Protective Coating Standard Pcs 100 Acp0166 [PDF]

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Standard Specification

PCS 100 PROTECTIVE COATING STANDARD

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SYDNEY WATER

Table of Contents A.

INTRODUCTION ................................................................................................................. 5 A.1. Purpose and Scope...................................................................................................... 5 A.2. Disclaimer..................................................................................................................... 5 A.3. Document Structure ..................................................................................................... 5 A.4. Mandatory and Informative........................................................................................... 5 A.5. Use of the Document.................................................................................................... 6 A.5.1. Design ................................................................................................................... 6 A.5.2. Construction .......................................................................................................... 6 A.5.3. Testing .................................................................................................................. 6 A.6. Referenced Documents................................................................................................ 6 A.7. Definitions..................................................................................................................... 7 B. GENERAL REQUIREMENTS.............................................................................................. 9 B.1. Quality Assurance ........................................................................................................ 9 B.1.1. Quality System ...................................................................................................... 9 B.1.2. Supplier’s Specification ......................................................................................... 9 B.1.3. Approved Applicators ............................................................................................ 9 B.1.4. Materials................................................................................................................ 9 B.2. Surface Preparation ................................................................................................... 12 B.2.1. General ............................................................................................................... 12 B.2.2. Mild Steel, Cast Iron and Ductile Iron.................................................................. 12 B.2.3. Galvanized Steel, Stainless Steel, Aluminium, and Copper ................................ 12 B.2.4. Plastics and FRP................................................................................................. 13 B.2.5. Concrete and Masonry ........................................................................................ 13 B.2.6. Existing Coatings ................................................................................................ 14 B.2.7. Pre-coated Proprietary Equipment ...................................................................... 15 B.2.8. Rectification of Metal Defects.............................................................................. 15 B.2.9. Pre-Cleaning ....................................................................................................... 15 B.2.10. Abrasive Blast Cleaning................................................................................... 15 B.2.11. Brush Blasting ................................................................................................. 16 B.2.12. Hand or Power Tool Cleaning.......................................................................... 17 B.2.13. Sealing for Reservoirs with Concrete Base ..................................................... 17 B.3. Coating Application .................................................................................................... 18 B.3.1. Application Constraints........................................................................................ 18 B.3.2. Additional Constraints for Application of Concrete Surface ................................. 19 B.3.3. Ventilation and Dehumidification ......................................................................... 19 B.3.4. Mixing.................................................................................................................. 19 B.3.5. Film Thickness .................................................................................................... 19 B.3.6. Edge Coating and Stripe Coats........................................................................... 20 B.3.7. Crevices and Gaps.............................................................................................. 20 B.3.8. Repair of Defects in New Coatings ..................................................................... 21 B.4. Inspection and Testing ............................................................................................... 22 B.4.1. Inspection and Test Plan (ITP)............................................................................ 22 B.4.2. Coating Inspector ................................................................................................ 22 B.4.3. Quality Control Records ...................................................................................... 22 B.4.4. Quality Control Testing........................................................................................ 23 B.5. Health and Safety....................................................................................................... 27 B.5.1. General ............................................................................................................... 27 B.5.2. Handling Of Chemicals........................................................................................ 27 WARNING – Document current at time of printing or downloading

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B.5.3. Pressure Equipment............................................................................................ 27 B.5.4. Earthing............................................................................................................... 27 B.5.5. PPE and Ventilation ............................................................................................ 28 B.5.6. Access................................................................................................................. 28 B.6. Environmental Protection ........................................................................................... 29 B.6.1. General ............................................................................................................... 29 B.6.2. Lead Paint ........................................................................................................... 29 B.6.3. Containment........................................................................................................ 29 B.6.4. External Surfaces................................................................................................ 30 B.6.5. Internal Surfaces ................................................................................................. 30 B.6.6. Assessing Emissions........................................................................................... 30 C. PROTECTIVE COATING SYSTEM SELECTION.......................................................... 32 C.1. Introduction................................................................................................................. 32 C.2. Maintenance Painting................................................................................................. 32 C.3. Recommended Coating Systems ............................................................................... 34 C.3.1. Water Reservoirs and Pipelines .......................................................................... 35 C.3.2. Sewage Pumping Stations and Water Pumping Stations.................................... 36 C.3.3. Sewage Treatment Plants and Water Filtration Plants ........................................ 37 C.4. Environment Exposure Class ..................................................................................... 39 C.5. Default Colours........................................................................................................... 40 D. COATING SYSTEM SPECIFICATIONS ........................................................................ 42 D.1. Summary Descriptions ............................................................................................... 42 CS-01.................................................................................................................................... 45 CS-02.................................................................................................................................... 46 CS-03.................................................................................................................................... 47 CS-04.................................................................................................................................... 48 CS-05.................................................................................................................................... 49 CS-06.................................................................................................................................... 50 CS-07.................................................................................................................................... 51 CS-08.................................................................................................................................... 52 CS-09.................................................................................................................................... 53 CS-10.................................................................................................................................... 54 CS-11.................................................................................................................................... 55 CS-12.................................................................................................................................... 56 CS-13.................................................................................................................................... 57 CS-14.................................................................................................................................... 58 CS-15.................................................................................................................................... 59 CS-16.................................................................................................................................... 60 CS-17.................................................................................................................................... 61 CS-18.................................................................................................................................... 62 VES ...................................................................................................................................... 63 NOV ...................................................................................................................................... 64 GAL ...................................................................................................................................... 65 TSZ....................................................................................................................................... 66 PMB ...................................................................................................................................... 67 EPM...................................................................................................................................... 68 CPL....................................................................................................................................... 69 CAC ...................................................................................................................................... 70 E. APPROVED COATING PRODUCTS ................................................................................ 72 F. ADDITIONAL INFORMATION (Informative)...................................................................... 76 F.1. General guideline for selection of coatings................................................................. 76 WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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F.2. Examples of asset types ............................................................................................ 78 F.2.1. Assets that may require higher protection ........................................................... 78 F.2.2. Assets that may require lower protection ............................................................ 78 F.3. Chemicals corrosivity ................................................................................................. 79

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A.

INTRODUCTION

A.1. Purpose and Scope This Document sets out the standard protective coating requirements to ensure high quality level of workmanship and long-term protective coating performance is achieved. It applies to construction and maintenance of Sydney Water’s drinking water, wastewater, stormwater, and recycled water infrastructures and associated equipment. This Standard shall be used in conjunction with all technical documents provided by the Supplier of the coatings to be used. This document also refers to, and shall be used in conjunction with, relevant Australian Standards (AS), Australian/New Zealand Standards (AS/NZS), and other international standards. Together they form an integrated specification that must be adhered to by the Applicator. If there are any contradictory recommendations or requirements between the documents, then it shall be referred to the Principal (Sydney Water).

A.2. Disclaimer Sydney Water develops and publishes this Document only for the purpose and scope stated above and on the understanding that: • Sydney Water Corporation and individual contributors are not responsible for the results of any action taken on the basis of information in this Document, nor any errors or omissions; • Sydney Water Corporation and individual contributors disclaim all and any liability to any person in respect of anything, and the consequences of anything, done or omitted to be done by a person in reliance upon the whole or any part of this Document; • This Document does not purport to be a comprehensive statement and analysis of its subjective matter, and if further advice is required, the services of a competent professional should be sought; and • Sydney Water Corporation reserves the right to make any changes to the content of the Document without giving notice or explanation.

A.3. Document Structure This Standard comprises of:
Section A: Introduction
Section B: General requirements
Section C: Selection of coating system
Section D: Specifications of coating system
Section E: Approved coating products
Section F: Additional information

A.4. Mandatory and Informative This document provides a mixture of mandatory and informative statements. They are deliberately combined throughout the document in order to provide relevant context and enable better understanding of the mandatory requirements.

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Where an obligation is given and it is not stated who is to undertake these obligations, they are to be undertaken by the Applicator. Where a submission, request or proposal is required and it is not stated who the recipient shall be, it is to be provided by the Applicator to Sydney Water (Principal) for approval. The use of this Standard does not relieve Supplier and Applicators of any responsibility for delivering the quality level of design, materials, workmanship, and performance, that they have been engaged to provide.

A.5. Use of the Document The following scenario illustrates a typical use of the document. A.5.1.

Design

The Designer or Project Manager uses this document, in particular Section C (Selection of coating system) and Section D (Specifications of coating system), as input for design Specification and/or Drawings. A.5.2.

Construction

The Applicator is engaged to apply the specified protective coatings in the design Specification and/or Drawings. The Applicator must follow the methodology specified in this document (Section B) and use approved materials and products only (Section E), and other sections referred by the Designer or Project Manager. A.5.3.

Testing

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

A.6. Referenced Documents AS/NZS 1345 AS 1627.1 AS 1627.4 AS 1627.9 AS/NZS 1715 AS/NZS 1716 AS/NZS 2310 AS 2700 AS 3894.1 AS 3894.3 AS 3894.4 AS 3894.5

Identification of the contents of piping Surface Preparation – Degreasing Surface Preparation - Abrasive Blast Cleaning Pictorial surface preparation standards for painting steel surfaces Selection, use and maintenance of respiratory protective equipment Respiratory protective devices Glossary of paint and painting terms Australian Standard Colour Code Site Testing of Protective Coatings Continuity Testing - High Voltage (brush) Method Site Testing of Protective Coatings Determination of film thickness Site Testing of Protective Coatings Degree of cure Site Testing of Protective Coatings Determination of surface profile WARNING – Document current at time of printing or downloading

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AS 3894.6 AS 3894.7 AS 3894.9 AS 3894.10 AS 3894.11 AS 3894.12 AS/NZS 4020 AS/NZS 4158 AS 4361.1 AS/NZS 4680 ASTM D4263

Site Testing of Protective Coatings Contamination Site Testing of Protective Coatings Determination of Surface Temperature Site Testing of Protective Coatings Determination of Adhesion Site Testing of Protective Coatings Inspection Report - Daily surface and ambient conditions Site Testing of Protective Coatings Inspection Report – Equipment Site Testing of Protective Coatings Inspection Report – Coating Testing of products for use in contact with drinking water Thermal-bonded polymeric coatings on valves and fittings for water industry purposes Guide to lead paint management - Industrial applications Hot dip galvanised (zinc) coatings on fabricated ferrous articles Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method

A.7. Definitions Refer to AS/NZS 2310 for a glossary of paint and painting terms which may be used in this document. The following definitions apply to this Specification: Steel or steelwork

Refers to all ferrous-based components including carbon steel, wrought-iron, cast iron and galvanized components.

Dry film thickness (DFT)

The dry film thickness of a coating remaining on the surface and above the peaks of the surface profile when the coating or system has hardened and cured.

Nominal dry film thickness (NDFT)

The dry film thickness specified for each coating layer or for the whole coating system.

Minimum dry film thickness

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

Maximum dry film thickness

The highest acceptable dry film thickness for each coating layer or for the whole coating system above which the performance of the coating layer or system could be impaired.

Gauge reading

A single DFT reading taken at one point.

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Spot measurement

The arithmetic average of three gauge readings made within a circle of approximately 40 mm diameter.

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B.

GENERAL REQUIREMENTS

This section contains general requirements covering methods of surface preparation and coating application, inspection and testing, quality control, quality assurance, health and safety and environment protection.

B.1. Quality Assurance B.1.1.

Quality System

The Applicator shall develop and implement a Quality Management System for the works. In all cases, this is to involve preparing ITPs (Inspection and Test Plans) for each coating system to be used and the provision of a suitable system of Quality Control (QC) records. B.1.2.

Supplier’s Specification

A written specification or coating schedule from the Supplier prior to the commencement of the work shall be submitted for each coating system. It must contain the requirements for the supply, storage, mixing, equipment, surface preparation, application, recoat times, curing, inspection, testing and repair of defects. B.1.3.

Approved Applicators

Surface preparation and coating application shall be undertaken by a pre-qualified painting contractor (Applicator). The Applicator shall be accredited by the Painting Contractors Certification Program (PCCP) to the class relevant to the work to be undertaken. Where the work involves the maintenance or removal of coatings which contain or may contain lead compounds or other toxic substances, such work shall only be undertaken by a pre-qualified Applicator holding a PCCP Class 5 certificate. It should be noted that there are some products specified herein that may be applied by a nonPCCP accredited Applicator. These products are typically linings for concrete and masonry structures. They include polymer modified mortars and bitumen, aluminate cements, and geosynthetics. For this work, the Applicator shall demonstrate that its personnel have successful track records in applying the nominated product. If the Supplier requires that the application of its products be undertaken only by an applicator that has been approved by the Supplier, then the Applicator shall be a Supplier-approved one. B.1.4.

Materials

a) Protective Coatings A list of approved protective coating products can be found in Appendix E. These coatings have been assessed to: • have satisfactory long-term track records; • originate from quality assured manufacturers and/or suppliers; • be part of a global product range; and • have relevant certifications issued by Australian Paint Approval Scheme (APAS), where available. Note that preference should be given to coatings approved by APAS. WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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APAS approved coating products are preferred by Sydney Water. If the listed APAS approved products are not available, then non-APAS approved products may be used. In the case of all listed products are not available, other products that can be demonstrated to have at least equal performance to the ones specified in the list may be used, subject to prior approval from the Sydney Water. Where available, all products used within a selected coating system should originate from a single supplier. Importantly, they must be compatible with each other and applied strictly in accordance with this Standard and the Supplier’s specification. Sydney Water reserves the right to make any changes to the content of the list without giving notice or explanation.

b) Thinners For each of the coating products, use only the specific thinner recommended by the Supplier for thinning of coating. Thinners shall not be decanted into previously used containers and all drums and cans are to have their original and traceable batch number. Solvents that are specified only for the cleaning of equipment shall not be used to thin any coating material. Prior to application of coating, all cleaning solvents shall be removed and flushed from the equipment. c) Transportation and Storage All products brought to site must be in their original unopened containers, bearing the manufacturer’s label, batch number, product code(s), coating colour, mix ratio information and expiry date where applicable. Products that have exceeded their expiry date or have deteriorated during storage shall not be used. All products are to be stored under cover and in a manner that ensures protection from extremes of temperature, contact with moisture or other conditions that could lead to deterioration of the material. Lids on solvent drums or cans must be kept closed when not in use to prevent contamination with water or other materials. Coatings about to be used shall be within a temperature range that meets the Supplier’s recommendations. If no recommendations are provided, the temperature of all components shall be between 15°C and 25°C at the time of mixing. d) Coatings in Contact with Drinking Water Any coating in contact with drinking water shall be certified to comply with AS/NZS 4020 by a NATA accredited laboratory. Overseas products that have ANSI/NSF 61 or BS 6920 certificates may be approved for use, if it can be demonstrated that the Supplier is in the process of obtaining AS/NZS 4020 certification. For the purposes of this specification, drinking water is assumed to include water at any stage of the treatment and delivery processes, and not just the final product. These coatings include those that are immersed in drinking water, frequently splashed, and where condensation occurs, hence subsequently the water enters the drinking water system.

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Attention must be given to the ratio of surface area to volume. The specified ratio of surface area to volume in the test certificate must be equal or greater than the actual structure ratio of surface area to volume. e) Cathodic Protection System Compatibility Where the coatings are nominated for structures that have cathodic protection (CP) system, a certificate of suitability from the Supplier shall be provided.

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B.2. Surface Preparation The following clauses in this section contain requirements for surface preparation according to substrate materials and approved methods. B.2.1.

General

The surface preparation method or combination of methods shall be selected taking into account the condition of the structure, the potential contaminants present, access to perform the work, and the required surface cleanliness and profile. Where possible for new construction, all preparation and the application of the first coat should be performed off site in a suitable enclosed workshop or otherwise in controlled conditions. To avoid excessive damage and repair to pre-primed or pre-coated surfaces, wherever possible, rolling, forming and fabrication operations shall be completed prior to the surface preparation and coating application. Prior to blast cleaning in order to achieve the required surface cleanliness and profile, any defects shall be repaired and all surfaces shall be pre-cleaned. B.2.2.

Mild Steel, Cast Iron and Ductile Iron

All mild steel, cast iron and ductile iron surfaces shall have an angular surface profile of 30 – 60 microns and a minimum Class 2½ (Sa 2½) finish in accordance with AS 1627.4, unless otherwise stated in the relevant coating table in Section D. All systems for immersion shall have a Class 3 (Sa 3) cleanliness standard, also with an angular surface profile of 30 – 60 microns. Where hot metal spray (aluminium, zinc/aluminium or zinc) is to be used, the surface shall be blast cleaned to a Class 3 (Sa 3) standard with a sharp, angular surface profile of 75 – 125 microns. B.2.3.

Galvanized Steel, Stainless Steel, Aluminium, and Copper

The surface of these non-ferrous metals shall be lightly abraded using hand or power tools, or brush blasted at low pressure in order to achieve a surface finish equivalent to Class 2. While the descriptions in AS 1627.4 and AS 1627.9 refer specifically to mild steel surfaces, and as such, will not be directly indicative of the appearance of other metallic surfaces, efforts shall be made to achieve a similar visual degree of surface cleanliness. The surface profile of the non-ferrous substrate shall be 20 microns or less. This is typically visually indicated in the form of a matte finish (not glossy). Galvanized steel shall not be blasted back to the steel surface, rather, the thickness of the remaining zinc layer shall be maximised, while still achieving the required level of surface preparation. Where galvanizing has been damaged or corroded back to bare steel, it shall be repaired using appropriate system.

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B.2.4.

Plastics and FRP

The surface shall be lightly hand or power tool abraded, or low pressure brush blasted to remove all visible gloss from the surface. The surface profile shall not exceed 20 microns. B.2.5.

Concrete and Masonry

a) New Concrete All new concrete works shall be cured to a minimum 28 days before application of coatings, unless otherwise approved. Any foreign materials such as oils, grease, waxes, form release agents, curing compounds, efflorescence, sealers, salts, laitance, or other contaminants shall be effectively removed. Abrasive blasting should be used to prepare the surfaces. All debris shall be removed following the cleaning and disposed of in an appropriate waste facility. Acid etching may only be used for horizontal surfaces only. The concentration of HCl solution used for acid etching shall not exceed 10%. The etched surface shall be adequately washed with fresh water to remove any residual acid. This is indicated when the water used for washing has reached around pH 7. The concrete surface finish shall be sufficiently rough to receive the coating. Typically it is equivalent to sandpaper with grit 80 or coarser. Level or grind concrete substrates to manufacturer's recommended tolerances and to produce a textured but uniform installation, including removal of all sharp edges, ridges or depressions. New concrete voids and depressions shall be filled with render/filler material, re-establishing plan finished grades and surface profiles Cementitious rendering products shall be used for surface levelling, filling voids, large bugholes, and for general concrete patching and shall be installed and cured according to manufacturer’s guidelines. Polymer modified filler and repair products shall be used for filling and repairing small bugholes, static cracks and joints, and for general concrete patching in order to provide uniform and void free surface for coating application. b) Old Concrete Any drummy or delaminated concrete sections, or concrete deteriorated by corrosion or other means, shall be broken out and removed so that sound substrate remains. Sound concrete shall have pH 10 or greater. This may be indicated using a phenolphthalein solution spray. All oil, grease and chemical contaminants must be removed from the surface of concrete. Concrete surrounding any corroded reinforcement bars shall be broken out beyond the limits of corrosion until clean bar is evident, and at least 20 mm behind the bar. Where there is a potential for excessive removal of substrate material, or the reinforcement bar has more than surface corrosion, a direction from the Principal shall be sought. Any exposed reinforcement shall be primed with zinc rich coating, and fully embedded without any air pockets being entrapped. The surface shall be steel trowelled, and its profile shall be made to achieve optimum bond with the protective coating. The broken out voids and lost concrete sections shall be restored back to the original surface level using a suitable patch repair mortar. Feathered edges shall be avoided by saw cutting to a minimum depth of 10 mm at the edges of the area to be patched.

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Static cracks wider than 0.3 mm shall be repaired. The path along the crack shall be chased forming a wedge-shaped slot of 20 mm wide x 20 mm deep. The slot is then filled with polymer modified repair mortar. The surface shall be struck flush with the cleaned concrete adjacent to the crack. Any active crack shall be treated as a joint, and repaired using a waterproof joint sealant system. Any infiltration at the crack shall be stopped first prior to undertaking crack repair. c) Masonry All oil, grease and chemical contaminants must be removed from the brick by chemical cleaning, hydroblast or abrasive blast to provide anchor profile on brickwork and to remove all existing paints, protective coatings, foreign particles, chemically attacked or unsound mortar. Loose brickwork and voids in the mortar joints should be re-pointed. All active hydrostatic leaks must be stopped prior to protective coating application. B.2.6.

Existing Coatings

All existing coatings shall be first visually inspected for damage and tested for adhesion using AS 3894.9 – Method A (Knife Test). A result of 0 to 2 on the scale provided in the standard is required. In areas where damage is present, or test results indicate an adhesion rating of greater than 2, the existing coating shall be fully removed to bare substrate and the surface shall be prepared for the application of new coating using the requirements detailed herein. If a large proportion of the existing coating is unsound, then removal of the entire existing coating shall be considered. In addition, it may be necessary to remove the existing coating when the combined system of existing and new coatings is not compatible with each other, or would become too thick. Where existing coating is in an exterior environment and is intended to be left principally intact by being either spot repaired, spot repaired and fully coated, or fully recoated; all surfaces are to be jetwashed clean using fresh water at a nozzle pressure of greater than 14 MPa (2000 psi) and less than 34 MPa (5000 psi). All sharp edges of the remaining sound coating shall be feathered, tapered or smoothed-off to an appropriate degree based on the accessibility and visibility of the coated surface. Excessive effort and input to feathered zones should be avoided. They could compromise the integrity of the existing coating system in the transition zone due to heating during sanding or grinding. Any bare areas shall be spot primed. All coated surfaces with intact, glossy and sound coating shall be lightly abraded to remove all visible gloss before overcoating, unless the subsequent coating layer is tolerant of this condition. The paint manufacturer shall be consulted when choosing a suitable primer product for any application onto previous coatings. Where the compatibility between the old and new coating system is

unknown, the new coating system shall be applied to a small area, and allowed to fully cure. A method for performing and evaluating a patch test to assess coating compatibility is detailed in ASTM 5064. The adhesion of the new coating system shall then be determined as described in Clause 4.4(2).

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B.2.7.

Pre-coated Proprietary Equipment

Equipment supplied pre-coated with the manufacturer’s factory coating system may be accepted providing the performance of the existing coating system and the level of surface preparation can be demonstrated as being equal to or greater than the relevant system specified in this document. If the existing coating does not meet the requirements of this specification, the existing coating system on the item shall be fully replaced or upgraded by the relevant system. Care shall be exercised to protect bearings, windings and all operational parts from contamination and damage when applying new paint system. Where the compatibility between the existing and new coating system is unknown, the new coating system shall be applied to a small area, and allowed to fully cure. A method for performing and evaluating a patch test to assess coating compatibility is detailed in ASTM 5064. The adhesion of the new coating system shall then be determined as described in Clause 4.4(2). B.2.8.

Rectification of Metal Defects

Prior to preparing the surface to the specified degree of cleanliness and surface profile required, the Applicator shall ensure the surface is free of all metal defects including but not restricted to • • • •

Cracks Burrs Sharp edges Coarse welds

• • • •

Porosity Weld splatter Fins Laminations

• • • •

Deep pitting Undercuts Slag Weld roughness

Sharp edges, bolt holes and corners, including sharp edges resulting from loss of section shall be ground to a minimum radius of 2 mm to meet the requirements of Preparation Grade P2 as defined in ISO 8501.3. Welds shall be ground to a smooth surface free of peaks and sharp edges to a degree where they are paintable. Where galvanizing has been welded or otherwise damaged, the damaged areas should be ground down, taking care to feather or taper edges. B.2.9.

Pre-Cleaning

All pre-cleaning processes shall be carried out in accordance with AS 1627.1 to remove oil, grease, dirt, bird droppings, algae, moss, etc. For heavy deposits of contaminants, it may be necessary to repeat pre-cleaning processes to achieve the required level of cleanliness or use a combination of processes. B.2.10.

Abrasive Blast Cleaning

The abrasive blast cleaning process shall be performed in accordance with AS1627.4. For all on-site work, use either almandine garnet or staurolite abrasive for the final blast, regardless of whether the work is carried out in a weatherproof containment or not.

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Do not use copper slag and other mineral slag abrasives that may contain various forms of heavy metals. Slag abrasives that are demonstrated to be free from heavy metals (less than 100 ppm lead) may be used as an abrasive for initial blasting of heavy coating films, but in all cases, the final blast cleaning shall be performed using new (not recycled) garnet or staurolite. Remove all inspirable dust, contaminants, surface preparation debris and toxic contaminants from abrasives used as a blasting medium prior to their re-use in the blasting process. The Principal’s approval must be sought before the re-use of any non-metallic abrasive. Abrasives are to be analysed before first use or re-use and must comply with the following: (a)

Moisture content: Maximum 0.2% as determined in accordance with ANZECC Method 102.

(b)

Soluble salt: Maximum conductivity of aqueous extract, 250µS/cm tested as per ISO 11127-6.

(c)

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

(d)

Total lead (Pb) content: Maximum of 100 mg/kg (ppm) tested as per US EPA Method 6010B.

(e)

Free crystalline silica: Maximum of 1% as determined by infrared spectroscopy or XRD analysis.

(f)

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

Blasting abrasive shall be non-metallic, dry, clean, sharp and angular, free from contaminants, and of a type and size adequate to give the relevant surface profile amplitude and an angular profile shape. Recycling of abrasives contaminated with bitumen, coal tars, oil or grease is not permitted. A suitable containment must be used to prevent the spread of emissions. A vacuum blasting system may be used as an alternative to prevent the spread of emissions. Dust and spoil shall be removed from the surface immediately prior to coating or recoating by blowing with clean, dry air followed by either vacuum cleaning or careful brushing. All horizontal surfaces, e.g., tank bottom plates, ledges, etc., must be vacuum cleaned before coating. Vertical or overhead surfaces can be blown down with compressed air. Where nominated in the specification or the ITP, tests for the presence of dust on the prepared steel surface shall be conducted in accordance with AS 3894.6, Method C, Determination of surface dust. A rating of 2 or better is required for atmospheric service, and a Rating 1 or better for immersion service. The prepared surface must be coated before any contamination or corrosion occurs. Flash rusting typically occurs within four hours of blasting, unless dehumidification is provided. In all cases, the specified standard of surface cleanliness and surface profile height and shape, must exist at the time the primer is applied to any surface area. B.2.11.

Brush Blasting

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

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B.2.12.

Hand or Power Tool Cleaning

In the event that abrasive blast cleaning is impractical and at the sole discretion of the Principal, surfaces may be mechanically cleaned using hand or power tools such as needle guns. All hand or power tool cleaning shall be carried out in accordance with AS 1627.2. A suitable containment must be used to prevent the spread of emissions, such as drop sheets and/or side tarps. Dust and spoil shall be removed from the surface immediately prior to recoating by blowing with clean, dry air followed by either vacuum cleaning or careful brushing. The prepared surface shall be coated with primer before any contamination or corrosion occurs. B.2.13.

Sealing for Reservoirs with Concrete Base

Where a reservoir has a concrete floor and is fitted with a haunch joint at the junction of the wall and the floor, a bitumen seal is to be prepared in the following manner: 1. Cut a “Vee” groove into the bitumen seal so as to remove sufficient seal to expose not less than 20 mm of the embedded wall surface. 2. Prepare and coat the newly exposed steel using the coating system specified for the walls. 3. When the coating system has fully cured, reinstate the joint by refilling the ‘Vee” groove with a hot applied bitumen sealant

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B.3. Coating Application The section contains the requirements for application of coatings, and repair of damage to new coatings. Coating application shall be performed by competent and experienced personnel under close supervision to ensure that coatings are not applied until the specified standard of surface preparation has been achieved, weather conditions are suitable for coating application and curing, and the coating application and film thickness requirements are strictly followed. The applied coating shall be uniform in thickness and appearance and shall be free of defects such as runs, blisters, pinholes, holidays, overspray, inclusions, etc.; using application equipment (or a combination of equipment), a sequence of coating various surfaces and techniques that produce the required coverage, DFT, standard of finish and film integrity implied by this Specification and the product data sheets for the coating products employed. All overspray shall be removed by sanding from the surface of primer or intermediate coats before overcoating commences. The Contractor shall record all details of surface preparation, paint application, ambient weather conditions, and film thickness measurements on Daily Inspection Reports. As a guide, suitable forms are available in AS 3894.10 to 14. Airborne dust, insects and other foreign matter that settles onto and is protruding from the primer or intermediate coat surface shall be removed by sanding once the coating has sufficiently hardened. Where more than one coating layer is to be applied, the colour of successive coats (including stripe coats) shall be different to aid application and inspection. B.3.1.

Application Constraints

Unless overruled by the coating manufacturer’s product data sheet(s) or written instructions, the following limits of application and curing conditions are to apply: Final surface preparation, coating application or initial coating curing (at least 12 hours) shall not take place when: (a)

The relative humidity is above 85 percent; or

(b)

The substrate temperature is less than 3°C above the dewpoint; or

(c)

The ambient air temperature is below 10°C or above 30°C; or

(d)

The substrate temperature is below 10°C or above 35°C; or

(e)

The surface to be coated is wet or damp; or

(f)

Where the full prime coat application cannot be carried out before the specified cleanliness of the surface deteriorates.

Proper and effective control of the environment and conditions during the curing stage of all coating layers are to be maintained. WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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B.3.2.

Additional Constraints for Application of Concrete Surface

Application in direct sunlight and/or with rising surface temperatures is strongly not recommended, as this may result in blistering of the materials due to expansion of entrapped air or moisture (out-gassing) in the concrete. In such cases, it will be necessary to postpone the application until later in the day when the temperature of the substrate is falling. Concrete surfaces that have been in direct sunlight must be shaded for at least 24 hours prior to application and remain shaded until the initial set has taken place. Consult Manufacturer for application schedule guidelines specific to temperature conditions and possible sealer application recommendations to reduce out-gassing. B.3.3.

Ventilation and Dehumidification

If surface preparation and coating application is performed inside containments or on the interiors of enclosed areas, a mechanical ventilation system must operate during all application to improve visibility, lower the OH&S risk to operators, and assist in removing the desorbed solvent. After application and during the curing phase (typically overnight), a mechanical ventilation system will still be required to ventilate the containment for a period up to at least 24 hours after the end of application, although this could operate at a lesser number of air changes per hour during the curing period. Dehumidification units and/or heaters that vary the relative humidity and control the temperature may be required to prevent flash rusting and create optimum environmental conditions during coating application and curing. All heaters must be indirectly fired, i.e., no combustion products are to come into contact with the coating system or the ambient air in the containment. When using such equipment to vary coating application conditions, the equipment must be used during the whole time that work is being performed including the recommended curing period after the last application of the coating. B.3.4.

Mixing

Two-pack coatings shall be thoroughly mixed using the whole contents of each container to ensure the correct proportioning ratio has been maintained. Split or part packs shall not be used unless a reliable and repeatable method of proportioning the components is used. Coating materials containing heavy or metallic pigments that have a tendency to settle shall be kept in suspension in the fluid pot by a power driven mechanical agitator. Other coating materials shall be agitated as frequently as workability requires. If the coating material requires the addition of a catalyst, the pot life for the prevailing conditions must not be exceeded. When the pot life limit is reached, the materials must be discarded and all equipment cleaned. B.3.5.

Film Thickness

The Supplier should be consulted to determine if the dry film thickness (DFT) for a single coat called for by this specification is achievable. If the dry film thickness cannot be achieved in a single coat, then multiple coats may be used, so long as the specified dry film thickness for that coating system is achieved. In all cases, the DFT specified is to prevail, not the number of coats. Where multi-coat systems are specified in this document, the condition of the coated surface shall be in accordance with this Specification and the Supplier’s requirements prior to WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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application of subsequent coats. The specified time between coats shall be calculated from the product data sheets at the prevailing temperatures, and strictly adhered to. Application shall be carried out such that a smooth, uniformly coat within the correct film thickness range is obtained. There shall be no deep or detrimental brush marks or adverse spray patterns that could compromise the performance of the coating. Paint shall be worked into all crevices and corners without causing overbuild. The cured coatings shall be free of pinholes, voids, inclusions, bubbles, runs and sags. B.3.6.

Edge Coating and Stripe Coats

All areas such as external corners and edges, welds, bolts, nuts and interstices shall receive a stripe coat prior to application of the specified film thickness and to ensure continuity of the coating, except for the primer, which shall be stripe coated after the full coat has been applied. The stripe coat shall be allowed to touch dry prior to the next coating application. Where specified, a separate additional stripe coat, having a colour distinctly different to the underlying and subsequent coatings, is to be applied. The purpose of the stripe coat is to ensure that the final DFT achieved on difficult-to-spray areas will be between the minimum and maximum limits, but having excessive film build that could in itself be detrimental. Where stripe coats are specified, they shall be applied to all shadowed and other difficult-tospray areas such as: • unsealed and filled lap joints, • edges, • crevices formed by plates; • welds, • exposed edges, • bolt heads, • holes, and • nuts, • heavily pitted areas, • washers, • rivets, before the application of each full coat, except for primers, where the stripe coat is to be applied after the full coat is sprayed. Inorganic zinc silicate primers are generally not to be brush-applied as stripe coats. Stripe coats shall be applied by brush, roller, spray or other application method as applicable to the nature of the surface or structure. If the combination of a prior-applied stripe coat and then a spray-applied full coat does not achieve the correct coverage and film build in all areas, additional touch-up effort will be required to complete each layer to achieve the specified acceptance criteria before any subsequent coating layers commence. B.3.7.

Crevices and Gaps

Unless specified otherwise, fill any crevices and gaps that are not filled following application of the primer and intermediate coats. The filler material shall be compatible two-pack, marinegrade solventless epoxy filler, approved by the Supplier. As there is minimal corrosion protection afforded by the epoxy filler, it is not to be applied to bare or primed steel. The epoxy filler is to be applied after the first coat of epoxy high build, and is then to be sealed with a stripe coat of epoxy high build prior to the application of the balance of the coating system. WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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Fill gaps between back to back angles or other sections with an epoxy filler only at upward facing locations that have the potential to hold water and/or dirt such as at points of intersection of slats in latticed members. Apply a stripe coat of the epoxy build coat paint and other paints in the coating system to filled crevices and gaps prior to the application of the topcoat. Unsealed joints without any principal gap in atmospheric service only, such as on crossed lattice slats, shall be filled using compatible caulking gun-grade polyurethane. This filler shall be applied after the first coat of epoxy high build, be stripe coated and then topcoated. B.3.8.

Repair of Defects in New Coatings

Areas where inadequate coating thickness or pinholes have been detected, shall be repaired with the following methodology. 1. Remove all loose and flaking coatings until a sound, tightly adhering edge is achieved; 2. Pre-clean the surface to ensure the surface is clean and free of oil, grease, dirt and all contaminants; 3. Grind out or sand pinholes or minor faults sufficiently to ensure the repair coating will penetrate and eliminate the defect; 4. Feather, taper or smooth-off all sharp edges of the remaining sound coating to an appropriate degree; 5. Lightly abrade the damaged surface with a hand or power tool, or sweep blast to remove visible gloss; 6. Remove all dust using a slightly solvent-wet rag; and 7. Reinstate the surface by re-applying the coating system over the affected area.

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B.4. Inspection and Testing B.4.1.

Inspection and Test Plan (ITP)

Prior to commencement of the work, an ITP similar to the informative example in section E.3 shall be prepared for each coating system and submitted for approval. The ITP must also show the type, sequence, and number of tests to be taken in a given area and how the pass or reject criteria are determined. B.4.2.

Coating Inspector

A coatings inspector shall be nominated by the Applicator as their quality control officer to carry out inspections, to undertake the required testing and to make the appropriate records for all work performed in accordance with this document. The Applicator’s Coating Inspector shall be certified by either:
Australasian Corrosion Association (ACA);
Painting Contractors Certification Program (PCCP);
NACE International; or
Society of Protective Coatings (SSPC). The Principal may instruct a representative or an independent coatings inspector to carry out quality audits on the work from time-to-time on behalf of Principal. Access to the site for this purpose shall be provided at no cost to the Principal. B.4.3.

Quality Control Records

Quality Control (QC) records, in a format similar to AS 3894 – Parts 10, 11 and 12 or equal, shall be prepared and submitted for approval on a daily basis during the work. They shall consist of: 1. Inspection Report – Daily Surface and Ambient Conditions Report (Refer to AS 3894.10) (a) Details of prevailing weather conditions and other matters potentially influencing the durability of the applied coatings shall be recorded at regular intervals during the application process. These shall include, but not be restricted to: surface temperature (measured in accordance with AS/NZS 3894.7), air temperature, dew point, relative humidity, the difference between the surface temperature and the dewpoint and general weather observations. (b) Details of the final standard of surface preparation. Any defects in the surface to be painted shall also be recorded. 2. Equipment Report (Refer to AS 3894.11) Details of all production and test equipment used during application and inspection shall be recorded at the commencement of the work. Records shall be updated whenever calibration, standardisation, or replacement of equipment occurs.

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3. Inspection Report – Coating (Refer to AS 3894.12) Details of all paints, coatings and their component parts – including solvents and thinners used – shall be recorded. The results of QC testing shall be recorded for each stage of the work. All defects shall be recorded and subsequently repaired. These records shall be made available for inspection upon request at any time during the work and a copy provided daily to the Principal. Upon completion of the work, a full copy of all records shall be submitted to the Principal, even if these have been previously supplied. B.4.4.

Quality Control Testing

The following tests shall be carried out for the protective coating of all items and the results shall be recorded in accordance with the requirements detailed above. Defective work shall be marked with school grade chalk, self-adhesive inspection labels, or masking tape. Wax crayons or other grease-based markers shall not be used. 1. Inspection of Defects All surfaces, including previously and newly coated surfaces, shall be visually inspected for defects. The coating shall be free of lumps, bubbles, inclusions, ripples, sags, runs, air holes and other film faults. 2. Adhesion of Existing Coating Prior to the commencement of any surface preparation or coating application, areas of existing coating that have not experienced visible symptoms of deterioration shall be tested for the level of adhesion to the substrate. For substrates other than concrete, adhesion shall be determined in accordance with the requirements of AS 3894.9 – Method A (Knife test). For concrete substrates, tests shall be in accordance with AS 3894.9 – Method C (Pull-off test) using 50 mm diameter test stubs. The tests shall be carried out at the same frequency as that described in the standard. Where the test result indicates an adhesion rating of greater than 2 for the Knife test, or bond strength of less than 1 MPa for the Pull-off test, the area of existing coating represented by the test shall be completely removed to bare substrate, and the surface shall be prepared for the application of new coating in accordance with the requirements detailed in this document. 3. Surface Cleanliness Following pre-cleaning, the presence of residual amounts of soluble materials, oil and water, residual dust, mill scale, and other undesirable materials shall be determined in accordance with the requirements of AS 3894.6. Items which are highly unlikely to be contaminated by certain materials do not require testing for those substances, e.g., new steel items in the factory do not require testing for chloride. Unless otherwise instructed, inspection or testing for the level of surface contamination shall be at a rate equal to one test per each 50 m2 of cleaned steel up to 200 m2, then one test per each subsequent 200 m2 up to the first 1,000 m2 and one test per each 500 m2 thereafter; all per structure. Sites for surface contaminants inspection or testing are to be selected by, or agreed with, the Principal. WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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Remove any dirt or soluble materials by jet washing using fresh, potable water and test as per AS 3894.6, Method A. The maximum level of chloride shall be 7 µg/cm2 (micrograms per square centimetre). Do not use proprietary chloride extraction agents. Where the surface was blast cleaned, re-blast after salt testing. 4. Surface Appearance After surface preparation is complete, the surface shall be visually inspected using AS 1627.4 and AS 1627.9. Abrasive blast cleaned surfaces are to be inspected to ascertain the degree of surface cleanliness that has been achieved. 100% of all surfaces are to be inspected, and the specified class is to exist in each square decimetre (100 mm by 100 mm), not as an average of all areas. The class of blast cleaning surface preparation grade specified is nominated in the relevant coating system in Section D. Determinations of the class of blast that has been achieved are to be made under natural light (where possible), by viewing the surface at right angles to the substrate and without magnification. The written descriptions of the various classes of blast cleaning contained in Appendix B of AS 1627.4 are to prevail. The written descriptions can be augmented with the pictorial representation contained in AS 1627.9. The specified surface preparation standard – in cleanliness, profile height and shape – is to exist in all respects at the time the primer is being applied. For metallic substrates, two sets of coupons of the same material as the substrate shall be prepared at the commencement of works, to show the minimum standard of surface preparation to be achieved. Following approval, they may be used as on-site QC Secondary Standards for both profile and the degree of surface cleanliness. One set of coupons would be retained by the Applicator, and one set by the Principal. 5. Surface Profile Following abrasive blasting of metallic substrates, the surface profile amplitude shall be determined using Methods A or B of AS 3894.5. The profile shape or nature is to be angular and sharp, not peened or rounded, and free from raised or folded hackles. The profile shape is generally more important to coating performance than amplitude. The nature of the profile is to be ascertained in representative areas by inspecting with an illuminated microscope or magnifier. The amplitude of the surface profile (the average peak to valley depth) is to be assessed in accordance with Method A or Method B of AS 3894.5, and reported as per the designations provided in Table 1 of AS 3894.5. The achievement of the surface profile shape and amplitude is to be recorded on the Daily Inspection Report.

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6. Temperature and Relative Humidity Prior to coating application, the surface temperature, dew point, ambient temperature, and relative humidity shall be measured and recorded once every four hours of each shift. A calibrated psychrometer or electronic climatic measuring gauge shall be used to determine these readings. The application of coatings shall not proceed when conditions are contrary to the Supplier’s technical literature. 7. Moisture Content – Concrete and Masonry Structures Below Water Table Prior to coating application, the moisture content of concrete substrates shall be tested using a moisture meter or qualitatively using the method described in ASTM D 4263, which involves taping down a 450 mm by 450 mm piece of 75 to 150 micron thick polyethylene film for a period of 24 hours. Coatings shall not be applied if any moisture is found on the backside of the film, or if the moisture content exceeds 4%. 8. Wet Film Thickness A gauge for measuring wet film thickness shall be used during the application to minimise the possibility of low dry film thickness. The gauge shall be used and readings recorded in accordance with Australian Standard AS 3894.3 – Appendix C: Determination of wet film thickness by comb gauge. 9. Dry Film Thickness After the application of coating layer or system for any given area, the dry film thickness of the applied coating shall be determined in accordance with the requirements of AS 3894.3, except as modified herein. DFT gauges shall be calibrated and verified in accordance with the procedure established in Appendix D of AS 3894.3 or as instructed by the equipment manufacturer. In all cases, only the coating thickness above the peaks of the surface profile will count as achieved DFT. A DFT Inspection Plan shall be prepared for each contiguous area, establishing the number, frequency and distribution of DFT readings to be taken according to the guidance provided in AS 3894.3. Usually, the surfaces to be measured are to be divided into zones of about 10 m2 each. Thickness determinations shall be taken at representative locations in accordance with the Inspection Plan using spot measurements (as defined above) for each determination. For most coating systems, a minimum DFT and a maximum DFT will be specified for each coating layer and for the complete coating system. If they are not stated, the specified thickness shall be the minimum. The average DFT of spot measurements for each 10 m² shall be between the minimum and maximum DFT. No single spot measurement shall be less than 80% of the minimum DFT and more than 120% of the maximum DFT. Non-conforming area shall be investigated, reported, and repaired according to Clause B.3.7.

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10. Adhesion of New Coatings At the completion of coating for any given area, the level of adhesion of the coating to the substrate shall be determined as described in Clause B.4.4(2) above. The number of tests shall be minimised so as to limit damage to the coating. All test locations shall be repaired after the test, as described in Clause B.3.2, such that they blend in with the surrounding areas. Subject to the Principal’s consent, test coupons made from the same or similar substrate and sprayed at the same time and in the same manner as the workpiece, can be used for destructive evaluations of adhesion. 11. Film Continuity Continuity testing to determine the presence of holidays, pinholes, cracks and other discontinuities shall only be undertaken on new lining or coating systems that are cured, are intended for immersion or underground service, and have not been exposed to water or high relative humidity since being applied. Coating systems for normal atmospheric exposure should not be continuity tested. Coating systems containing potentially conductive pigments, e.g., metallic zinc or aluminium, shall not be continuity tested. All continuity testing shall be conducted in accordance with AS 3894.1, however for high build systems and/or where high volume solids coating materials are used, the Supplier shall be consulted to verify that the voltage suggested by the formulae in AS 3894.1 is appropriate for that coating. If the suggested test voltage is above the Supplier’s recommendation, the lower voltage is to be used. If the number of defects is greater than five and are spread randomly over an area of not less than 10 m², the Applicator shall repair in accordance with Clause B.3.7. Where several defects fall within a circle of 100 mm radius, they shall collectively be deemed to be a single defect. The entire area within the circumference shall then be repaired in accordance with the requirements in Clause B.3.2. Film continuity testing may be carried out on the repaired area if requested by the Principal. 12. Degree of Cure The degree of cure of a coating shall be determined using AS 3894.4 – Method C. Full cure shall be achieved before the coating is placed in service, subjected to continuity testing or adhesion testing.

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B.5. Health and Safety B.5.1.

General

All works shall comply with relevant Sydney Water and legislative health and safety requirements. The Applicator shall implement a Safety Management System specifically for industrial coating application, which addresses the requirements of the following clauses. B.5.2.

Handling Of Chemicals

Material safety data sheets (MSDSs) of all products shall always be available for review during transport and at all times when the product is in use. Attention shall be paid to all warning labels attached to the coating and/or related product containers, the MSDSs and the Supplier’s relevant technical literature. Copies of MSDSs shall be made available on-site, and procedures shall be made to comply with all MSDS directions. The Supplier’s instructions for the safe handling of products shall be followed to minimise the risk of injury or creation of health hazards to personnel. Handling of coatings, solvents and chemicals shall be carried out with due care and diligence. Personnel not directly concerned with coating operations shall be protected against the effects of products used during surface preparation and coating application. The correct use of personal protective equipment shall be employed during the surface preparation, coating material preparation and application and site clean up. Disposal of chemicals must be treated with due regard to environmental protection, and shall be in accordance with manufacturer’s guidelines and statutory requirements. No Smoking and Flammable Liquid signs shall be displayed, and suitable fire fighting equipment shall be readily available at the work site. B.5.3.

Pressure Equipment

Details on how to operate all pressure equipment in a safe manner shall be made available to relevant personnel. The details must include the inspection method, and frequency of inspection of such equipment. A mechanical restraint is to be used on all hose-to-hose and all hose-to-equipment connections to prevent injurious disengagement. All blast hose connections are to be pinned with a safety clip. All associated connections to pressure equipment shall be regularly inspected, and well maintained. B.5.4.

Earthing

All coating application equipment, particularly spray and blast cleaning equipment, shall be earthed to eliminate any electrostatic charge. WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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B.5.5.

PPE and Ventilation

Health and safety instructions on the use of coatings and sealants printed on the MSDS and warning labels shall be fully understood before any work is undertaken. All necessary protective equipment and clothing shall be provided for all personnel. Appropriate air-fed masks shall be used during abrasive blasting and coating operations. Compressed air for breathing shall be supplied from an oil- and water-free source and be fitted with a comprehensive monitoring and alarm system for the key air quality parameters. All air lines conveying air for breathing shall be diver-grade, be used only for that purpose and have connection fittings that are not compatible with air lines for other duties. Other personnel in the vicinity shall wear suitable protective masks or respirators when necessary. Suitable respirators shall be worn to protect operators from dust, fumes, and vapours, in compliance with AS/NZS 1715 and AS/NZS 1716. First aid equipment, including eye wash bottles, shall be available at the work site. Eye wash bottles shall be located at or near the material pump, mixing area, and paint storage point. Adequate ventilation shall be provided in confined spaces. Appropriate personal protective equipment shall be used when entering confined spaces. When using air-fed masks in these areas, attention shall be paid to the possibility of explosive vapour build-up. Sufficient extractor fans shall be employed to ensure that airborne dust, rust, and vapours are withdrawn from any confined space during abrasive blasting, solvent cleaning, and coating operations. B.5.6.

Access

Scaffolding, platforms, lifts, or floating stages must only be erected and operated by licensed or qualified personnel. The appropriate tagging system, as stipulated by the relevant authorities, shall be employed and clearly displayed. Adequate warning notices shall be posted where overhead work is in progress. Personnel entering confined spaces shall have a valid ‘working in confined spaces’ licence issued by an authorised training body. Safety harnesses, standby personnel, and any other appropriate safety precautions detailed in AS 2865 and/or the NSW WorkCover Code of Practice for Confined Spaces shall be utilised. A robust written system for recording personnel entering and exiting from confined spaces must be in operation for all work in or adjacent to confined spaces.

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B.6. Environmental Protection This section outlines the responsible management and minimisation of all emissions and debris generated during surface preparation and paint application processes, and the collection and disposal of all wastes in an acceptable manner. B.6.1.

General

All works shall comply with relevant national, state, and local legislation concerning the preparation and coating of surfaces. The Applicator shall refer to Workcover NSW Health and Safety Guide: Spray Painting for guidance concerning the control of paint emissions, waste management, and public safety for both new and previously painted structures. B.6.2.

Lead Paint

Where lead paint is present, all work shall be performed in accordance with AS 4361.1. A dedicated specification shall be prepared. It shall include surface preparation, ventilation, encapsulation, waste disposal, and any other health and environmental protection measures. The work shall be undertaken by a pre-qualified Applicator holding a PCCP Class 5 certificate. B.6.3.

Containment

Where the works are to be performed on-site, the Applicator is responsible for the design and erection of a suitable containment structure designed to prevent the escape of emissions into the environment, soils, waterways, and for the protection of the public. Emissions include, but are not limited to: paint overspray, spills, wastewater, sludge, or dust from abrasive blasting and other site discharges associated with the work. It is the Applicator’s responsibility to ensure the design of the containment system complies with all national, state and local legislation, and that no visible emissions escape to the environment from the contained work area. A containment system may include, but is not restricted to: cover panels, screens, tarpaulins, hoardings, and shrouds; supported by scaffolding or other structures which when used separately or in combination, will enclose the entire working area. All necessary measures to recover any removed coating, spent abrasive, and associated debris shall be undertaken. All collected residues and waste materials shall be disposed of properly in accordance with the appropriate statutory requirements. Prior to the commencement of the works, the details of the proposed containment system to be installed for the control of emissions shall be submitted to the Principal. It should be noted however that the submission of the proposed containment details would not in any way constitute the approval or acceptance of responsibility for the containment by the Principal.

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B.6.4.

External Surfaces

Where vacuum shrouded power tools and vacuum blast cleaning are used in conjunction with brush or roller application of the coatings, a fully sealed structure for the containment of emissions may not be required. Where open power tools or vacuum shrouded power tools and/or spot abrasive blast cleaning are used in conjunction with the spray application of the coatings, a sealed containment system is required. B.6.5.

Internal Surfaces

When treating the internal surfaces of sealable structures such as vessels and reservoirs, emissions may be controlled by utilising the walls, floor, and roof as the principal component of the containment. Sealing may be more complete by using rigid or flexible framing, sealed joints, maintenance holes, hatches, re-sealable entryways, and air-locks having a negative internal air pressure. A suitable dust collection unit and appropriate air flow shall be provided, and provision made for waste management. The minimum emission control level for an internal containment system is Level C, referred to in AS 4361.1. The capacity of the dust extractor shall be sufficient for the volume of the contained structure, so as to produce not less than six air changes per hour. Where six air changes per hour cannot be achieved continually, a 60 minute time interval is to be allowed, with the dust extractor operating, between the completion of the blast cleaning activity, and the commencement of coating operations. B.6.6.

Assessing Emissions

Surface preparation, paint removal operations, and the application of paint may each produce emissions. The potential of various activities to generate emissions is categorised in AS 4361.1. The Applicator shall estimate the potential level of emissions, and install an appropriate containment to protect the environment, the public and other nearby personnel from any hazard. Visible emissions may be permitted providing the duration of the discharge does not exceed the cumulative level listed in Table below or extend beyond the controlled area delineated by a boundary line or barrier. Table 1

Guide to Estimating Emissions Emission Level

Description

0

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

1

Random emissions having a cumulative duration of no more than 1% of the work day (e.g. five minutes in an eight hour work day). WARNING – Document current at time of printing or downloading

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2

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

3

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

4

Emissions are unrestricted and may occur at any time.

Notes: 1. The work-day activities for timing emissions encompass surface preparation and cleanup only. 2. The maximum emission level for internal and external abrasive blast cleaning shall be Level 2 or as required by the relevant statutory organisation, whichever is the most restrictive.

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C.

PROTECTIVE COATING SYSTEM SELECTION

C.1. Introduction Conditions vary for each asset site, ranging from severe marine to comparatively benign inland environments. Within each site, macro and micro climates may be present, such as humid underground conditions, aggressive chemical and sewer gas exposure, through to above ground conditions where strong sunlight, salt spray and weather influence corrosion rates. In addition, different assets have different requirements for the level of protection required, depending on how critical the asset is, its exposure condition, required life, and maintenance requirements. This section provides a guide to choosing the most suitable coating system. It starts by describing the special requirements associated with maintenance works, then the recommended coating systems for new works. Lists of default coating systems are also provided to assist specification of the most appropriate coating systems for specific items and/or areas. The lists generally reflect a risk-based framework that incorporates Sydney Water’s experience, industry best practice (standards and specifications), and consultation with experts. The risk model can be found in Appendix F.

C.2. Maintenance Painting Maintenance painting is defined where patch repair is undertaken or existing coatings is not fully removed. The selected coating system for maintenance painting should generally be similar to the existing one. Attention must be given to the requirements stated in Clause B.2.6 and the use of suitable primer coat. Where existing coatings are mostly sound, it may be possible to ‘spot-repair’ any exposed substrate and ‘feathered’ areas with the coating system specified in section C.3, without overcoating the existing coating. There are some circumstances where maintenance painting has special requirements. These circumstances, and their remedies, are listed below. Table 2

Recommended coating systems for specific maintenance painting

Scope

Coating System

Additional Notes

Repair of damaged galvanizing

CS-11 or CS-12

System CS-11 should used to spot repair hot dip galvanizing which has become damaged during construction or in service. This system should be used to spot repair galvanizing which is to be used with or without additional coatings. Where a significant proportion of the zinc cover has been removed from the surface due to corrosion, system CS-12 should be used. Note that in some cases, it may be more economical to simply replace the item or regalvanise.

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Scope

Coating System

Additional Notes

Patch repair of alkyd coating

CS-15

A number of Sydney Water assets have in the past been coated with alkyd coatings, including above-ground pipelines, the external surfaces of reservoirs, timber items, and some galvanized items. Where these coatings only require repair in isolated areas, an alkyd coating system CS-15 should be used for spot repair. This ensures appearance match to the surrounding coatings and minimise incompatibility potential issues.

Painting over existing alkyd and lead based coatings

CS-08 or CS-09

Where an existing coating system is in a high enough state of breakdown to warrant full recoating, but it is not economical or feasible to blast back to the substrate, then a surface tolerant epoxy system should be used. CS-08 should be used where UV resistance and retention of gloss are required. CS-09 should only be used where colour matching is crucial. For outdoor applications, CS-09 must incorporate MIO pigments.

Painting over coal tar epoxy

CS-09

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

Painting over bitumen coatings

CS-18

System CS-18 should be used for painting over aged bitumen coatings without prior removal of the bitumen. However for bituminous coating in immersion service e.g. internal surface of reservoirs, it must completely removed and then coated with either CS05 or CS-06.

Heavily pitted and riveted steel surfaces in immersion service (e.g. steels tanks and reservoirs)

CS-07 or CS-05

The ultra high build epoxy system, CS-07, should be used for heavily pitted surfaces in immersion service.

Maintenance of immersion service coatings with little corrosion

CS-06

The existing coating shall be blasted back to Sa-3 surface cleaniness level and coated with the solventless epoxy system, CS-06.

Waterproof membrane in water reservoirs

PMB

Some concrete floor and bottom walls of steel reservoir leaks. Where repair is needed, polymer-modified bitumen membrane should be used.

Refurbishment of concrete sewerage structures in live environment

CAC

The surfaces of some concrete and masonry structures, eg. maintenance holes, access chambers, sewer tunnels, wet wells, are difficult to be fully dried due to operational constraints, as it has good tolerance to high moisture content in concrete substrate.

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

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C.3. Recommended Coating Systems This section is applicable to all painting works. However consideration must be given to the previous section (C.2) when undertaking maintenance painting. Tables 3 to 5 recommend the appropriate coating systems for the common areas/items present in Sydney Water facilities. The tables also contain the items’ common materials of construction and their typical exposure condition (refer to Section C.4). Some items may not have been listed or may be known by some other name. Should this be the case, select the specified system for a similar listed item, which operates under the same exposure conditions, is constructed of the same material, and has equal criticality. A risk-based framework provided in Appendix E may also be consulted. Where a substrate is left uncoated or a coating is intended for protection against specific chemicals, ensure that the material has an adequate corrosion resistance for the specific environment. A table in Appendix F.3 is provided as a guideline. Pipes, valves, fittings that have factory-applied fusion bonded external/internal coating or suitable cement lining typically do not require additional coatings. If there is any doubt or alternative choices, the matter should be referred to the Principal.

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C.3.1.

Water Reservoirs and Pipelines

The recommended coating systems for water reservoirs and pipelines are detailed in the following table. Table 3

Water Reservoirs and Pipelines

Item/Area

Substrate Material

Exposure Class

Recommended System

Hand rails, ladders, platforms,

Carbon steel

Moderate to high

GAL

walkways, covers

Aluminium

Wall plates

Carbon steel

External

Not required Moderate

CS-01

High

CS-03

Roof plates, wind girders

Carbon steel

High

CS-03

Pipes, valves, fittings, supports

Carbon steel

Moderate

GAL, CS-01

High

CS-03

Immersion

CS-06

Carbon steel

Extreme

TSZ

Carbon steel

Immersion

CS-06

Hand rails, ladders, platforms,

Carbon steel

Immersion

CS-06

walkways, covers

Aluminium, FRP

Roof framing, roof supporting

Carbon steel

structures, roof cladding underside

Aluminium

Base ring and other areas that cannot be accessed after construction Internal Pipes, valves, fittings, wall plates, columns, floor plates, overflow and off-take structures/fittings

Not required Immersion

GAL, CS-06 Not required

Miscellaneous paintings Aesthetic painting

CS-14

Anti-graffiti treatment

CS-17

Non-slip surface treatment

CS-10

Damaged galvanising

CS-11, CS-12

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C.3.2.

Sewage Pumping Stations and Water Pumping Stations

The recommended coating systems for Sewage Pumping Stations and Water Pumping Stations are detailed in the following table. Table 4

Sewage Pumping Stations and Water Pumping Stations

Item/Area

Substrate Material

Exposure Class

Recommended System

Hand rails, ladders, platforms,

Carbon steel

Moderate to high

GAL, CS-01

Immersion to extreme

CS-06

Moderate to extreme

Not required

and frames

Aluminium, stainless steel, FRP

Pipes, valves, fittings, structural

Carbon steel

Moderate

GAL, CS-01

steelwork, crane rails, motors,

High

CS-03

pumps, gear boxes

Immersion

CS-06

Extreme

CS-07, VES

High

CS-08, CS-13

Extreme

CS-07, VES, NOV, CPL

Extreme

CS-07, VES, NOV, EPM, CPL, CAC

walkways, covers, cable trays, electrical/control cabinets, door

Chemical bunds, sump pits

Sewage wet wells, inlet

Concrete

Concrete

maintenance holes, and emergency storage tank Miscellaneous paintings Aesthetic painting

CS-14

Anti-graffiti treatment

CS-17

Non-slip surface treatment

CS-10

Damaged galvanising

CS-11, CS-12

Notes: 1. Emergency storage tanks that do not share the same air space with the wet wells, typically do not require protection. 2. Concrete areas that are 500 mm below the lowest sewage level i.e. continuously immersed may be left unprotected.

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C.3.3.

Sewage Treatment Plants and Water Filtration Plants

The recommended coating systems for Sewage Treatment Plants and Water Filtration Plants are detailed in the following table.

Table 5

Sewage Treatment Plant and Water Filtration Plant

Item/Area

Substrate Material

Exposure Class

Recommended System

Hand rails, ladders, platforms,

Carbon steel

Moderate to high

GAL, CS-01

Immersion to extreme

CS-06

Moderate to extreme

Not required

door and frames

Aluminium, stainless steel, FRP

Pipes, valves, fittings, structural

Carbon steel

Moderate

GAL, CS-01

steelwork, crane rails, gantry,

High

CS-03

conveyors, motors, gear boxes

Immersion

CS-06

pumps, air blowers

Extreme

CS-07, VES

Moderate

CS-01

High

CS-03

Low

Not required

Moderate

CS-01

High

CS-03

Tanks, vessels containing sludge

Immersion

CS-06

or grit e.g. digesters, thickeners,

Extreme

CS-07, VES

High

CS-09

Extreme

CS-07, VES, NOV, EPM, CPL, CAC

Carbon steel

Immersion

CS-05, CS-06

Concrete

Low

Not required

Concrete

High

CS-08, CS-13

Extreme

CS-07, VES, NOV, CPL

Immersion

CS-06

walkways, decking, covers, cable trays electrical/control cabinets,

[External surfaces of:]

Carbon steel

Tanks, vessels, storage bins, hoppers, thickeners, clarifiers, grit

Concrete

chambers, digesters, walls [Internal surfaces of:]

Carbon steel

clarifiers, grit chambers, sewage

Concrete

inlet works, primary tanks [Internal surfaces of:] Tanks, vessels containing water or treated sewage e.g. thickeners, clarifiers Chemical bunds, sump pits

[Immersed surfaces of:]

Carbon steel

Rake arm, skimmer, scum beach, conveyors, pumps, drum screen, disintegrators, dewatering presses, penstocks, lift gates (outside inlet works) WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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Item/Area

Substrate Material

Exposure Class

Recommended System

Miscellaneous paintings Aesthetic painting

CS-14

Anti-graffiti treatment

CS-17

Non-slip surface treatment

CS-10

Damaged galvanising

CS-11, CS-12

Notes: 1. Concrete areas that are 500 mm below the lowest sewage level (continuously immersed), typically do no require coating protection.

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C.4. Environment Exposure Class The classes of exposure condition are explained the Table 6 below Table 6

Exposure Class Details

Exposure Class

Ferrous substrate

Extreme

•

Continually subjected to highly corrosive chemicals

•

Continually subjected to non-ventilated septic sewage atmosphere

•

Areas of high abrasion or impact

•

Buried in corrosive soil

•

Exposure category D in accordance with AS 3735

•

Constantly immersed in or splashed by water or sewage, or in the water vapour space

•

Internal surface of a pipe, valves and fittings.

•

Marine environment (within 1km of shoreline) including ocean outfall treatment plants

•

Subjected to occasional splashes of sewage/sludge

•

Subjected to moderately corrosive chemicals

•

Buried in non-corrosive soil

•

Category D, E-M or E-I in accordance with AS/NZS 2312

•

Inland region (further than 1km from shoreline), e.g. Sydney metropolitan area

•

Not subjected to corrosive chemicals

•

Subjected to occasional water condensation and splashes

•

Category B and C in accordance with AS/NZS 2312

•

Immersion

High

Moderate

Low

Cementious substrate

Not applicable

•

Frequently subjected to moderately corrosive chemicals (e.g. bund areas)

•

Continually subjected to ventilated septic sewage atmosphere

•

Exposure category C in accordance with AS 3735

•

Marine and coastal environments i.e. subjected to salt spray

•

Subjected to oil and grease (e.g. workshops and garages)

•

Concrete surfaces which will be washed frequently with high pressure water

•

Exposure category B2 in accordance with AS 3735

Benign indoor environment only

•

Outdoor and indoor in inland region

•

Dry environment

•

Not subjected to corrosive chemicals

•

No subjected to corrosive chemicals

•

Category A according to AS/NZS 2312

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C.5. Default Colours The following table provides default colour for various items. Table 7

Default Coating Colours

Item

Colour to AS 2700

Buildings - process units, unless directed otherwise

G66 Environmental Green

Cable trays [if required to be painted]

Y45

Manilla

Clarifier Bridge Steelwork

N24

Silver Grey

Compressor/Receiver

44Y

Salmon Pink

Concrete bunds

N35

Light Grey

Conduits [electrical]

X15

Orange

Conduits [communications]

---

White

Crane, gantry

Y14

Golden Yellow

Desktop equipment for control and operations

Y54

Oatmeal

Doors, frames, architectural accents

X61

Wombat [internal]

---

To match colour of buildings [external]

N14

White [internal surface]

B25

Aqua [external surface]

N14

White [internal surface]

Electrical cabinets/SCA’s [indoor]

Electrical cabinets/SCA’s [outdoor]

G66 Environmental Green [external surface] Electrical kiosk in SPS

N35

Light Grey

Equipment Guards

Y11

Canary

Flash Mixer Assembly

N24

Silver Grey

Floors, checker plate grid floors, steps [non-slip]

N35

Light Grey

Galvanizing - repair of

---

Silver

Hand rails, ladders, platforms [if required to be painted and not galvanised]

Y14

Golden Yellow

Hoppers and tanks [internal]

---

White

Hoppers and tanks [external] (Note 3)

G66 Environmental Green

Mechanical/electrical equipment

T45

Cootamundra

Mobile plant

Y14

Golden Yellow

Motors, pumps, gear boxes – non immersed

T45

Cootamundra

Penstocks & lift gates [above ground]

G66 WB Environmental Green (Note 1, 2)

Penstocks & lift gates [below ground]

T45

Pipes, fittings [above ground] (Note 4)

G66 Environmental Green

Pipes, fittings [below ground] (Note 4)

Y45

Manilla

Pump set

---

To match colour of pipe work

Rake arm access bridges

---

Galvanizing

Cootamundra

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Item

Colour to AS 2700

Structural steel, crainage, frames [above ground]

G66 Environmental Green

Structural steel, gantry rails [below ground]

Y45

Tanks and Vessels [External] (Note 3)

G66 WB Environmental Green (Note 1, 2)

Tanks and Vessels [Internal lining]

---

White

Valve Bodies

---

Colour to match pipe work

Valve Handles

Y11

Canary

Vent shafts, outdoor kiosks

G66 WB Environmental Green (Note 1, 2)

Walls, ceilings, roofs

Y45

Manilla

Manilla (internal) To match colour of buildings [external]

Notes: 1. WB Environmental Green is similar in colour to AS 2700 G66 with the addition of Micaceous Iron Oxide (MIO) pigments. 2. Colours for MIO pigmented paints (NSW State Government Authorities). 3. All external hoppers, tanks and vessels shall be painted WB Environmental Green unless otherwise specified. Where colour identification is required the units may be painted the same colour as the corresponding pipe work. 4. Where substrate surface can be painted and pipe content identification in accordance with AS/NZS 1345 is not required. Pigmented plastic pipes and fittings are excluded.

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D.

COATING SYSTEM SPECIFICATIONS

This section contains detailed specifications for recommended coating systems.

D.1. Summary Descriptions The following table describes each coating typical uses, characteristics and performances. Table 8

Summary Table

System

Description

Cost

Weather ability

Durability

CS-01

A thin-film, two-coat epoxy and polyurethane-based coating system, with a moderate level of protection and where a solid colour or MIO polyurethane topcoat is required. Mild exterior atmospheric exposure or interior where polyurethane is preferred.

1

3

2

CS-02

A thin-film, two-coat epoxy-based coating system, with a moderate level of protection and where a solid colour or MIO epoxy topcoat is required. Mild exterior atmospheric exposure or interior where epoxy is preferred.

1

2

2

CS-03

A high performance three coat zinc, epoxy and polyurethane-based coating system, with a high level of protection and where a solid colour or MIO polyurethane topcoat is required. The benchmark coating system for steel in all exterior atmospheres up to severe. Intended for new construction or where a full blast during maintenance is being performed.

2

3

3

CS-04

A high performance three coat zinc, epoxy and MIO epoxy-based coating system, with a high level of protection and where an MIO epoxy topcoat is preferred instead of polyurethane. Suitable for all atmospheric exposure. Intended for new construction only when adjacent to like-coated items. Not preferred for maintenance.

2

2

3

CS-05

A high performance epoxy-based immersion-grade lining system primarily intended for reservoir internals (including roof support structures), valves, screens, pumping stations, access shafts, etc. Suitable for immersion and vapour space exposure.

2

1

3

More tolerant system than CS-06 for complex wetted surfaces, e.g. riveted or lapped tank plates, roof structures inside reservoirs, etc. CS-06

A high performance solvent-free epoxy-based immersion-grade lining system primarily intended for reservoir internals, etc. Not preferred for riveted tanks or complex or awkward surfaces, e.g., roof rafters. For immersion and vapour space exposure.

2

1

3

CS-07

A high performance UHB (ultra high build) epoxy-based immersiongrade coating or lining system primarily intended for underground, immersion, valves, screens, areas of high abrasion, etc. Not preferred for riveted tanks or complex or awkward surfaces. Generally for immersion or buried exposure. Suitable for immersion in potable water and for some acid gas vapour conditions.

3

1

3

CS-08

A surface tolerant epoxy and polyurethane system primarily for spot repairs and then full overcoating of existing exterior coating systems, of a variety of generic forms, that are in fair condition and where a full polyurethane finish coat is required. Primarily for maintenance. Ideal as a repair and upgrade coating.

2

3

3

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System

Description

Cost

Weather ability

Durability

CS-09

A surface tolerant epoxy system primarily for spot repairs and then full overcoating of existing exterior coating systems, of a variety of generic forms that are in fair condition and where an epoxy finish is acceptable. Primarily for maintenance. Ideal as a repair and upgrade coating.

2

2

3

CS-10

A surface tolerant epoxy system primarily for overcoating concrete and steel floors, platform decks or steps where a non-slip finish is required. New work or maintenance.

2

2

2

CS-11

A zinc-rich epoxy-based coating system specifically for spot repairing new galvanising that has been damaged, cut, ground or welded; or repairing corroded zones on exposed and weathered galvanising (e.g., existing welds that were not properly treated).

2

2

2

CS-12

A zinc-rich epoxy and epoxy-based coating system specifically for spot repairing and fully overcoating aged and weathered galvanising that is showing areas of spot rusting and where a full overcoat to the existing galvanising will provide an extension to its life. For mild and moderate environments not needing a more elaborate coating system and where an epoxy topcoat is acceptable.

2

2

3

If the aged galvanising needs a higher performance overcoating system and/or if a polyurethane topcoat is preferred, refer to CS-03. CS-13

A chlorinated rubber coating system to provide light to medium protection duty against acid attack on concrete. For mild and moderate environments not needing a more elaborate acid-resistant coating system such as vinyl ester. Suitable in acid storage areas, secondary containments, bunds, etc., subject to splash, spray, spillage or immersion. Do not use where solvents, fuels or oil may be present. Do not use for exposure to strong hydrogen sulphide (H2S) or where hydrochloric acid (HCl) vapours or liquid could be present.

2

2

2

CS-14

An acrylic-based paint system, predominantly for decorative painting or repainting. New work or maintenance. Atmospheric exposure – interior or exterior. Not normally used for steelwork unless in a very benign, interior exposure. Ideal for the repainting of principally decorative paint systems.

1

1

1

CS-15

An alkyd-based paint system, predominantly for decorative painting. Maintenance of existing alkyd-based systems (including MIO alkyd). Not intended for new work. Atmospheric exposure – interior (nonMIO materials) or exterior (only MIO materials).

1

2

1

CS-16

A water-based epoxy system primarily for decorative or seal coating. Generally for interior use. Can be used as a repair coating.

2

2

2

CS-17

A polyurethane-based, anti-graffiti coating system. Atmospheric exposure – exterior. To be applied over existing sound coating systems where graffiti can be a problem. Moderate cost.

2

3

3

CS-18

A polyurethane-based coating system specifically for coating over aged bitumen coatings. Atmospheric exposure – exterior. To be applied over bitumen where bleeding can be a problem. High durability (especially with the polyurethane topcoat).

2

2

3

VES

A vinyl ester coating system for steel and concrete to provide superior acid resistance. Interior or exterior exposure. Generally for new substrates.

3

3

3

Requires a specialist and experienced applicator. WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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System

Description

Cost

Weather ability

Durability

NOV

A high build epoxy novolac system for the lining of concrete surface exposed to corrosive chemicals such as chemical bunds and highly aggressive, non-ventilated sewers. Suitable for concrete rehabilitation when corroded surface is rendered with suitable epoxy mortar. Interior, high duty exposure including ponding, immersion or corrosive vapours.

3

2

3

1

3

2

3

3

3

2

2

2

3

2

3

2

1

3

1

3

2

Requires a specialist and experienced applicator. GAL

Hot dip batch galvanising of fabricated steelwork and metalwork. Requires a specialist and experienced applicator.

TSZ

Hot zinc metal spraying of fabricated steelwork and metalwork. Generally for new steel only. Exterior, high duty exposure (not ponding or immersion). Excellent weatherability and durability (especially with the polyurethane topcoat). Requires a specialist and experienced applicator.

PMB

Polymer modified bitumen membrane is commonly used for waterproofing water retaining structures such as water reservoirs. Requires a specialist and experienced applicator.

EPM

An ultra high build epoxy or polyurethane mortar system for the lining of water retaining concrete with high exposure to H2S gas and its acid derivatives e.g. wet wells, maintenance holes, inlet works, etc. Primarily for interior, high duty exposure including ponding, immersion or corrosive vapours. May also be suitable for drinking water facilities, if the product has been tested and certified for such purpose. Requires a specialist and experienced applicator.

CPL

Concrete protective lining commonly known as geomembrane materials that made from high grade HDPE or PVC. Must have anchors or ribs that are embedded into concrete substrate. Highly durable when not exposed to long-term UV. Highly cost effective when used in new construction. Requires a specialist and experienced applicator.

CAC

Calcium aluminate cement mortar is lining material that is specially designed for protection against corrosive sewer environment. Not suitable for chemical bund/sump pit lining. Requires a specialist and experienced applicator.

Note that the ratings represent (1) low, (2) moderate, and (3) high.

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Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Galvanised Other metals, Concrete, Previous timber, plastics masonry coatings Sa 2½ blast Sand, whip blast Sand and dust Whip blast, Sand if glossy or lightly roughen off remove nibs, dust off Zinc-rich epoxy Epoxy zinc Surface tolerant Concrete epoxy Surface tolerant primer [P1] phosphate epoxy [C1] primer [P4] epoxy [C1] primer [P2] High build epoxy [C2] or surface tolerant epoxy [C1]. Applied to all nominated surfaces. Colour: N-35 Light Grey or as nominated High build acrylic polyurethane [T1]. Gloss or semigloss. Colour: as nominated (including MIO) Excluding the stripe coat

Oil & Grease Removal Substrate Surface Preparation

Primer

Stripe Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-01

75 µm

50 µm

(60 µm)

(50 µm)

75 µm

50 µm

125 µm (90 µm ZRE) (100 µm) 125 µm

150 µm

100 µm

250 µm

Notes: 1. For steelwork in moderate environments, use a surface tolerant epoxy primer at 125 µm NDFT instead of the zinc-rich epoxy primer. 2. The zinc-rich epoxy (ZRE) will have a lower tolerance of maximum DFT (approx 90 µm) than the surface tolerant epoxy. 3. Spot surface preparation and spot priming may be needed for paint systems with minor breakdown.

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Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Galvanised Other metals, Concrete, Previous timber, plastics masonry coatings Sa 2½ blast Sand, whip blast Sand and dust Whip blast, Sand if glossy or lightly roughen off remove nibs, dust off Zinc-rich epoxy Epoxy zinc Surface tolerant Concrete epoxy Surface tolerant primer [P1] phosphate epoxy [C1] primer [P4] epoxy [C1] primer [P2] High build epoxy [C2] or surface tolerant epoxy [C1]. Applied to all nominated surfaces. Colour: N-35 Light Grey or as nominated High build epoxy [C2] or surface tolerant epoxy [C1]. Gloss or semigloss. Colour: as nominated (including MIO) Excluding the stripe coat

Oil & Grease Removal Substrate Surface Preparation

Primer

Stripe Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-02

75 µm

50 µm

(60 µm)

(50 µm)

125 µm (90 µm ZRE) (100 µm)

75 µm

50 µm

125 µm

150 µm

100 µm

250 µm

Notes: 1. For steelwork in moderate environments, use a surface tolerant epoxy primer at 125 µm NDFT instead of the zinc-rich epoxy primer. 2. The zinc-rich epoxy (ZRE) will have a lower tolerance of maximum DFT (approx 90 µm) than the surface tolerant epoxy. 3. Spot surface preparation and spot priming may be needed for paint systems with minor breakdown.

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Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Galvanised steel Other metals, Previous coatings plastics Sa 2½ blast Sand, whip blast or Sand and dust off Sand if glossy lightly roughen Zinc-rich epoxy primer Epoxy zinc phosphate Surface tolerant Surface tolerant [P1] primer [P2] epoxy [C1] epoxy [C1]

Oil & Grease Removal Substrate Surface Preparation Primer

Stripe Coat

Intermediate Coat Stripe Coat Topcoat Total Dry Film Thickness

High build epoxy [C2]. Surface tolerant epoxy [C1]. Applied to all nominated surfaces. Applied to all nominated surfaces. Colour: X-41 Buff or as nominated Colour: X-41 Buff or as nominated High build epoxy [C2]. Surface tolerant epoxy [C1]. Colour: N-35 Light Grey or as nominated Colour: N-35 Light Grey or as nominated High build acrylic polyurethane [T1]. Applied to all nominated surfaces. Colour: as nominated (including MIO) High build acrylic polyurethane [T1]. Gloss or semigloss. Colour: as nominated (including MIO) Excluding stripe coats

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-03

75 µm

50 µm

125 µm (90 µm ZRE)

(60 µm)

(50 µm)

(100 µm)

150 µm

125 µm

200 µm

(60 µm)

(50 µm)

(100 µm)

75 µm

50 µm

125 µm

300 µm

225 µm

450 µm

Notes: 1. For steelwork in moderately severe or damp environments, a surface tolerant epoxy primer at 125 µm NDFT can be used instead of the zinc-rich epoxy primer. 2. The zinc-rich epoxy (ZRE) will have a lower tolerance of maximum DFT (approx 90 µm) than the surface tolerant epoxy. 3. Do not use the zinc-rich epoxy primer (for steel) if ponding or a long time-of-wetness is possible. 4. Where zinc-rich coatings are not preferred, epoxy zinc phosphate can be used over steel. 5. For extreme durability, a second topcoat of high build polyurethane at 75 µm could be added. WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

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Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Galvanised steel Other metals, Previous coatings plastics Sa 2½ blast Sand, whip blast or Sand and dust off Sand if glossy lightly roughen Zinc-rich epoxy primer Epoxy zinc phosphate Surface tolerant Surface tolerant [P1] primer [P2] epoxy [C1] epoxy [C1]

Oil & Grease Removal Substrate Surface Preparation Primer

Stripe Coat Intermediate Coat Stripe Coat Topcoat Total Dry Film Thickness

High build epoxy [C2]. Applied to all nominated surfaces. Colour: X-41 Buff or as nominated High build epoxy [C2]. Colour: N-35 Light Grey or as nominated High build epoxy [C2]. Applied to all nominated surfaces. Colour: as nominated High build MIO epoxy [C2]. Semigloss. Colour: MIO as nominated Excluding stripe coats

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-04

75 µm

50 µm

(60 µm)

(50 µm)

125 µm (90 µm ZRE) (100 µm)

125 µm

100 µm

(60 µm)

(50 µm)

125 µm

100 µm

(100 µm) 200 µm

325 µm

250 µm

525 µm

200 µm

Notes: 1. For steelwork in moderately severe or damp environments, a surface tolerant epoxy primer at 125 µm NDFT can be used instead of the zinc-rich epoxy primer. 2. The zinc-rich epoxy (ZRE) will have a lower tolerance of maximum DFT (approx 90 µm) than the surface tolerant epoxy.

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Issue: 01

Date: 23 December 2010 Page 48 of 80

Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Other metals Previous epoxy Concrete coatings Sa 3 blast Sand or whip blast Sand if glossy (do not Blast sweep blast) Non-inhibited epoxy primer [P3] Non-inhibited epoxy Concrete epoxy primer [P3]. primer [P4] (thinned) High build epoxy [C2]. Applied to all nominated surfaces. Colour: X-41 Buff or as nominated High build epoxy [C2]. Semigloss. Colour: N-35 Light Grey or as nominated High build epoxy [C2]. Applied to all nominated surfaces. Colour: as nominated High build epoxy [C2]. Semigloss. Colour: White or as nominated Excluding stripe coats

Oil & Grease Removal Substrate Surface Preparation Primer Stripe Coat Intermediate Coat Stripe Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-05

50 µm

40 µm

75 µm

(60 µm)

(50 µm)

(100 µm)

150 µm

125 µm

200 µm

(60 µm)

(50 µm)

150 µm

125 µm

(100 µm) 200 µm

350 µm

290 µm

475 µm

Notes: 1. When lining concrete, blast quite heavily to open out bugholes and remove laitance. Each epoxy layer should be sprayed and immediately back-rolled whilst wet in multiple directions to ensure full wetting and penetration. Concrete may require extra film build and/or number of applications. 2. If intended for immersion duty in drinking water system, use only drinking water-approved epoxy lining materials and the specified solvent(s).

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Issue: 01

Date: 23 December 2010 Page 49 of 80

Preliminary Cleaning Oil & Grease Removal Substrate Surface Preparation Primer

Remove silt and wash Remove oil and grease in accordance with AS 1627.1 Steel Other metals Sa 3 blast Sand or whip blast Non-inhibited epoxy primer [P3]

Stripe Coat

High build epoxy [C2] or High build solvent free [C3]. Applied to all nominated surfaces. Colour: N-35 Light Grey or as nominated High build solvent-free epoxy [C3]. Gloss or semigloss. Colour: White or as nominated Excluding the stripe coat

Topcoat Total Dry Film Thickness

Concrete Whip blast Concrete epoxy primer [P4] (thinned)

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-06

50 µm

40 µm

75 µm

(60 µm)

(50 µm)

(100 µm)

500 µm

400 µm

700 µm

550 µm

440 µm

775 µm

Notes: 1. If intended for immersion duty in drinking water system, use only drinking water-approved epoxy lining materials. 2. Solvent-free epoxy materials are not to be thinned and should only be applied by applicators experienced in handling solvent-free epoxy materials. 3. The stripe coat can be a high solids, (solvent-based) potable water-approved material (subject to the Supplier’s consent) rather than a solvent-free epoxy. 4. The solvent-free epoxy can be applied in two applications, providing the atmospheric and substrate conditions are controlled (e.g., by the use of DH equipment) so as to avoid the potential for amine bloom (carbamate) or other exudate forming between the solvent-free epoxy layers. 5. When lining concrete, blast quite heavily to open out bugholes and remove laitance. Each epoxy layer should be sprayed and immediately back-rolled whilst wet in multiple directions to ensure full wetting and penetration. Concrete may require extra film build and/or number of applications.

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Issue: 01

Date: 23 December 2010 Page 50 of 80

Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Other metals Concrete Sa 3 blast Sand or whip blast Whip blast Non-inhibited epoxy primer [P3] Concrete epoxy primer [P4] (thinned) High build [C2] or UHB epoxy [C4]. Applied to all nominated surfaces. Colour: X-41 Buff or as nominated UHB high solids epoxy [C4]. Semigloss. Colour: N-35 Light Grey or as nominated High build [C2] or UHB epoxy [C4]. Applied to all nominated surfaces. Colour: as nominated UHB high solids epoxy [C4]. Semigloss. Colour: White or as nominated Excluding stripe coats

Oil & Grease Removal Substrate Surface Preparation Primer Stripe Coat Intermediate Coat Stripe Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-07

50 µm

40 µm

75 µm

(60 µm)

(50 µm)

(100 µm)

750 µm

600 µm

900 µm

(60 µm)

(50 µm)

(100 µm)

750 µm

600 µm

900 µm

1550 µm

1240 µm

1875 µm

Notes: 1. If intended for immersion duty in drinking water system, use only drinking water-approved epoxy lining materials. 2. For concrete, double the thickness of the UHB epoxy to apply a NDFT of 1500 µm per layer. 3. When lining concrete, blast quite heavily to open out bugholes and remove laitance. Each epoxy layer should be sprayed and immediately back-rolled whilst wet in multiple directions to ensure full wetting and penetration. Concrete may require a greater number of applications.

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Issue: 01

Date: 23 December 2010 Page 51 of 80

Preliminary Cleaning

Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Previous coated Concrete Previously coated steel concrete Power tool clean to Jetwash, spot power Whip blast Jetwash and locally AS 1627.2 or Sa 2 tool clean to power grind if needed blast AS 1627.2 or Sa 2 blast Surface tolerant epoxy [C1] / [P4] Surface tolerant epoxy [C1]. Semigloss. Colour: as nominated (including MIO) Surface tolerant epoxy [C1]. Applied to all nominated surfaces. Colour: N-35 Light Grey or as nominated Surface tolerant epoxy [C1]. Semigloss. Colour: as nominated (including MIO) High build acrylic polyurethane [T1]. Gloss or semigloss. Colour: as nominated (including MIO) Excluding the stripe coat (and any non-slip materials)

Oil & Grease Removal Substrate Surface Preparation

Spot Primer Spot Intermediate Coat Stripe Coat Intermediate Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-08

75 µm

50 µm

125 µm

100 µm

80 µm

150 µm

(60 µm)

(50 µm)

(100 µm)

75 µm

50 µm

125 µm

75 µm

50 µm

125 µm

325 µm

230 µm

525 µm

Notes: 1. If spot repairs and a full overcoat are being conducted, the primer and a spot intermediate coat of surface tolerant epoxy are to be applied to the spot cleaned zones and out onto sound coating. Thereafter, an additional full intermediate coat of surface tolerant epoxy and a full topcoat should be applied. 2. If coating bare concrete, prime with surface tolerant epoxy, with the first coat thinned about 15%. 3. Can be made into a non-slip system by adding an aggregate in with or onto the wet intermediate coat and sealing in with the topcoat. WARNING – Document current at time of printing or downloading BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

Issue: 01

Date: 23 December 2010 Page 52 of 80

Preliminary Cleaning

Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Previous coated Concrete Previously coated steel concrete Power tool clean to Jetwash, spot power Whip blast Jetwash and locally AS 1627.2 or Sa 2 tool clean to power grind if needed blast AS 1627.2 or Sa 2 blast Surface tolerant epoxy [C1] / [P4] Surface tolerant epoxy [C1]. Semigloss. Colour: as nominated (including MIO) Surface tolerant epoxy [C1]. Applied to all nominated surfaces. Colour: N-35 Light Grey or as nominated Surface tolerant epoxy [C1]. Semigloss. Colour: as nominated (including MIO) Excluding the stripe coat (and any non-slip materials)

Oil & Grease Removal Substrate Surface Preparation

Spot Primer Spot Intermediate Coat Stripe Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-09

75 µm

50 µm

125 µm

100 µm

80 µm

150 µm

(60 µm)

(50 µm)

(100 µm)

125 µm

100 µm

175 µm

300 µm

230 µm

450 µm

Notes: 1. If coating bare concrete, prime with surface tolerant epoxy, with the first coat thinned about 15%. 2. If spot repairs are being conducted, the primer and a spot intermediate coat of surface tolerant epoxy are to be applied to the spot cleaned zones and out onto sound coating. Thereafter, the topcoat should be a full coat. 3. MIO-pigmented epoxies will have a better exterior durability than solid colours. 4. Can be made into a non-slip system by adding an aggregate in with or onto the wet intermediate coat and sealing in with the topcoat.

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Issue: 01

Date: 23 December 2010 Page 53 of 80

Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Previous coated Galvanised Concrete Previously steel steel coated concrete Sa 2½ blast Jetwash, spot Sand, whip blast Whip blast or Jetwash, sand power tool clean or lightly roughen lightly roughen glossy zones and to AS 1627.2 or dust off Sa 2 blast Zinc-rich epoxy Surface tolerant Epoxy zinc Surface tolerant epoxy [P4] primer [P1] epoxy [C1] phosphate primer [P2] Surface tolerant epoxy [C1] plus non-slip aggregate. Semigloss. Colour: as nominated (including MIO) Surface tolerant epoxy [C1]. Semigloss. Colour: as nominated (including MIO) Excluding the non-slip aggregate

Oil & Grease Removal Substrate Surface Preparation

Primer

Intermediate Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-10

75 µm

50 µm

125 µm (90 µm ZRE)

125 µm

100 µm

175 µm

125 µm

100 µm

175 µm

325 µm

250 µm

475 µm

Notes: 1. When coating bare concrete, the primer coat should be thinned by about 15%. 2. The zinc-rich epoxy (ZRE) will have a lower tolerance of maximum DFT (approx 90 µm) than the surface tolerant epoxy. 3. If spot repairs are being conducted, the primer and an additional spot intermediate coat of surface tolerant epoxy at 75 µm are to be applied to the spot cleaned zones and out onto sound coating. Thereafter, the intermediate coat and the topcoat should be full coats. 4. If borders or lines are required (e.g., for safety marking) use appropriately coloured polyurethane over the topcoat. 5. MIO-pigmented epoxies will have a better exterior durability than solid colours.

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Issue: 01

Date: 23 December 2010 Page 54 of 80

Preliminary Cleaning

Remove mud, dirt, zinc salts and other loose contamination on and around zones to be coated. Wash using low pressure water washing or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 New or aged galvanising Spot sand, grind, power tool clean or whip blast Zinc-rich epoxy primer [P1]. Colour: Grey

Oil & Grease Removal Substrate Surface Preparation Spot Primer Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-11

75 µm

60 µm

90 µm

75 µm

60 µm

90 µm

Notes: 1. If the zinc-rich epoxy is to be brush- or roller-applied, more than one application will be required to achieve the specified DFT.

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Issue: 01

Date: 23 December 2010 Page 55 of 80

Preliminary Cleaning

Remove mud, dirt, zinc salts and other loose contamination. Wash using low pressure water washing or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Aged galvanising Sand, grind, power tool clean or whip blast Zinc-rich epoxy primer [P1]. Colour: Grey Surface tolerant high build epoxy [C1]. Colour: N-35 Light Grey (typical) or aluminium

Oil & Grease Removal Substrate Surface Preparation Spot Primer Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-12

75 µm

60 µm

90 µm

75 µm

60 µm

110 µm

150 µm

120 µm

200 µm

Notes: 1. If the zinc-rich epoxy is to be brush- or roller-applied, more than one application will be required to achieve the specified DFT.

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Issue: 01

Date: 23 December 2010 Page 56 of 80

Preliminary Cleaning

Remove mud, dirt and other contamination. Wash using high pressure water jetting or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Concrete or masonry Whip blast, grind, power tool clean or acid etch High build unmodified chlorinated rubber [C7]. Colour: Grey High build unmodified chlorinated rubber [C7]. Colour: N-35 Light Grey (typical) or as nominated

Oil & Grease Removal Substrate Surface Preparation Primer Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-13

75 µm

50 µm

100 µm

75 µm

50 µm

100 µm

150 µm

100 µm

200 µm

Notes: 1. Do not use alkyd-modified chlorinated rubber or solvent acrylic-based “chlorinated rubber” materials. 2. A suction coat of chlorinated rubber thinned with up to 25% of solvent may be required as a primer over porous concrete. 3. In hot weather or if painting outdoors, more coats at a lesser film build per application may be required to avoid pinholing or blistering.

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Issue: 01

Date: 23 December 2010 Page 57 of 80

Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using low pressure water cleaning or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Galvanised Other metals, Concrete, Previous timber, plastics masonry coatings Power tool clean Power or hand Sand and dust Remove nibs, Sand if glossy to AS 1627.2 sand off dust off Alkyd zinc Galvanised iron Waterborne acrylic primer/sealer Consult phosphate metal primer [P9] [P5] manufacturer primer [P8] Waterborne acrylic [T3] Gloss, semigloss or low gloss. Colour: to match topcoat (including MIO if specified) Waterborne acrylic [T3] Gloss, semigloss or low gloss. Colour: as nominated (including MIO if specified)

Oil & Grease Removal Substrate Surface Preparation Primer

Intermediate Coat Topcoat Total Dry Film Thickness

Notes: 1. Spot surface preparation and spot priming may be needed for paint systems with minor breakdown. 2. For concrete, the third coat may not be necessary.

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Date: 23 December 2010 Page 58 of 80

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-14

40 µm

25 µm

60 µm

40 µm

25 µm

60 µm

40 µm

25 µm

60 µm

120 µm

75 µm

180 µm

Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using low pressure water cleaning or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Steel Galvanised Other metals, Previous coatings timber, plastics Power tool clean to Power or hand sand Sand and dust off Sand if glossy AS 1627.2 or Sa 1 blast Alkyd zinc phosphate Epoxy zinc phosphate Waterborne acrylic Surface tolerant metal primer [P8] (50 primer [P2] (75 µm) primer/sealer [P5] or epoxy [C1]. (75 µm) µm) alkyd primer/sealer (40 µm) Alkyd enamel [T6] Gloss, semigloss or low gloss. Colour: to match topcoat (including MIO if specified) Alkyd enamel [T6] Gloss, semigloss or low gloss. Colour: as nominated (including MIO if specified) (Differs by virtue of primer DFT)

Oil & Grease Removal Substrate Surface Preparation

Primer (NDFT in brackets)

Intermediate Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-15

40 – 75 µm

NDFT x 0.7

NDFT x 1.6

40 µm

25 µm

60 µm

40 µm

25 µm

60 µm

120 – 155 µm

AR

AR

Notes: 1. 2. 3. 4. 5. 6. 7.

Do not use over concrete. Do not apply alkyds direct to galvanising, electroplated items or to other zinc-based coatings. Ensure a short recoat time between epoxy primers and alkyds. For steelwork in less benign environments, use a surface tolerant epoxy primer at 75 µm NDFT instead of the alkyd zinc phosphate primer. Surface tolerant epoxy should be suitable as a primer for most aged and sound existing coatings. A test patch is suggested. Spot surface preparation and spot priming may be needed for paint systems with minor breakdown. AR = As Required. WARNING – Document current at time of printing or downloading

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Issue: 01

Date: 23 December 2010 Page 59 of 80

Preliminary Cleaning

New: Wash and dust off Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using low pressure water cleaning or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Concrete, render, concrete block, Previous epoxy, alkyd Other metals, timber, plaster board or acrylic coatings plastics Remove nibs, sand and dust off Sand and dust off Water-based epoxy primer [P7] Water-based epoxy [C9] Gloss or semigloss. Colour: as nominated Water-based epoxy [C9] Gloss or semigloss. Colour: as nominated

Oil & Grease Removal Substrate Surface Preparation Primer Intermediate Coat Topcoat Total Dry Film Thickness

Notes: 1. Additional topcoats may be required to achieve opacity with some colours. 2. A non-slip aggregate can be added to the final coat or between the topcoats.

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Issue: 01

Date: 23 December 2010 Page 60 of 80

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-16

50 µm

40 µm

75 µm

75 µm

50 µm

100 µm

75 µm

50 µm

100 µm

200 µm

140 µm

275 µm

Preliminary Cleaning

New: Wash and dust off

Oil & Grease Removal Substrate Surface Preparation Primer First Topcoat Second Topcoat Total Dry Film Thickness

Existing: Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using low pressure water washing or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Freshly applied coatings Aged previous coatings, bare concrete Can be applied direct if still within recoat Sand, jetwash, whip blast or lightly roughen window of the last coating layer Consult manufacturer if needed Surface tolerant epoxy primer [C1] Clear anti-graffiti coating [T5]. Usually gloss Clear anti-graffiti coating [T5]. Usually gloss (Excluding primer if needed)

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-17

75 µm

50 µm

120 µm

50 µm

40 µm

90 µm

50 µm

40 µm

90 µm

100 µm

80 µm

180 µm

Notes: 1. A higher DFT will apply if a primer is used. 2. If a colour other than the surface tolerant epoxy is required of aged, existing surfaces, use a coloured or MIO polyurethane over the surface tolerant epoxy. 3. If coating bare concrete, prime with surface tolerant epoxy, with the first coat thinned about 15%. 4. Surface tolerant epoxy should be suitable as a primer for most aged and sound existing coatings. A test patch is suggested. 5. Spot surface preparation and spot priming may be needed for paint systems with minor breakdown.

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Date: 23 December 2010 Page 61 of 80

Preliminary Cleaning

Remove mud, dirt, chalk, algae, bird droppings and other loose contamination. Wash using high pressure water cleaning or spot clean using buckets, brushes and water Remove oil and grease in accordance with AS 1627.1 Aged previous bitumen coatings Jetwash Alkyd aluminium [C10] – leafing grade Surface tolerant high build epoxy [C1]. Colour: aluminium (typical) or MIO High build acrylic polyurethane [T1]. Usually gloss. Colour: as nominated (including MIO) (Excluding optional topcoat)

Oil & Grease Removal Substrate Surface Preparation Primer Intermediate Coat Topcoat (Optional) Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CS-18

40 µm

25 µm

60 µm

200 µm

150 µm

300 µm

75 µm

50 µm

125 µm

240 µm

175 µm

360 µm

Notes: 1. 2. 3. 4.

The high build surface tolerant epoxy may need to be applied in multiple coats to achieve the NDFT. If a colour other than the surface tolerant epoxy is required, use a coloured or MIO polyurethane over the surface tolerant epoxy. A higher DFT will apply if a topcoat is used. Spot surface preparation and spot priming may be needed for paint systems with minor breakdown.

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Issue: 01

Date: 23 December 2010 Page 62 of 80

Preliminary Cleaning

New: Wash and dust off New: High pressure water jet Existing: Remove mud, dirt, chalk, algae, bird Existing: Remove mud, dirt, algae, droppings and other loose contamination. degenerated coatings or degraded concrete Wash using low pressure water cleaning or and other contamination. Wash using high spot clean using buckets, brushes and water pressure water jetting Remove oil and grease in accordance with AS 1627.1 Steel Concrete Abrasive blast to Sa 3. Ensure profile is 75 to Abrasive blast to remove laitance and cement100 microns and is sharp and angular rich fines. On vertical and overhead surfaces, open out all bugholes and porosity. Ensure remaining concrete is sound and intact Vinyl ester primer [P6] Glass flake-reinforced vinyl ester [C6] Colour: Buff or Light Grey Glass flake-reinforced vinyl ester [C6] Colour: White or as nominated

Oil & Grease Removal Substrate Surface Preparation

Primer Intermediate Coat Topcoat Total Dry Film Thickness

Notes: 1. All parts of the vinyl ester system need to be applied in strict accordance with the manufacturer’s written instructions. 2. Do not mix vinyl esters with other generic coating materials.

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Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

VES

50 µm

40 µm

80 µm

500 µm

400 µm

750 µm

500 µm

400 µm

750 µm

1050 µm

840 µm

1580 µm

Preliminary Cleaning

New: High pressure water jet Existing: Remove mud, dirt, algae, degenerated coatings or degraded concrete and other contamination. Wash using high pressure water jetting Remove oil and grease in accordance with AS 1627.1 New or existing concrete New: Abrasive blast to remove laitance and cement-rich fines. Open out all bugholes and porosity. Fill any voids that are not paintable using epoxy filler. Existing: Remove degraded/corroded concrete until sound concrete is reached. Render uneven surface with suitable patching or rendering epoxy mortar material. Consult manufacturer if needed Epoxy novolac [T7] Colour: Clear or as nominated Epoxy novolac [T7] Colour: Clear or as nominated

First Topcoat

Maximum DFT

Description

Primer Intermediate Coat

200 µm

150 µm

300µm

200 µm

150 µm

300µm

400 µm

300 µm

600µm

Nominal DFT

Item

Oil & Grease Removal Substrate Surface Preparation

Minimum DFT

NOV

Total Dry Film Thickness Notes:

1. All parts of the epoxy novolac system need to be applied in strict accordance with the manufacturer’s written instructions. 2. Trowel/brushed applied epoxy novolac topcoat may require multiple coats to reach the specified thickness.

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GAL Item

Description

Preliminary Cleaning Oil & Grease Removal Substrate

Remove mud, dirt and other loose contamination. Remove any marking paint using caustic or paint stripper Remove oil and grease in accordance with AS 1627.1 New or existing carbon steel. Avoid the use of silicon-killed steel or phosphorous additives that are present to an extent that they can adversely affect the galvanising process Vent all closed or ponding sections and provide suitable drainage holes so that all surfaces are accessible to the galvanising process Remove any heavy rust by abrasive blasting. If a thicker galvanising layer is desired, abrasive blast all surfaces to at least Sa 2 Pickle in hot sulphuric acid or ambient temperature hydrochloric acid to remove all scale, oxides and rust Rinse in fresh water Immerse in a flux solution containing zinc ammonium chloride and wetting agents or equal After drying, immerse in a bath of molten electrolytic zinc at a temperature of approximately 455 to 460°C and remain until the item has reached bath temperature. Withdrawal from the bath is to be at a controlled slow rate and at an inclination that will facilitate even drainage and a uniform formation of the pure zinc (eta) layer over the underlying zinc/iron alloy layers Immediately after extraction from the bath, the item is to be quenched in fresh water that does not contain potassium dichromate, soluble oil or similar wet stain reducing agents Steel Thickness (t) Ave Galv Mass (g/m2) Galv Thickness (µm) Min/Ave t ≤ 1.5 mm 320 35/45 1.5 < t ≤ 3.0 mm 390 45/55 3.0 < t ≤ 6.0 mm 500 55/70 t ≥ 6.0 mm 600 70/85

Venting Surface Preparation Pickling Rinse Fluxing Galvanising

Quenching Zinc weights

Notes: 1. All hot dip galvanising is to be performed in accordance with AS 4680. 2. Galvanised steel intended for immersion or in the vapour space of reservoirs, should be abrasive blasted before galvanising and not topcoated.

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Preliminary Cleaning Oil & Grease Removal Substrate Surface Preparation Metal Spraying Primer (Optional) Stripe Coat

New: Wash and dust off Remove oil and grease in accordance with AS 1627.1 Steel Abrasive blast to Sa 3. Ensure profile is 75 to 125 microns and is sharp and angular Apply thermal sprayed 99.9% pure zinc using a twin-wire arc spray process Epoxy zinc phosphate primer [P2] High build epoxy [C2] Applied to all nominated surfaces. Colour: as nominated To match adjacent surfaces, e.g., MIO epoxy [C2] (125 µm) or Polyurethane [T1] (75 µm). Colour: as nominated (including MIO) Excluding stripe coat

Topcoat (Optional)

Total Dry Film Thickness

Notes: 1. Quoted DFTs are for high build epoxy. If polyurethane is used, the NDFT would be 350 um. 2. The zinc metal spray can be left untopcoated in some environments.

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Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

TSZ

200 µm 75 µm

150 µm 50 µm

(60 µm)

(50 µm)

300 µm 125 µm (100 µm)

125 µm

100 µm

200 µm

400 µm

300 µm

625 µm

Preliminary Cleaning

New: High pressure water jet Existing: Remove mud, dirt, algae, degenerated coatings or degraded concrete and other contamination. Wash using high pressure water jetting Remove oil and grease in accordance with AS 1627.1 New or existing concrete Abrasive blast to remove laitance, cement-rich fines, and to create the required surface profile/roughness. Open out all bugholes and porosity. Fill voids with suitable repair material e.g. trowelled PMB. Ensure remaining concrete is sound and intact PMB [C11], brushed/rolled Applied to all nominated surfaces. Colour: as nominated PMB [C11], sprayed Colour: as nominated Excluding stripe coat

Oil & Grease Removal Substrate Surface Preparation

Stripe Coat Coat Total Dry Film Thickness

Notes:

1. Geotextile must be used on joints.

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Minimum DFT

Description

Nominal DFT

Item

Maximum DFT

PMB

(1 mm)

(0.5 mm)

(2 mm)

2 mm

1.5 mm

5 mm

2 mm

4 mm

6 mm

Preliminary Cleaning

New: High pressure water jet Existing: Remove mud, dirt, algae, degenerated coatings or degraded concrete and other contamination. Wash using high pressure water jetting Remove oil and grease in accordance with AS 1627.1 New or existing concrete Abrasive blast to remove laitance, cement-rich fines, and to create the required surface profile/roughness. Open out all bugholes and porosity. Fill any voids that are not paintable using epoxy filler. Ensure remaining concrete is sound and intact Consult manufacturer if needed Ultra high build epoxy/polyurethane mortar [C8] Colour: Light Grey or as nominated Ultra high build epoxy/polyurethane mortar [C8] Colour: Light Grey or as nominated

Oil & Grease Removal Substrate Surface Preparation

Primer (optional) Intermediate Coat Topcoat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

EPM

1.5 mm

1 mm

2 mm

1.5 mm

1 mm

2 mm

3 mm

2 mm

4 mm

Notes: 1. All parts of the epoxy mortar system need to be applied in strict accordance with the manufacturer’s written instructions. 2. Geotextile shall be applied between the coats when polyurethane mortar is used.

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CPL Item

Description

Preliminary Cleaning Oil & Grease Removal Substrate

Remove mud, dirt and other loose contamination. Remove any marking paint using caustic or paint stripper Remove oil and grease in accordance with AS 1627.1 New and existing concrete. Predominately suitable for new concrete structures where liners are attached onto formwork and cast onto the concrete during construction Use only non-destructive attachment methods such as double sided adhesive tapes and polymer strings. Where nails are used to attach liners, they must only be used on areas where welding will be carried out i.e. edges. All nails must be removed, if used, and all penetrations be patched. Specially designed joining pieces must be used to joint and align segments, and to avoid grout/concrete contaminating the joints. Liners should be tensioned when attached during cold temperature and where the structure would be subjected to large temperature variation. Pre-fabricated corners pieces should be used to minimise corner welding Where lining existing structure, use only the manufacturer recommended flowable grout material. Ensure concrete pour is well vibrated to avoid honeycombing and air entrapment. Must only be carried out by a formally qualified geomembrane welder approved by the manufacturer HDPE [T8] PVC [T9] Confined spaces: Light colours e.g. white, beige Surfaces subjected to UV: Black

Securing to formwork

Corners Grouting Welding Lining Material Colour

Notes: 1. 2. 3. 4. 5.

All parts of the concrete protective liner system need to be applied in strict accordance with the manufacturer’s written instructions. Liners must have anchoring studs/ribs manufactured during the extrusion process of the sheet Minimum thickness is 2 mm for corrosion protection only, but should be greater for areas that are subjected to high abrasion and impact Trafficable areas must be lined with non-slippery profile All welding must be tested prior to putting the structure into service

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Preliminary Cleaning

New: High pressure water jet. Remove all curing agent and release formwork oil. Existing: Remove mud, dirt, algae, degenerated coatings or degraded concrete and other contamination. Wash using high pressure water jetting Remove oil and grease in accordance with AS 1627.1 New or aged concrete. Predominately suitable for aged concrete where surface profile is rough. Abrasive blast to remove laitance, cement-rich fines, and to create the required surface profile/roughness. Open out all bugholes and porosity. Ensure remaining concrete is sound and intact Not required. Ensure that substrate is fully saturated with water. Calcium aluminate cement mortar with aluminate clinker [C12]

Oil & Grease Removal Substrate Surface Preparation

Primer Spray Coat Total Dry Film Thickness

Maximum DFT

Description

Minimum DFT

Item

Nominal DFT

CAC

25 mm

20 mm

30 mm

25 mm

20 mm

30 mm

Notes: CAC Composition Substances

Additional notes: a. Optimum water:cement ratio is between 0.4 to 0.45;

Weight %

Al2O3

39-47

b. Glass fibres may be used for strength and shrinkage control;

CaO

35-40

SiO2

2-7

c. The maximum aggregates size is 2.5 mm for repointing and lining masonry structures;

Fe2O3

9-17

Polymer additives

≤0.5

Others

≤5

d. Water used in mixing shall be potable standard water; and e. Accelerators may be used for curing sections that are exposed to early flows, subject to prior approval from Principal WARNING – Document current at time of printing or downloading

BMIS Document Number: ACP0166 Document Owner: Policy Standards & Materials Manager

Issue: 01

Date: 23 December 2010 Page 70 of 80

The CAC material shall have: a. Compressive strength (@ 28 days)

≥ 40 MPa

b. Flexural strength (@ 28 days)

≥ 3.5 MPa

c. Bond strength (@ 28 days)

≥ 2.5 MPa

d. Drying shrinkage (@ 56 days)

≤ 600 microstrain

e. Coefficient of thermal expansion

8 – 12 x 106/°C

f.

≤ 80 mg per 1000 cycles

Taber abrasion @ 7 days

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E.

APPROVED COATING PRODUCTS

A list of approved protective coating products can be found in this section. These coatings have been assessed to: • have satisfactory long-term track records; • originate from quality assured manufacturers and/or suppliers; • be part of a global product range; and • have relevant certifications issued by Australian Paint Approval Scheme (APAS), where available. APAS approved coating products are preferred by Sydney Water, and therefore should be their uses shall be considered first. If the listed APAS approved products are not available, then the listed non-APAS approved products may be used. Sydney Water reserves the right to request a documented evidence of the unavailability of a listed product. In the case of all listed products are not available, other products that can be demonstrated to have at least equal performance to the ones specified in the list may be used, subject to prior approval from the Sydney Water. Where available, all products used within a selected coating system should originate from a single supplier. Importantly, they must be compatible with each other and applied strictly in accordance with this Standard and the Supplier’s specification. Sydney Water reserves the right to make any changes to the content of the list without giving notice or explanation.

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Table 9

List of Approved Protective Coating Products

Code

Description

References

International

Jotun

PPG

Dulux

P1

Zinc rich epoxy primer

APAS 2916/1

Interzinc 72

Barrier

Amercoat 68K

Zincanode 402

AS/NZS 3750.9 T.2

Interzinc 315

Amercoat 471

Zincanode 202

Epoxy zinc phosphate primer

APAS 2971

Interzinc 52

Penguard Special

Amercoat 182ZPK

AS/NZS 3750.13

Intercure 200

Jotaprime 510

Duremax GPE Zinc Phosphate

Non-inhibitive epoxy primer

APAS 2971

Interline 982

Jotaprime 505

Amercoat CC24

Luxepoxy 4 White Primer

Ceilcote 680

Penguard ClearSealer

Amerlock 400

Durebild STE

P2

P3

P4

AS/NZS 3750.13

Concrete epoxy primer

Interline 982

Amerlock 2K

Interseal 1036 Interplus 1180 P5

Waterborne acrylic primer/sealer

APAS 0172

Intercryl 853

Acrylic Sealer Undercoat

Chemclear

Permaclad VE Primer EPL

Steelshield 2000

Jotaprime 250

Amercoat 185K

Metalshield HB

Jotun Galvanite

Taubmans Prep Right

Galvanised Iron Primer

Jotamastic 87

Amerlock 400

Durebild STE

AS/NZS 3730.23

P6

Vinyl ester primer

Ceilcote 380

P7

Water based epoxy primer

Interprime 371

P8

Alkyd zinc phosphate metal primer

APAS 0162 or 2921

P9

Galvanised iron primer

APAS 0134

Surface tolerant epoxy

APAS 0156 or 2977

C1

Taubmans Ultraprep Pro

Interprime 198

AS 3730.15 Interplus 356 Interplus 1180

Amerlock 2K

AS/NZS 3750.1

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Others

Code

Description

References

International

Jotun

PPG

C2

High build epoxy

APAS 2973

Intercure 420

Jotacote 605

Amerlock 400

AS/NZS 3750.14 High build epoxy (potable water use)

APAS 2973P

Dulux

Others

Amerlock 2K Interline 850

Amerlock 400

Duremax GPE

Jotacote 410

Amercoat CC703/3

Luxepoxy STL

Luxepoxy STL

AS/NZS 3750.14 AS/NZS 4020

C3

High build solvent free epoxy

APAS 2974

Interzone 954

AS/NZS 3750.14

Interline 975

High build solvent free epoxy (potable water use)

APAS 2974P

Interline 975

Tankguard 412

Amercoat CC703/3

Interzone 485

Jotacote UHB

Amercoat CC703/2

Interline 975

Jotacote UHB

Amercoat CC703/2

Luxepoxy UHB

Ceilcote Flakeline 242

Chemflake Special

Permaclad VE504 GF EPL

Steelshield 2000

Jotacote 740

Acidol 340

Luxachlor HB

AS/NZS 3750.14 AS/NZS 4020

C4

Ultra high build epoxy

APAS 2975

Ultra high build epoxy (potable water use)

APAS 2975P

AS/NZS 3750.2

AS/NZS 3750.2 AS/NZS 4020

C6

Ultra high build vinyl ester

C7

High build chlorinated rubber

APAS 2903 AS/NZS 3750.11

C8

Ultra high build epoxy/polyurethane mortar

Polibrid 705E

C9

Water based epoxy

Intergard 765

C10

Alkyd aluminium leafing grade

Intertherm 891

C11

Polymer modified bitumen

Fernco Ultracoat

Amercoat 335

Industrial Aluminium Liquid Rubber

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Enviropoxy WBE

Issue: 01

Date: 23 December 2010 Page 74 of 80

Code

Description

C12

Calcium aluminate cement

T1

References

International

PPG

Interthane 990

AS/NZS 3750.6

Interthane 870 (MIO)

Waterborne gloss acrylic

APAS 0280

Intercryl 853

T4

Flexible high build acrylic

APAS 0117

Intercryl 988

T5

Anti-graffiti topcoat

APAS 1441

Interfine 1080

Hardtop AS

Sigmadur 550

Weathermax HBR

Jotun Acrylic Gloss

Taubmans All Weather

Weathershield X10

Taubmans Armawall

Acrashield HB

PSX 700

Quantum Clearcoat

AS/NZS 3730.7/8/9/10

Imperite 300

Amershield Clear Alkyd enamel

Others

BASF Shotpatch 80 SP APAS 2911

T6

Dulux

Kerneos Sewpercoat

Gloss 2-pack acrylic polyurethane

T3

Jotun

APAS 0015 or 2910

Interlac 665 Interlac 192 (MIO)

Taubmans Ultra Enamel

Super Enamel

AS/NZS 3750.12 T7

Epoxy novolac

Ceilcote Flakeline 2000

Sigma Novaguard 840

T8

HDPE lining

AKS

T9

PVC lining

Plastiline

Note: Grey/light coloured text represent not-APAS approved products and black coloured text represent APAS approved products.

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Sikagard 63N

F.

ADDITIONAL INFORMATION (Informative)

F.1. General guideline for selection of coatings Table 10

Ferrous materials Exposure Class

Extreme •

Continually subjected to highly corrosive chemicals

•

Continually subjected to nonventilated septic sewage

•

Asset Type

Immersion •

High

Constantly immersed in or splashed by water or sewage, or in the vapour space

Areas of high abrasion or impact

•

Buried in corrosive soil

•

Exposure category D in accordance with AS 3735

Moderate

Low

•

Marine environment (within 1km of shoreline) including ocean outfall treatment plants

•

Inland region (further than 1km from shoreline), e.g. Sydney metropolitan area

•

Subjected to occasional splashes of sewage/sludge

•

Not subjected to corrosive chemicals

•

Subjected to moderately corrosive chemicals

•

Subjected to occasional water condensation and splashes

•

Buried in non-corrosive soil

•

•

Category D, E-M or E-I in accordance with AS/NZS 2312

Category B and C in accordance with AS/NZS 2312

•

Benign indoor environment only

•

Dry environment

•

No subjected to corrosive chemicals

•

Category A according to AS/NZS 2312

Assets requiring higher protection •

Difficult access for inspection and maintenance

•

Structural items

•

High capital and maintenance cost items

•

High operational risk associated with failure

•

Long term coating durability (15-25 years)

GAL (indoor & outdoor) CS-07

CS-01 (outdoor) VES

Easy access for inspection and maintenance

•

Non structural items

•

Low capital and maintenance cost items

•

Low operational risk associated with failure

•

Short to medium term coating durability (70% is highly corrosive, otherwise moderately corrosive

Aluminium Sulphate

45-50% (ph 2-3)

Moderately corrosive

Ammonia (ammonium hydroxide)

25% (as NH3)

Not corrosive

Calcium Nitrate

30-60%

Moderately corrosive

Citric Acid/Sodium Citrate

Variable

Moderately corrosive

Ethanol

>96%

Not corrosive, but acrylic coatings must not be used

Ferric Chloride

43% (pH 3)

Highly corrosive to carbon steel and stainless steel (304 & 316)

Hydrofluosilicic Acid

19-21%

Highly corrosive to aluminium, carbon steel, stainless steel (304 & 316) and concrete, only use vinyl ester or epoxy novolac

Lime (Hydrated)

Delivered as powder, made up on site as Not corrosive, but galvanised items should be slurry coated with epoxy or polyurethane

Magnesium Hydroxide

55%

Not corrosive, but galvanised items should be coated with epoxy or polyurethane

Methanol

>98%

Not corrosive, but acrylic coatings must not be used

Potassium Permanganate

Delivered as crystals, dissolved on site. Moderately corrosive to steel, concrete Potential for exposure to saturated should be seal coated solutions (6.4% at 20degC)

Sodium Bisulphite

approx 34% (pH 4.7)

Moderately corrosive to steel, reinforced concrete should be seal coated

Sodium Hydroxide

45-50%

Moderately corrosive Highly corrosive to carbon steel and moderately corrosive to stainless steel 304

Sodium Hypochlorite

Approx 14%

Sulphuric Acid

70%

Reinforced concrete should be coated, use vinyl ester, epoxy novolac, or chlorinated rubber only Highly corrosive to aluminium, carbon steel, stainless steel (304 & 316) and concrete, only use vinyl ester or epoxy novolac

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Date: 23 December 2010 Page 79 of 80

Document Control Review date:

23-12-2010

File name:

PCS 100

Document no:

ACP0166

Protective Coatings Standard

Registered file:

2009/10705F

Author(s):

Original 01-01-2011 effective date:

Next review:

Dec 2011

Jerry Sunarho (Standards Engineer) Mark Leszczynski Mark Droomgol (Specialist Consultant, KTA-Tator Australia)

Stakeholders consulted:

Christie Sebaratnam (Principal Engineer) Jeff Beer (Plant Manager Level 2) Michael Cox (Plant Manager Level 2) Milan Rubcic (Principal Engineer) Rajiv Madhok (Senior Engineer) Robert Chilton (SOO 5-6) Saba Sabanathan (MEO 5-6) Sudhakar Nagarajan (Contract Officer) Vangeli Perakis (Inspection Testing & Monitoring Consultant)

Approved by:

Janssen Chan (Policy, Standards & Materials Manager)

Revision History No

Date

Description

1

23/12/10 First issue. This document replaces all previous Sydney Water protective coating specifications

End of Document

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