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QC10-H-061 M21 Painting of Piping, Equipment and Structural Steelwork PDF
QC10-H-061 M21 Painting of Piping, Equipment and Structural Steelwork PDF
QC10-H-061 M21 Painting of Piping, Equipment and Structural Steelwork PDF
LOCATION: TITLE:
SPECIFICATION M21
PAINTING OF PIPING, EQUIPMENT
AND STRUCTURAL STEELWORK
Specification M21
Subject: Page 2 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
LIST OF CONTENTS
1 SCOPE ...........................................................................................................................................3
2 CODES AND STANDARDS ..........................................................................................................3
2.1 General ..........................................................................................................................................3
2.2 Codes and Standards ..................................................................................................................3
2.3 Project Specifications .................................................................................................................4
3 GENERAL ......................................................................................................................................4
3.1 Environmental Conditions ..........................................................................................................4
3.2 Definitions ....................................................................................................................................4
3.3 Abbreviations ...............................................................................................................................4
3.4 Conflicting Requirements, Exceptions ......................................................................................4
4 TECHNICAL REQUIREMENTS ....................................................................................................4
4.1 General ..........................................................................................................................................4
4.2 Surface Preparation and Cleaning of Surfaces ........................................................................5
4.3 Painting .........................................................................................................................................7
4.4 Galvanizing ................................................................................................................................ 10
5 INSPECTION, TESTING, CERTIFICATION ............................................................................... 11
5.1 General ....................................................................................................................................... 11
5.2 Inspection of Surface Preparation - Derusting ...................................................................... 12
5.3 Inspection of Shop Painted Items ........................................................................................... 12
5.4 Inspection and Acceptance of the Painting ........................................................................... 12
6 PRESERVATION, MARKING AND SHIPPING ......................................................................... 12
6.1 Preservation .............................................................................................................................. 12
6.2 Marking ...................................................................................................................................... 13
6.3 Shipping ..................................................................................................................................... 13
7 DOCUMENTATION .................................................................................................................... 13
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 3 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
1 SCOPE
This specification covers the minimum requirements for the design, materials, surface
preparation, inspection, testing, acceptance and supply of shop and field painting of above
ground installations in NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS.
2.1 General
The latest edition of the below mentioned codes, standards, specifications, instructions, etc.
shall establish the minimum standards for the work.
BS 3083 Specification for hot-dip zinc coated and hot-dip aluminium/zinc coated
corrugated steel sheets for general purposes
ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles
specifications and test methods
ISO 8501-1 Preparation of steel substrates before application of paints and related
products – Visual assessment of surface cleanliness – Part 1: Rust
grades and preparation grades of uncoated steel substrates and of
steel substrates after overall removal of previous coatings
ISO 11124 Preparation of steel substrates before application of paints and related
products – specifications for metallic blast cleaning abrasives
ISO 11126 Preparation of steel substrates before application of paints and related
products – specifications for non-metallic blast cleaning abrasives
ISO 14713 Zinc coatings – Guidelines and recommendations for the protection
against corrosion of iron and steel in structures
SSPC VIS-1 Guide and Reference Photographs for Steel Surfaces Prepared by Dry
Abrasive Blast Cleaning
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 4 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
Besides the a.m. codes and standards the Contractor shall observe the following
specifications:
3 GENERAL
The environmental and operating conditions, product data, etc. under which the water
transmission system shall operate are defined in the general project specifications.
3.2 Definitions
The definitions of the terms “Contractor”, “Engineer”, etc. are given in the general and special
conditions of the contract.
3.3 Abbreviations
BS British Standard
DIN Deutsches Institut für Normung e.V. (German Institute for Standardisation)
DFT Dry Film Thickness
ISO International Organization for Standardization
SSPC The Society for Protective Coatings
The Contractor shall notify the Engineer of any conflict between this specification, the codes
and standards and any other specifications included as part of the contract documents, which
may be applicable for the scope and requirements of this specification.
Any exceptions to this specification and referenced documentation shall be raised by the
Contractor and approved by the Engineer in writing.
