Addendum to the Transnet Corrosion Protection Specification S.pdf · Addendum to the Transnet Corrosion Protection ... Addendum to the Transnet Corrosion Protection Specification

Addendum to the Transnet Corrosion Protection

Specification

REF: Ngqura Managanese Terminal H341803-2000-35-123-0003 Rev0

November 2013

ECIPRG EN XXX XXX 00

Document2

07 November 2013

Addendum to the Transnet Corosion Protection Specification


Addendum to the Transnet Corrosion Protection Specification


November 2013

Eastern Cape Infrastructure Joint Venture (ECI – JV), 63 Worraker Street, Newton Park, Port Elizabeth, 6045

t +27 (0) 41 507 4300 W www.ecijv.co.za

Addendum to the Transnet Corosion Protection Specification REF: Ngqura Managanese Terminal H341803-2000-35-123-0003 Rev0

ECIPRG/EN/XXX/XXX/00 07 November 2013 Document2

Revision Date Originator Checker Approver Description Standard

0 T.O Nkabinde C Dickson

Issue and revision record

This document is issued for the party which commissioned it and for specific purposes connected with the above-captioned project only. It should not be relied upon by any other party or used for any other purpose. ECI accept no responsibility for the consequences of this document being relied upon by any other party, or being used for any other purpose, or containing any error or omission which is due to an error or omission in data supplied to us by other parties.

This document contains confidential information and proprietary intellectual property. It should not be shown to other parties without consent from ECI and from the party which commissioned it. This document has been issued by ECI, an unincorporated joint venture between: PD Naidoo & Associates Consulting Engineers (Pty) Ltd Reg Nr 1997/014/139/07; Mott MacDonald South Africa (Pty) Ltd Reg Nr 2005/034935/07; LDM Consulting (Pty) Ltd Reg Nr 2003/000818/07; SFC Engineers (Pty) Ltd Reg Nr 2002/027360/07.



Chapter Title Page

Reference i

1 Scope 2

2 Amendments & Interpretations 3

2.1 Amendments ______________________________________________________________________ 3 2.2 Interpretations _____________________________________________________________________ 3

Appendices 5

Appendix A. Corrosion Protection Specification ______________________________________________________ 6

Contents


i ECIPRG/EN/XXX/XXX/00 07 November 2013 Document2

This document is an addendum to the Transnet Capital Projects (TCP) Corrosion

Protection Specification for the Ngqura 16 Mtpa Manganese Terminal, Document

number H341-2000-35-123-0003 Rev 0, dated 12 December 2012. A copy of this

document is appended as Appendix A. This document must be read in

conjunction with the original specification.

Reference



2

The scope of the Manganese Corrosion Protection Specification is extended to apply to corrosion

protection of all structural steel and plant installed at the port of Ngqura except those that are in marine

applications or immersed in sea water. These applications will have specific corrosion protection

specifications developed.

1 Scope



3

2.1 Amendments

The following amendments are applicable:

Section 3.4.1 Replace ISO 8540 with ISO 8504.

Section 4.4.8 Exclude this clause in its entirety.

Section 4.6.1 should read: Hot-dip galvanising shall be carried out by companies with ISO 9001

certification and who are accredited members of the Hot-Dip Galvanisers Association of Southern Africa

(HDGASA).

2.2 Interpretations

The application of this specification results in the selection of the appropriate and most cost effective

Corrosion Protection Systems (CPS) for each of the areas constituting the project. The CPS choices are

then summarised for acceptance by the Project Manager and associated costs are tabled accordingly in

the Bill of Quantities at tender stage.

The following interpretations are applicable:

Approved by (or to the satisfaction of) the Project Manager, Engineer or the Architect

accepted by the Project Manager or the Supervisor

a duty, procedure, decision

or action of the Engineer or

the Architect and of the

Superintendent, client

representative, Site

Supervisor or Clerk of Works

an action of the Project Manager or the Supervisor depending

on the context. Clause 14 of the ECC Core Clauses determines

what the actions of each are. Either may delegate in terms of

Clause 14.2.

