatings are applied by brush or roller, the paint shall be spread onto the surface
with a minimum practical number of passes.
» Shop applied erection colour codes and mark number shall be painted with the same material as the
finish coat but be of contrasting colour. For inorganic zinc rich primed surfaces not top coated an
inorganic marking paint shall be used.
» Unless otherwise specified, before commencing to paint, the work of all other trades shall be
completed as far as is practicable within the area to be painted, except for installation of fittings, floor
sanding and laying flooring materials.
» Before painting in any section of the works, the area shall be cleaned out and protected against dust
entry. Drop sheets of adequate size and thickness shall be used to prevent marking of areas requiring
protection. Masking shall be used wherever necessary to protect finished work or other surfaces liable
to damage during painting. Any accessories or surfaces that are damaged directly or indirectly as a
result of painting shall be repaired or replaced.
» Door furniture, switch plates, light fittings and the like shall be removed and replaced on completion of
painting.

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» During preparation of surfaces, painting, and inspection, light levels shall be maintained such that the
luminance (photometric brightness) of the surface is at least equal to that produced under daylight
and/or maximum permanent artificial illumination conditions.
» Paint and related materials shall be stored and prepared in the area assigned. Necessary precautions
shall be taken to prevent fire and accumulation of solvent fumes. Paint-soiled rags, waste and the like
shall be removed or stored in airtight metal containers under water at the end of each day's work.
Empty cans and other debris arising out of the painting work shall be removed from the site upon
completion of work.
» Paint shall be mixed and applied in accordance with the manufacturer's recommendations. Paint shall
not be mixed in areas or on surfaces liable to be damaged from spillage.
» Marks, paint spots and stains shall be cleaned off with damaged surfaces restored to their original
condition. Where necessary for aesthetic reasons, damaged paint work or misses shall be touched up
only with the paint batch used in the original application.
» `Wet Paint' warning notices shall be placed conspicuously and not removed until paint is dry, unless
approval is given and precautions are taken to deny access to all but painting staff.
» Different finishing coats shall be cut in neatly in straight lines unless otherwise specified. Each coat
shall be allowed to harden for the drying time (for time between coats) recommended by the
manufacturer.
» Where recommended by the manufacturer, sanding between coats from top to bottom and dusting
down before recoating shall be done.
» Tinted and/or thinned prime or seal coats shall be applied consistent with the paint manufacturer's
recommendations or which may be necessary on porous surfaces, or for any additional finishing
coats necessary to achieve the required colour, opacity, texture or film thickness.
Each coat of paint shall be uniform in colour, gloss, thickness and texture. The standard of workmanship with
regard to final colour, gloss and texture shall match the sample area specified.

3.11 Film Thickness


The film thickness is the minimum dry film thickness, including primer coats specified in the coating 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.
The total dry film thickness shall not exceed that specified by more than 20% or 30 µm, whichever is the
greater.
Total dry film thickness on metallic substrates shall be determined by means of a properly calibrated
Elcometer inspector gauge. Calibration shall be performed at the start of each inspection operation.
Both wet paint and dry film thickness gauges shall be provided and operated to ensure the correct thickness
of each coat and of the full system is achieved.

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3.12 Handling of Finished Coated Items
All steelwork that has been coated shall be handled with care so as to preserve the coating in the best
practical condition.
Steelwork shall not be handled until the coating has completely cured and dried hard. The final coat shall be
allowed to cure and dry for a minimum of two days before handling.
Slings used for the handling of the finish coated steelwork shall be covered with a rubber hose or similar soft
material.
Wherever possible, wooden supports in contact with coated steel during transport and storage shall be
covered with a soft material such as rubber to minimise damage to the coating. Hessian sacks and bags
shall be used during transportation between coated steelwork and holding down chains to prevent damage
to the coating.
No signwriting, stencilling or marking whatsoever shall be applied to painted surfaces of plant, machinery
and equipment unless specifically approved and compatible with the specified coating system.

3.13 Rectification and Touch-up Painting


All faults in the preparation or application of paint systems shall be rectified. Areas of paint that are found
to include deficiencies in any of the following areas shall be removed and touched up as specified.
» Sags or runs
» Mud cracks
» Lack of adhesion
» Incomplete curing/hardening
» Inadequate film thickness
» Mechanical damage.
All shop-primed and topcoated steel shall receive touch up of all damaged areas prior to and after
erection.
After erection, areas damaged due to weld spatter, flux and other deleterious matter shall be cleaned
accordingly and touched up.
Touch up of primed surfaces shall include surface preparation by abrasive blasting or power tool
cleaning and application of appropriate primer to maintain coating continuity and thickness. Surface
preparation for touch up and application of coating shall conform with the system requirements and the
manufacturer's recommendation unless otherwise approved.
Touch up of finish coat surfaces shall include the following:
» Damage to prime coat: power tool clean according to AS 1627, Part 2, apply primer and then the
finish coat.
» Damage only to finish coat: clean surface dirt according to paint manufacturer's recommendations
and apply finish coat.
Approval of cleaning and application methods shall be sought prior to the commencement of touch up
works. If application by brush is approved, the completed works shall be free of brush strokes.

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4. Inspection and Testing

All work shall be inspected and appropriate testing carried out progressively to ensure that it is in
accordance with the specified requirements and inspection and testing records shall be maintained. In
addition, facility shall be made available for inspection of the works at any time during the performance of
the works.
Three days notice shall be provided prior to commencement of any work.
Prior to any work proceeding, sample panels shall be treated with each approved paint system to be
employed to establish an agreed standard of workmanship.

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5. Application Records

Written records shall be maintained of this work so that complete traceability of all work and materials
provided under this Specification is maintained.
These reports shall be maintained on a daily basis.
As a minimum, these reports should include appropriate information concerning the following:
» Job identification (work area).
» Surface preparation performed and equipment used.
» Coating applied and equipment used.
» Material used, batch number, colour and thinner.
» Application details including which coat was applied, wet film thickness and dry film thickness.
Weather conditions, including temperature of air and surface during application, relative humidity, wind
conditions (if work done outside) and general weather conditions.

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