4 TECHNICAL REQUIREMENTS
4.1 General
The criteria governing good workmanship shall be proper surface preparation, neat
appearance, free of blisters, bubbles, craters, sags, runs, lap marks and unnecessary brush
marks. Other criteria include the thorough mixing, straining, uniformity of dry film thickness,
removal of dust, grease and other foreign matter, proper drying time between coats and
protection of surfaces not to be painted.
Regarding maintenance work (storage), application and inspection of coating work, choice of
coating, the number of paint manufacturers should be minimized. At any rate, similar parts of
structures/components (such as structural steel, containers, piping, etc.) shall only be coated
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 5 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
Cleaning with chemical solvents shall only be a preliminary stage for the cleaning work
described below. Installations contaminated with oil, grease or other soluble impurities shall be
cleaned with appropriate and approved chemical solvents before mechanical cleaning. If acids
or alkaline solutions are used the treated areas shall be cleaned from the cleaning agents and
neutralized. Only approved and non-harmful cleaning agents shall be used.
Special attention shall be paid to parts made out of synthetic material and of nonferrous metal
not resistant to these cleaning agents. These parts shall be protected against contact with
aggressive solvents. When using inflammable and aromatic solvents or hydrocarbons, works
shall be executed with special care and adequate ventilation shall be foreseen.
The concentration of the solvents shall be kept to a minimum. Benzole and hydrocarbon
solvents shall as far as possible not be used. Appropriate precautions against burning,
cauterization and against contamination of the ground shall be foreseen.
For derusting of sheet steel material, pickling with acid may be applied.
In order to prevent contamination by oil, grease or other soluble impurities, areas with prime
and intermediate coat shall be treated with suitable cleaning agent. Cleaning shall be done
free of residues, e.g. with alkaline detergents and thorough washing done with fresh water.
Rusty spots shall be removed according to required purity. Metallic areas which are provided
with temporary corrosion protection shall be cleaned. No oxidation products shall remain on
the surface. Furthermore it shall be taken care that on hot components neither destructive nor
reaction products will be released, because this could damage the insulation, when the surface
heats up.
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 6 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
Contamination caused by salts, acids and alkali solutions shall be eliminated by rinsing with
water up to a pH value of 6 - 8.
Surface preparation shall be in accordance with the ISO 8501-1 or SSPC- Specifications.
After arrival on site, steel work protected by shop primer shall be cleaned of salt, sand, oil, etc.
before the first coat of paint is applied on site. Shop primer damaged during transport shall be
rectified by blast-cleaning and coating before application of the site coats.
Corroded and damaged areas of shop painted pipe and steel work shall be derusted and
repainted.
The repainting shall match the requirements of the already existing coating. For differences in
the color shade and other defects the Contractor shall be fully responsible.
In cases of doubt the precoatings shall be removed and treated like uncoated installations.
The prime coat shall be applied on derusted areas immediately after mechanical cleaning.
Derusted areas remaining without prime coat overnight, shall and any metal surfaces showing
evidence of flash rusting shall be reconditioned before applying the prime coat.
Precoatings may be used to substitute the first prime coat only. The second prime coat and the
other coats shall be applied in each case.
4.2.2.1 Cleaning with Wire Brushes and/or Scrapers
All surfaces to be coated, shall be cleaned with wire brushes, scrapers, or hammers from
paint residues,
splatters,
mill scale,
welding splashes,
welding slag and
other impurities
which might influence the coating or its adhesion on the surfaces.
Sharp edges shall be rounded off.
During derusting special attention shall be paid to the, very adhering, so called "hard rust".
This "hard rust" shall be completely removed, if necessary with some strokes of a hammer
without damaging the installation.
The use of chisels and other tools which might cause notches is not permitted.
If a protective coating of concrete is required, concrete shall be allowed to cure before painting.