2.3 Abbreviations

DFT Dry film thickness

CPS Corrosion protection system

HDGASA Hit-Dip Galvanisers Association of Southern Africa

NACE National Association of Corrosion Engineers

2 Amendments & Interpretations



4

ISO International Standards Organisation

SANS South African National Standards

SAQCC South African Qualification & Certification Committee

OHS Act Occupational Health and Safety Act no. 85 of 1993 as amended.

NOSA Subsidiary company of MICROmega specialising in occupational health and safety.

ASTM American Society for Testing & Materials



5

Appendices

Appendix A. Corrosion Protection Specification ______________________________________________________ 6



6

Appendix A. Corrosion Protection Specification

Transnet Capital Projects Specification Specification No. H341803-2000-35-123-0003 Discipline Structural Steel

H341803-2000-35-123-0003, Rev 0, Page ii

Table of Contents Table of Contents ....................................................................................................................... ii

1. Scope .................................................................................................................................... 1

2. General Requirements .......................................................................................................... 1

2.1 Design Considerations ........................................................................................................... 1 2.2 Applicator Skills and Competency........................................................................................... 1 2.3 Equipment ........................................................................................................................... 2

2.3.1 Measuring and Testing Equipment .............................................................................. 2 2.3.2 Spray Equipment ....................................................................................................... 2 2.3.3 Blast Cleaning Equipment ........................................................................................... 2 2.3.4 Mixing Equipment ...................................................................................................... 2

2.4 Coating Materials .................................................................................................................. 2

3. Surface Preparation .............................................................................................................. 3

3.1 General ................................................................................................................................ 3 3.2 Pre-Cleaning......................................................................................................................... 3 3.3 Mechanical and Hand Cleaning .............................................................................................. 3 3.4 Abrasive Blast Cleaning ......................................................................................................... 3 3.5 Surface Cleanliness ............................................................................................................... 4 3.6 Soluble Salts ........................................................................................................................ 4 3.7 Sweep Blasting of Galvanised Surfaces .................................................................................. 5

4. Coating Application .............................................................................................................. 5

4.1 Approval .............................................................................................................................. 5 4.2 Mixing .................................................................................................................................. 5 4.3 Coating ................................................................................................................................ 5 4.4 Application ........................................................................................................................... 6 4.5 Ambient Conditions ............................................................................................................... 7 4.6 Galvanising .......................................................................................................................... 7 4.7 Powder Coating .................................................................................................................... 8 4.8 Patch Repairs ....................................................................................................................... 8 4.9 Fasteners and Friction Grip Surfaces ...................................................................................... 8

5. Shop Painting ....................................................................................................................... 8

6. Site Painting ......................................................................................................................... 9

7. Safety Precautions ............................................................................................................... 9

7.1 General ................................................................................................................................ 9 7.2 Safety Plan ......................................................................................................................... 10 7.3 Fire Hazards ....................................................................................................................... 10 7.4 Storage of Hazardous Materials ........................................................................................... 10 7.5 Scaffolds and Rigging ......................................................................................................... 10

8. Inspection and testing .......................................................................................................10

8.1 Inspection and Phase Clearance .......................................................................................... 10 8.2 Inspection of Fabrication Quality ......................................................................................... 10 8.3 Surface Preparation ............................................................................................................ 10 8.4 Visual Inspection ................................................................................................................ 11


H341803-2000-35-123-0003, Rev 0, Page iii

8.5 Dry Film Thickness (DFT) .................................................................................................... 11 8.6 Adhesion Tests ................................................................................................................... 11 8.7 Pin-Hole Detection (EID) Tests ............................................................................................ 12

9. Quality Assurance ...............................................................................................................12

9.1 Applicator Qualification ....................................................................................................... 12 9.2 Quality Control ................................................................................................................... 12 9.3 Quality Surveillance ............................................................................................................ 13 9.4 Release Certificate .............................................................................................................. 14 9.5 Data Book .......................................................................................................................... 14

10. Corrosion Protection System Selection ..............................................................................14

11. Alternative Coating Materials .............................................................................................14

12. Guarantees .........................................................................................................................15

12.1 Guarantee Type and Period ................................................................................................. 15 12.2 Other Defects ..................................................................................................................... 15 12.3 Guarantee Reference Areas ................................................................................................. 15

13. Handling and Storage .........................................................................................................16

13.1 Handling ............................................................................................................................ 16 13.2 Loading .............................................................................................................................. 16 13.3 Off-Loading ........................................................................................................................ 16 13.4 Cover .............................................................................................................................. 16 13.5 Stacking ............................................................................................................................. 16

14. Colour Codes .......................................................................................................................16

15. Related Documents ............................................................................................................19

15.1 South African Bureau of Standards (SANS) Codes of Practice, Specifications and Methods ............................................................................................................................. 19

15.2 International Organisation for Standardisation ...................................................................... 19 15.3 RAL (Reichs Ausschuss fur Lieferbedingungen) ..................................................................... 20 15.4 National Association of Corrosion Engineers ......................................................................... 20 15.5 Hot-Dip Galvanisers Association Southern Africa ................................................................... 20 15.6 ASTM International ............................................................................................................. 20

Appendices

Appendix A: Corrosion Protection System Index .................................................................................. 21Appendix B: Protective Coating Specifications ..................................................................................... 23


H341803-2000-35-123-0003, Rev 0, Page 1

1. Scope This specification details the requirements for the corrosion protection of steel work and equipment for the Ngqura Manganese Terminal and covers the selection and application of protective coating systems and the requirements for labour, equipment, quality assurance and quality control.

2. General Requirements The requirements of ISO 12944 shall apply as a minimum to all coating application activities. Supplementary requirements are given in this document. In the event of conflict between this document and the ISO standard, the requirements of this document will prevail.

The coating applicator shall be responsible for ensuring that he is fully conversant with the requirements of this specification and the relevant coating systems.

2.1 Design Considerations 2.1.1 Steel components should be designed to be accessible for the purposes of applying,

inspecting and maintaining the protective coating system.

2.1.2 The guidelines to ensure accessibility and suitability for painting shall be drawn from ISO 12944-3 ‘Paint and varnishes – Corrosion protection of steel structures by protective paint systems’ Part 3 – ‘Design considerations’.

2.1.3 Steel components that are to be hot-dip galvanised shall be designed in accordance with ISO 14713 ‘Protection against corrosion of iron and steel structures – zinc and aluminium coatings – guidelines and the ‘Design for Hot-dip Galvanising’ guidelines from the Hot-Dip Galvanisers Association Southern Africa.

2.2 Applicator Skills and Competency 2.2.1 The applicator shall have an implemented Quality Management System certified to ISO 9001.

2.2.2 The applicator shall ensure that there are at all times sufficient suitably qualified, experienced and skilled staff to carry out, supervise and inspect all activities.

2.2.3 Staff shall be qualified in terms of the South African Qualification and Certification Committee for Corrosion Protection {SAQCC(Corrosion Protection)} and/or NACE as follows:

Applicators: General Heavy Duty Coatings Applicator (PA1)

Supervisors: General Paint Supervisors (PS1)

Inspectors: Coating Inspectors (Level 2), or

NACE CIP Levels 2 or 3

2.2.4 The required ISO, SAQCC and/or NACE certification documentation shall be provided at the time of tender.


H341803-2000-35-123-0003, Rev 0, Page 2

2.3 Equipment

2.3.1 Measuring and Testing Equipment The applicator shall have a blast profile gauge, wet film comb and a dry film thickness gauge at the shop/site at all times. Specialised testing equipment such as pin-hole detectors shall be available if required. The applicator shall also have at the shop/site instrumentation to measure the psychrometric conditions and the substrate temperature.

All test equipment shall have current calibration certificates.

2.3.2 Spray Equipment The spray equipment used shall be capable of properly atomising the material and shall be equipped with suitable pressure regulators and gauges. Air caps, needles and nozzles shall be of the type recommended by the coating manufacturer.

All spray painting equipment shall be fitted with suitable oil and moisture traps.

2.3.3 Blast Cleaning Equipment Effective oil and water separators shall be utilised on all airlines used for abrasive blast cleaning. The separators shall be of the ‘cartridge’ type.

2.3.4 Mixing Equipment All coatings shall be mixed with power mixers. Low speed mixers which do not induce air into the coating shall be utilised.

2.4 Coating Materials 2.4.1 Only approved coating materials as detailed in the relevant specifications shall be used.

2.4.2 Coating materials from different manufacturers shall not be mixed in the same coating systems. All paints, solvents and cleaning agents for a specific coating system shall be supplied by the same manufacturer.

2.4.3 Coatings shall only be supplied by the approved coating manufacturers. The applicator shall obtain a copy of the coating Batch Certificate, the Product Data Sheet and the Material Safety Data Sheet from the coating manufacturer prior to using the material.

2.4.4 The solvents used shall be those recommended and manufactured by the coating manufacturer. Where the recommended ‘solvent’ and ‘clean-up thinners’ for a material differ, the ‘clean-up’ solvent must not be added to the coating for dilution purposes.

2.4.5 Excessive dilution of paints is not permitted. Solvent additions for application purposes shall be in strict accordance with the coating manufacturer’s Product Data Sheet. The maximum capacity of containers shall be 25 litres.

2.4.6 The coating manufacturer’s recommended shelf life and other storage requirements shall be met.

2.4.7 The colours of the paints to be used shall be as specified in Section 14.


H341803-2000-35-123-0003, Rev 0, Page 3

2.4.8 All paints and coatings shall be brought to site in new unopened containers. All containers shall be clearly marked with the manufacturer’s material batch numbers.

2.4.9 The applicator shall ensure that the colour selection of the coat immediately prior to the finishing coat shall be suitable for complete obliteration by the finishing coat.

3. Surface Preparation

3.1 General 3.1.1 Sharp edges shall be dressed to a radius of not less than 2 mm, but no more than half of the

wall thickness.

3.1.2 All burrs, rags and weld spatter shall be removed as per the requirements of ISO 12944-3.

3.1.3 Welds should be free from imperfections (e.g. asperities, undercutting, blowholes, craters, spatter) which are difficult to cover effectively with a protective paint system.

3.2 Pre-Cleaning 3.2.1 Oil and grease shall be removed by high pressure water washing with detergent solution and

rinsing with clean water prior to abrasive blast cleaning and application of the coating.

3.2.2 Chemical contamination shall be removed by means of neutralising or flushing or both prior to additional surface preparation.

3.3 Mechanical and Hand Cleaning 3.3.1 Mechanical cleaning shall be in accordance with the procedure specified in Clause 4.3 of

SANS 10064 (ISO 8540).

3.3.2 The standard of surface preparation shall be in accordance with ISO 8501/1 and as specified in the relevant coating system.

3.3.3 Cleaning by means of hand or power-tools, i.e. wire brushes, chipping hammers, scrapers, grinders, sanders, needle descalers etc. may only be used where specified in the generic coating specification and the condition of the substrate metal is such that efficient cleaning can be achieved and where the protective system is designed for application to brushed or ground surfaces, e.g. in the case of surface tolerant coatings.

3.4 Abrasive Blast Cleaning 3.4.1 Abrasive blast cleaning shall be carried out in accordance with Clause 4.3 of SANS 10064

(ISO 8540) and the degree of cleanliness achieved shall be in accordance with ISO 8501/1 as specified in the relevant coating system.

3.4.2 The profile, peak to valley, when measured by SANS 5772 (ISO 8503-4) shall be as specified in the relevant manufacturer’s Product Data Sheet for the primer coating being used.


H341803-2000-35-123-0003, Rev 0, Page 4

3.4.3 The required blast profile height shall as recommended in the Product Data Sheet for the coating being applied. It is important that the blast profile does not exceed the specified thickness of the primer or first coat, especially where delays in overcoating are expected/ encountered. Any primed or coated surfaces showing signs of “measle” corrosion shall be considered defective and shall be re-blasted.

3.4.4 The abrasive may be any abrasive material (except silica sand) which meets the following requirements. It shall be composed of clean, sound, hard particles free from foreign substances such as dirt, oil, grease, toxic substances, organic matter and water soluble salts. It shall be capable of producing the angular surface profile as specified for the relevant coating system.

3.4.5 The applicator shall satisfy himself that the abrasive materials used conform to all national health and safety standards such as NOSA and the OHS Act.

3.4.6 All abrasive media shall be stored in an area that is completely dry and covered to allow for good preservation of the materials.

3.4.7 In all cases, after blast cleaning, all traces of blasting media and dust shall be removed from the surface by vacuum cleaning. Cleaned surfaces shall not be contaminated with oil, grease, rust or other deposits before coating.

3.5 Surface Cleanliness 3.5.1 No coating shall be applied to any surface containing traces of grit, grease, oil, loose rust,

millscale, surface contaminants (i.e. dust), chemical fall-out, salt deposits or corrosion products of any kind.

3.5.2 The following requirements shall apply prior to coating application:

3.5.2.1 Freedom from dust and debris shall be less than dust quantity rating 1 when tested in accordance with ISO 8502-3.

3.5.2.2 If the blast cleaned surface changes colour, or rust bloom begins to form, the surface shall be reblasted.

3.6 Soluble Salts 3.6.1 Soluble iron salts such as ferrous chloride and ferrous sulphate are found on surfaces in

marine and industrial environments. As these salts are soluble in water they can cause osmotic blistering of coatings which are applied to the steel and must be removed prior to painting.

3.6.2 Soluble salts shall be removed by cleaning and flushing with fresh potable water. Persistent salt deposits may be removed by proprietary solutions with the prior approval of the Engineer.

3.6.3 Soluble salts levels shall be measured using Weber Rielly Soluble Salts Test Kits or equivalent approved methods. The acceptable level of salts shall be as specified by the coating manufacturer.


H341803-2000-35-123-0003, Rev 0, Page 5

3.7 Sweep Blasting of Galvanised Surfaces 3.7.1 Sweep blasting shall be carried out in accordance with HDGASA01-1990 – Code of Practice

for Surface Preparation and Application of Organic Coatings, clause 4.3.3.

3.7.2 The sweep blasting must not damage the galvanised surface or remove any of the zinc layer.

4. Coating Application

4.1 Approval 4.1.1 No work shall be performed until the Quality Control Plan is approved by the Engineer and

the guarantee Reference Areas have been identified and agreed.

4.2 Mixing 4.2.1 The applicator shall ensure that all paints are mixed in accordance with the manufacturer’s

instructions.

4.2.2 During application, containers shall be agitated often enough to keep pigments in suspension.

4.3 Coating 4.3.1 All surfaces shall be coated as specified.

4.3.2 Surfaces which do not require coating shall be suitably protected.

4.3.3 Successive coats shall be of distinctly different colour to the previous coat to ensure correct intercoat coverage. However, two finishing coats of the same colour may be applied to achieve complete colour uniformity. If required, zinc rich primers shall be tinted to provide a colour that contrasts with the abrasive blast cleaned substrate. Special attention shall be given to cracks, crevices and edges to ensure complete coverage and paint thickness.

4.3.4 The primer coat shall be applied as soon as possible after the surface preparation operation and at least during the same shift as the blast cleaning operation, but under no circumstances may the primer be applied over rust bloom or over surfaces that have changed colour due to humidity or other contamination.

4.3.5 Coating application and cleaning shall not take place when site conditions are likely to negatively affect these operations. The applicator shall ensure that the necessary protective equipment is used to prevent contamination of the coatings and to minimise delays due to such site conditions.

4.3.6 On pre-coated surfaces all traces of soluble salts and other corrosive airborne contaminants shall be removed with potable water and surfaces shall be allowed to dry prior to further paint application.

4.3.7 Concealed surfaces shall be completely coated. Suitable sponges may be used for application of coating to concealed surfaces or back to back angles. In the case where it is impractical to coat the concealed surface, the opening shall be sealed utilising an approved mastic material.


H341803-2000-35-123-0003, Rev 0, Page 6

4.3.8 All edges, corners, bolt holes, cut ends and weld beads shall be stripe coated by brush application, prior to the application of the intermediate coat. The stripe coating shall be an additional coat of the specified intermediate coat. In order to assist in its identification, the stripe coat shall be a different colour to both the specified intermediate coat and finishing coat.

The stripe coat is not intended to increase the overall specified dry film thickness of the system but to ensure that the minimum thicknesses required are actually achieved at edges.

4.4 Application 4.4.1 Unless otherwise specified, all coatings applied in the shops shall be spray applied.

4.4.2 In instances where spray application is considered not to be possible, practical or feasible, such as on site after erection, coatings may be applied by brush and/or roller.

4.4.3 The applicator should note that many of the high build coatings specified in the relevant systems are only capable of achieving their recommended film thicknesses by spray application. Other application methods such as brush and roller can result in lower film builds being achieved per coat. The applicator must take cognisance of this in his tender. If during the course of the project the applicator is instructed to change his method of application any labour cost implications must be brought to the attention of the Engineer before any such costs are incurred.

4.4.4 All application work shall be carried out in strict accordance with the recommendations and instructions given in the most current Product Data Sheet supplied by the coating manufacturer. This includes required climatic conditions, methods of surface preparation, substrate temperatures, blast profiles, minimum and maximum coating thicknesses, overcoating times, application equipment and methods to be utilised and pertinent requirements not listed in this specification. The Product Data Sheet shall be deemed to be part of this specification.

4.4.5 When the primer and intermediate coats are applied in the shops and finishing coats are applied on site, long overcoating times are required for the intermediate coats. In the case of the micaceous iron oxide epoxy intermediate coats the recoatable generic has been specified in order to take account of these long overcoating periods. If the coating manufacturer has any special cleaning requirements for weathered intermediate coats prior to the on-site application of the finishing coat, these requirements shall be made known to the applicator at the time of tender in order to facilitate the correct costing of these additional cleaning activities.

4.4.6 Prior to the application of any coating material, the selected manufacturer’s Product Data Sheet for the material being used shall be obtained by the applicator. A copy of the Product Data Sheet shall be signed by the coating manufacturer. This is to ensure that the latest Product Data Sheet has been provided to the applicator, that the coating manufacturer is aware of the relevant coating specification and the conditions under which the material will be applied and to allow for technical back-up where required in support of the joint guarantee as detailed in Section 12.0.


H341803-2000-35-123-0003, Rev 0, Page 7

4.4.7 All coatings shall be evenly applied to form a smooth, continuous, unbroken coating free from tears, runs, sags, wrinkles, blisters, mud-cracking, change in colour or gloss, orange peel, visible pin-holes, dirt, dust or fluff occlusions or any other visible defects. Each coat shall provide complete coverage.

4.4.8 All coatings intended for service in immersed conditions shall be tested for freedom from pinholes (Electrical Insulation Defects) in accordance with SANS 1217 Clause 4.3.4.2 or NACE RP0188-88 before being put into service.

4.4.9 Surfaces which rest on concrete or other floors shall receive the full coating system prior to erection.

4.4.10 The applicator shall take adequate precautions to protect areas being painted against contamination and fall-out from adjoining sections of the plant during painting operations, should this become necessary.

4.4.11 Coated steel to be embedded in concrete or soil shall be painted so that the coated areas extend at least 100 mm into the concrete or soil, unless otherwise specified.

4.4.12 Where surfaces are to be welded, no paint shall be applied within a reasonable distance of the weld (50 mm), unless otherwise stated.

4.4.13 Where the manufacturer’s standard paint finish on prefabricated or proprietary items such as pumps, motors, etc. is deemed inadequate for the specific service environment, the items shall receive the painting system as specified in the relevant system for that area applied over the manufacturer’s standards finish as per CPS 08.

4.4.14 The applicator shall apply the full painting system specified on the bearing surfaces of walkways before the gratings or relevant floor sections are put in place.

4.5 Ambient Conditions 4.5.1 Coatings shall not be applied under the following conditions:

• When the surface may become damaged by rain, air borne dust, chemical fall-out, fog or condensation

• When it is anticipated that these conditions will prevail during the drying period, suitable enclosures shall be provided to protect the surfaces

• When the ambient air temperature or the steel temperature is outside the coating manufacturer’s recommended range

• When the ambient relative humidity exceeds 85%

• When the steel temperatures is less than 3°C above the dew point.

4.6 Galvanising 4.6.1 Hot-dip galvanising shall be carried out by companies approved by the South African Bureau

of Standards and who are accredited members of the Hot-dip Galvanisers Association of Southern Africa.

4.6.2 Hot-dip galvanising shall be in accordance with the requirements of SANS 121 (ISO 1461).


H341803-2000-35-123-0003, Rev 0, Page 8

4.6.3 Galvanised surfaces that are to receive duplex organic coatings shall not be passivated.

4.6.4 All shop and site repairs to hot-dip galvanising shall be carried out in strict accordance with the requirements of SANS 121 (ISO 1461). The zinc rich paint used for site repairs to galvanising shall contain a minimum of 80% zinc in the dry film in accordance with ISO 12944.

4.7 Powder Coating 4.7.1 When powder coating is specified, both the fabrication of items for powder coating as well as

the powder coating application shall comply with SANS 1274 or equivalent.

4.7.2 Textured or ‘structured’ powder coatings will not be acceptable due to variations in film thicknesses.

4.8 Patch Repairs 4.8.1 Following transport and erection, all areas of coating damage shall be patch repaired by

brush application.

4.8.2 The extent of the damage shall be carefully inspected to assess which coats in the system have been damaged.

4.8.3 When the damage extends to the steel substrate, all coats in the system shall be re-instated. Areas to be primed shall be cleaned of dust, dirt, grease or other deleterious matter and mechanically cleaned to grade St 3 of ISO 8501/1.

4.8.4 All edges of existing coatings shall be feathered back to a hard edge. The patch primer used shall be in accordance with the requirements of the relevant coating system.

4.9 Fasteners and Friction Grip Surfaces 4.9.1 All nuts and bolts shall be hot-dip galvanised as specified.

4.9.2 Friction grip areas shall be left uncoated with the exception of steel work that is either galvanised or primed with inorganic zinc silicate.

4.9.3 The uncoated friction grip areas shall be sealed to prevent the ingress of corrodants. The sealer used shall be recommended by the coating manufacturer as being suitable for the environment and compatible with the protective coating system. The sealing material shall be applied either by gun or spatula after erection. Where possible the sealant should be the same colour as the finishing coat.

5. Shop Painting 5.1 The applicator shall furnish the materials specified and ensure that they are applied in strict

accordance with this specification.

5.2 The applicator shall be wholly responsible for surface preparation and coating application. The coated surfaces shall meet the minimum dry film thickness required by this specification.

5.3 Unless otherwise specified, the primer and intermediate coats are to be applied in the shops with finishing coats being applied on site after erection and repairs to the handling damage.


H341803-2000-35-123-0003, Rev 0, