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Revision Issued Appr. Appr. Date Revision Description

Vendor-No. Document No 2345052 Format Rev. 0

A4

CONTRAT : 2.2068 JORF LASFAR – SUPERSTRUCTURES

ROYAUME DU MAROC - OFFICE CHERIFIEN DES PHOSPHATES

Scale: Issued Appr. Appr. Date Zone/Descr.:

N.A. M.K. JMM 15.12.11 Pattern no.:

QUAIS 1, 2 and 4
SITE PROCEDURES
REPAIR INSTRUCTION
Paint Touch-Up, Weld repairs
The Information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not
be duplicated, disclosed, or utilized without written consent from FLSmidth.
No.:
PJ-Q3392-FLS-PR-PRO-45052

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TABLE OF CONTENTS

1.  General Information 3 

1.1.  Scope 3 
1.2.  Regulations and Standards 3 
1.2.1.  General 3 
1.2.2.  Standards and Codes 3 
2.  Surface Treatment 4 
2.1.  Workmanship 4 
2.2.  Surface Preparation 4 
3.  Weld repair 4 
3.1.  Workmanship 4 
3.2.  Surface Preparation 4 
3.3.  Pre-Heating 4 
3.4.  Welding Equipment 4 
3.5.  Welding Consumables 4 
3.6.  Quality of Welds 5 
3.7.  Weld Inspections 5 
3.8.  Repair of different types of defects 6 
3.8.1.  Lack of fusion 6 
3.8.2.  Pores 6 
3.8.3.  Impermissible pores 6 
3.8.4.  Elevation of welding seam 6 
3.8.5.  Missing weld-ends 6 
4.  Painting 6 
4.1.  Workmanship 6 
4.2.  Quality of Coatings 7 
4.3.  List of Paint Manufacturers 7 
4.4.  Surface Preparation 7 
4.5.  Painting System 7 
4.6.  Painting 7 

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1. General Information
1.1. Scope
This procedure is valid for all touch-up painting and weld repair activities on site
before or after erection/installation.

1.2. Regulations and Standards

1.2.1. General
The Manufacturer shall agree that the work (equipment and material) supplied
by him will be manufactured and inspected on basis of international codes and
standards relevant to such work and effective at the time of the contract signing.

1.2.2. Standards and Codes

All works performed by the Manufacturer shall be in strict accordance with the
latest revision of the relevant international and Morrocco Standard and Codes
unless specifically noted otherwise in the contract documents.
Any proposed deviations from these Standards and Codes shall be submitted
by the Manufacturer to FLSmidth whose approval may not be granted unless
the degree of strength and quality be at least equal to those represented by the
Standards and Codes specified.

Ident - No. Description

BS 5493 Protective coating of iron and steel structure against corrosion

EN ISO 12944 1-8 Paints and Varnishes- Corrosion protection of steel structures by protective paint
systems.
Part 2: Classification or Environnements
ISO 8501 Preparation of steel surface before application of coatings-sandblasting
DIN 55928 Corrosion protection of steel structures by the application of coatings

DIN EN ISO 2178 Measurement of coating thickness; magnetic method

DIN 55670
DIN EN 729/ 1-4 4 Quality requirements for welding structures
DIN EN 22553 Welding symbols on drawings

EN 287-1 Welder qualification

EN 15607 Requirements and acceptance of welding procedures

EN 473 ND-Testing
DIN EN 571-1 Dye penetration test
DIN EN 1290 Magnetic particle test

DIN EN 1712-1714 UT-Testing of weld joints.....

ISO 5817 Arc-welded joints in steel: Guidance of quality level for imperfections

DIN 4762 Surface roughness, terminology

DIN 18800 Structural Steel work: design & Construction

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2. Surface Treatment
2.1. Workmanship
• All work shall be carried out by competent tradesmen using appropriate
equipment in good working order.
• There shall be supervision by experienced personnel.

2.2. Surface Preparation

Before surface preparation commences:
• All surface defects including cracks and paint defects shall be removed.
• All oil and grease shall be removed.
Damaged coatings shall also be cleaned to the above standard. Surface to be
cleaned to SSPC6 / SA 2 ½ by sand-blasting prior to painting. Power tool
cleaning of steel surfaces may be approved by FLSmidth where sand-blasting is
not practicable (e.g. near bearings, electrical equipment, …).
Any imperfection revealed by blasting shall be removed and the surface re-
blasted.

3. Weld repair
3.1. Workmanship
• All work shall be carried out by competent tradesmen using appropriate
equipment in good working order.
• Welders to be qualified acc. EN287-1
• There shall be supervision by experienced personnel.

3.2. Surface Preparation

Acc. 2.2

3.3. Pre-Heating
Material thicker 20mm has to be pre-heated to a minimum of 120°C prior to
welding.

3.4. Welding Equipment

The welder/supervisor to ensure, that the used equipment is in full function and
in a state of calibration.

3.5. Welding Consumables

Welding Consumables have to comply with the relevant DIN-Standards (EN440).
Low hydrogen basic electrodes class H5 shall be used for general purpose.

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3.6. Quality of Welds

All welds shall be inspected in accordance with ISO 5817 “Arc-welded joints in
steel - Guidance on quality levels for imperfections“ for the surface and the
volume conditions.
Main structure to be within quality level “B” acc. ISO 5817. Secondary structure
should be within the tolerances of quality level “C”.

3.7. Weld Inspections

UT-Testing on butt-welds shall be conducted in accordance with EN 1714 Class
B (as equivalent to Quality level “B” according to ISO 5817).
The manufacturer shall arrange for all non-destructive testing to be performed at
a testing laboratory registered by an approved authority if not available in his
manufacturing or if such laboratory is doubt.
Proof of compliance with the requirements specified for the quality level shall be
provided by non-destructive testing with visual means and other means
defined below.

(A) Visual Means of NDT implies two levels of testing as follows:

(1) 100% visual scanning to determine that no welds called for in the
drawings are omitted and to detect gross defects.
(2) Visual examination to examine a percentage of the welds to determine
whether the required weld quality according to ISO 5817 has been
achieved.

(B) Other Means of NDT are

(1) ultrasonic testing (UT) according to EN 1714 (replacing DIN 54125)
(2) magnetic particle testing (MT) according to DIN EN 1290 or
(3) dye (liquid) penetrated testing (PT) according to DIN EN 571-1

The extent of testing shall be in accordance with EN 25817 and depend on the
quality level (QL) specified on drawings as follows:
Test Subject Test Alternative Extent
Test
I All full penetration butt welds RT UT&MT 100% of the length of all weld
resp. critical welds specified as less than 1000 mm and
all butt welded connections on
20% of the length of all weld
primary load bearing
longer than 1,000 mm
II All other butt welds RT UT&MT 20% of the length of all weld
less than 1,000 mm and 10%
of all other joints
III Fillet welds resp. partial joint MT PT 25% of the length of all weld
penetration groove welds (PJP)

IF UT is applied the same weld is to be tested by MT for possible surface

defects!
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All welds failing to meet the permissible levels of imperfections allowed in

ISO 5817 (surface conditions) or EN 1714 (for UT-tests) shall be removed or
repaired and then re-tested, along with at least 2 additional samples of 20 %.

3.8. Repair of different types of defects

All welds have to meet quality levels acc. ISO 5817:
B … main structure
C … secondary structure (walkways, …)
D … secondary structure (handrails, …)

3.8.1. Lack of fusion

Welding seam has to be grinded to the ground-level (base material).
Weld preparation to be done if necessary/possible
Fill-up welding seam acc. drawing

3.8.2. Pores
If pores are permissible in accordance with DIN EN5817, they have to be closed by
following actions to prevent corrosion:
• Strip-coating
• Silicone (and re-paint acc. Point 4)
• Mastic (and re-paint acc. Point 4)

3.8.3. Impermissible pores

Welding seem to be grinded until pores disappear
Perform a weld test acc. 3.7

3.8.4. Elevation of welding seam

To be grinded acc. drawing resp. international standards

3.8.5. Missing weld-ends

To be filled up by fillet-weld to prevent corrosion

4. Painting
Painting of all surfaces shall be to the appropriate system as specified by the
relevant Standards.
The system must follow the requirements of the FLS Specification 2345023.

4.1. Workmanship
• All work shall be carried out by competent tradesmen using appropriate
equipment in good working order.
• There shall be supervision by experienced personnel.

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4.2. Quality of Coatings

• Each coat shall be applied in a smooth, even layer, free of sags, runs,
holidays and other faults.
• Pot life shall not be exceeded and a mixed coating which has started to
react shall be discarded.
• The Manufacturer shall ensure that the paint applied completely covers the
surface being painted and is thoroughly worked into joints, corners and
blind areas.
• Where similarly colored coats are to be applied successively, the base
coats shall be slightly tinted.
• All gauges and nameplates shall be masked during painting any that are
defaced by painting shall be cleaned to the satisfaction of FLSmidth or
replaced.

4.3. List of Paint Manufacturers

• Ameron
• Carboline
• Hempel
• Sigma
• International
• US Coatings

4.4. Surface Preparation

Acc. 2.2

4.5. Painting System

The following painting system is specified in order to meet the requirement of
protection of steel structure parts against corrosion. Refer to paint specification
2345023.

Field of application: Structural steel and misc. equipment

1st coat - primer: organic zinc or modified epoxy, 60 micron thick (1).
2nd coat - intermediate: polyamide epoxy coat, 120 micron thick (1).
3rd coat - final: polyurethane, 50 micron thick (1).

Notes: (1) The above thicknesses are to be intended as “minimum dry

film minimum thicknesses”.

Machinery equipment has to be handled acc. Manufacturers standard .

4.6. Painting
After cleaning the surfaces shall:

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y Be kept free of moisture and contaminants, such as dust, spray or
perspiration from hands;
y Receive the first application of protective coating within four hours;
y Be re-cleaned if they have become contaminated or rusted.
All surfaces immediately before the application of any coating shall be clean
and dry, free from dust and loose particles and free of soluble salts.
If more than 10% of the complete surface had been damaged during the
transport or erection phase, the complete part has to be re-painted.

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