After the preliminary preparations outlined in the above chapter, the surfaces of all piping,
equipment and structural steelwork shall be sandblasted according to:
Specification M21
Subject: Page 7 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
For this reason the grain size of the sand used for blasting shall not surpass 1.2 mm. For
sandblasting only first class dry quartz sand or equivalent material shall be used. Sand shall be
free of salts. The quartz sand shall be stored in a dry condition and maintained dry during use.
Compressed air for sand blast cleaning shall be clean, free of condensation water and oil mist.
All adjacent surfaces shall be protected against damage, stains and paint spatter by the
Contractor. Every precaution shall be taken to protect work from dust throughout painting.
Therefore name plates, signs, glasses, flanges, lightning arrestors, measuring instruments,
windings, seals, valve stems, actuators, actuator-driven parts and areas with markings shall be
protected against flying sand and rebounding sand from sandblasting by the Contractor, i.e. an
ample supply of clean dust sheets shall be available.
After completion of work these protections shall be removed by the Contractor.
Men which are working with air abrasive cleaning tools shall be furnished with approved shot
blast helmets, fresh air masks or hoods.
After blasting, abrasive sand shall be cleaned from the surfaces by brushing with clean hair,
bristle or fibre brushes, blown with clean, dry, compressed air, or vacuum cleaned.
Transport and erection damages, as well as damages which result out of additional welding
shall be repaired as soon as possible. The damaged areas shall be derusted with rotating or
steel brushes, abrasive wheels, abrasive blasting according to standards ISO 8501-1 (Sa 2.5)
or SSPC SP10, (near white metal).
Wood surfaces shall be sanded clean. All nail holes shall be puttied and sanded clean before
priming.
4.3 Painting
4.3.1 General
Blasted surfaces shall be provided with a prime coat, of the appropriate coating system,
immediately after blasting. Before applying the first coat, the surface shall be free of dust, sand
and other atmospheric impurities, and all surfaces shall be inspected and accepted by the
Engineer.
The Engineer has the right to instruct that the paint be removed from areas, which were not
inspected before coating.
When using the provided coating material, strict adherence to all application instructions given
in product data of coating manufacturer is necessary, in order to obtain the maximum
performance.
For a multi-layer coating system, each layer shall have a different color shade in order to
clearly identify number of coats applied.
The last finish coat shall be applied in the specified color shade.
4.3.2 Material
The manufacturer’s recommendations and instructions for thinning, mixing, handling and
applying his products shall be considered as part of this specification. All solvents and
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 8 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
additives may only be used in accordance with the directions of the manufacturer.
Before use, the paints shall be mechanically mixed thoroughly, in accordance with the paint
manufacturer’s instructions. Agitation during application shall be provided, where specified by
the manufacturer.
During painting work, and after work interruptions, the paints shall be mixed again, in order to
avoid the settlement of pigments. Heavy paints with metallic solids shall be mixed very
carefully before use and, from time to time, during use.
Unserviceable, gelatinised paints and additives, shall not be used, and shall be destroyed in
suitable facilities.
The interval between applying the different coats, shall follow according to manufacturer’s
precautions. Each layer shall be cleaned and released from spray dust, before the next layer
will be applied. Prior to applying a further layer, the last one shall be repaired. All coatings shall
be applied without retarding.
The following application procedures are allowed:
1) Prime coats by airless spray
Areas like disconnection, angles, corners, etc. which are difficult to be reached can be
applied by brush or roller
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 9 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
Application by brush:
For coating rough surfaces, screws, small pipes, small fittings etc., round or oval brushes
shall be used. Large areas shall be coated with broad, flat brushes (up to ca. 15 cm).
Only first class brushes, which shall be carefully cleaned after each working period shall
be used.
The individual coatings shall be applied in even layers. Slits, recesses, notches, corners
etc. shall be covered with paint in adequate depth. Edges and protruding objects shall be
precoated. Brush traces shall be avoided. Surfaces not accessible by brush shall be
sprayed.
Application by roller:
This method can only be applied on large and even surfaces in order to apply the second
and following coats. The coating shall be smooth and of even thickness. Pouring out of the
paint with following spreading by roller is not permitted.
Application by spraying:
The condition of the spraying equipment and of its accessories shall ensure a perfect
coating. The nozzles must be exchangeable.
The working pressure shall be adjustable. Oil- and water separators shall be provided, if
necessary.
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 10 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
During spraying, all spraying equipment and its accessories shall be continuously checked
for achieving proper functioning.
Separated oil and water shall be removed out of the separators.
During spraying the paint shall be well mixed in the pistol container. The spraying pressure
shall be in accordance with the paint properties and with all influencing conditions
(additives, temperature, etc.).
The application of the paint shall be evenly and crosswise. The individual layers shall be
overlapping each other.
The nozzle shall be guided vertically to the surface.
The distance between the nozzle and the surface shall ensure that the paint particles are
not dry before reaching the surface.
Only paints especially recommended by the manufacturer for spraying shall be used.
Surface preparation and priming on vessels, equipment and structural steel, shall be
performed by the Contractor in the shop unless otherwise agreed to by the Engineer.
Galvanized surfaces shall be inspected and examined for bare or marred spots. All field welds
and all abrasions caused by handling, shipping, storing, or erecting shall be adequately
prepared, thoroughly cleaned, and touched up with a cold galvanizing compound as specified
herein.
Shop primed surfaces shall be inspected and examined for bare or marred spots. All such
areas shall be adequately prepared, thoroughly cleaned and touched up with specified primer
materials. The finish shall then be applied.
Field fabricated items shall be cleaned, primed and finished as specified in the painting
schedule. Cleaning, priming and finishing over manufacturer’s finish shall be as specified in the
painting schedule.
Flanges, unions, traps, drains, and field supports of hot insulated piping systems, which are
not insulated, shall be cleaned, primed and finished according to the line class or component
of which they are an integral part.
Flanges, nozzles, clips, manways, saddles and other attachments to hot insulated vessels,
heaters, boilers and exchangers, which will protrude through the insulation, shall be cleaned
and primed prior to erection.
Vessels and exchangers scheduled to be insulated for Exposure Protection (IEP) will require
no further jobsite painting.
4.4 Galvanizing
Galvanizing work shall conform in all respects to ISO 1461, BS 3083 and shall be performed
by the hot dip process unless otherwise specified.
It is essential that details of steel structures or parts of it, which are to be hot-dip galvanized,
shall be designed to suit the requirements of the process. They shall be in accordance with BS
4479, ISO 14713, ISO 12944 and DIN 55928.
Vent holes and drain holes shall be provided to avoid high internal pressures and air locks
during immersion and to ensure that molten zinc is not retained in pockets during withdrawal.
Careful cleaning of welds is necessary before welded assemblies are dipped.
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
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Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
All defects of the steel surface including cracks, surface laminations, laps and folds shall be
removed in accordance with DIN EN 10025. All drilling, cutting, welding, forming and final
fabrication of unit members and assemblies shall be completed, where feasible, before the
structures are galvanized.
Structural steel items shall be first grit-blasted according to chapter the standards ISO 8501-1
(Sa 2.5) SSPC SP10, (near white metal), or pickled in a bath.
The minimum average coating weight, shall be as specified in ISO 1461. The minimum
average coating weight on steel sections 5 mm thick and over, shall be 900 g/m², on steel
sections 2 – 5 mm thick, shall be 600 g/m².
Galvanized contact surfaces to be joined by high-tensile friction-grip bolts shall be roughened
before assembly so that the required slip factor acc. to EN 1993 part 1 is achieved. Care shall
be taken to ensure that the roughening is confined to the area of the mating faces.
Protected slings shall be used for off-loading and erection. Galvanized work which is to be
stored at the works or on site shall be stacked so as to provide adequate ventilation of all
surfaces to avoid wet storage staining (white rust).
Small areas of the galvanized coating damaged in any way shall be restored by:
Cleaning the area of any weld slag and executing thorough wire brushing in order to prepare a
clean surface.
Application of two coats of zinc-rich paint, or application of a low melting point zinc alloy repair
rod or powder to the damaged area, which is heated to 300 ° C.
Connections between galvanized surfaces and copper, copper alloy or aluminum surfaces
shall be protected by suitable tape wrapping.
Potential warpage problems, that may require a modification in design, shall be brought to the
attention of Engineer by the Contractor before proceeding with fabrication.
Galvanizing shall be omitted from the surface of all structural steel in contact with concrete
fireproofing. However, partially fireproofed steel structures shall be fully galvanized in order to
avoid partial dipping and possible warpage.
Materials furnished and/or used by the Contractor in connection with the galvanizing shall be
subject to inspection and approval by the Engineer. Any materials not meeting the specified
requirements will be rejected, and shall be replaced with materials of the specified type and
quality.
The Engineer reserves the right to reject any unsatisfactory materials and non- fitting steel
structures resulting from galvanizing. Warped or twisted structural shapes are not acceptable
and shall be straightened prior to shipment. The finished galvanized coating shall be inspected
by the Engineer for acceptability.
5.1 General
Prior to surface preparation and painting, the Contractor shall submit an Inspection and Test
Plan (ITP) for approval by the Engineer. This ITP shall include, as minimum, the working
procedure for surface preparation, the method of applying the paint, and the colors of the
coats.
An ITP for painting of equipment surface in the manufacturer’s work is not required.
All project materials, surface preparation and painting works shall be inspected and tested in
accordance with the requirements of the applicable design codes and the requirements of this
specification.
All equipment and instruments foreseen for the painting work, as well as all paints, require the
acceptance of the Engineer, prior to use.
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 12 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
Each individual coating must be inspected and accepted by the Engineer, before applying the
next one.
Before applying the first prime coat, the derusting and the preparation of the surface, must be
inspected and accepted by the Engineer.
The following standards and methods shall be used for the inspection of blast cleaned steel:
ISO 8501-1
SSPC VIS-1-80-05
For shop painted items, the Contractor shall be fully responsible for surface preparation and
paint application as specified herein. Workmanship, color-code and DFT may be subject to
final inspection by the Engineer at the workshop after the complete painting system has been
applied.
Prior to acceptance of painting all material not used for painting and insulation, as well as all
empty containers and other rubbish, shall be removed from site.
After completion of all works and after cleaning-up the jobsite, all surfaces shall be inspected
and all detected damages shall be carefully marked and repaired in a workmanlike manner.
The acceptance of the painting consists of a visual inspection, measurements of the dry film
thickness on spots selected at random and - in cases of doubts - of destructive tests.
Dry film measurements shall be taken with a Nordson "Mikrotest" dry film gauge or equivalent.
Scope of inspection for measurements of the DFT shall be according to the requirements of
the Engineer. The Engineer reserves the right to measure the film thickness at any spot
selected by him.
All defects such as blisters, detached paint layers, heavy falsifications of color shade, colors
showing through, rust on the metal sheet cover etc. shall be repaired in a workmanlike
manner.
6.1 Preservation
Paint and coating materials shall be stored in air tight containers. Paint and coating materials
shall be adequately protected against freezing and shall not be exposed to direct sunrays as
recommended by the manufacturer of paint. The closure of the paint container shall be of high
quality.
Paint containers shall be opened only just before use and shall be closed immediately
afterwards.
The paints may only be poured into very carefully cleaned containers.
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEMS
Specification M21
Subject: Page 13 of 13
Painting of Piping, Equipment and Structural Steelwork
Doc. - No.: Q C 1 0 - H - 0 6 1 Rev. 1
6.2 Marking
The following paint and coating data shall be clearly marked on the paint containers in
English and Arabic language:
Type of paint
Shade / color
Date of fabrication
Product number
Adhesion
Water absorption
Permeability
6.3 Shipping
Delivery shall furnish paint and coating materials of the manufacturer, type, quality and
color as specified in this specification.
Paint and coating materials shall be delivered to the site in their original factory- packed
unopened containers with legible manufacturer’s labels attached.
7 DOCUMENTATION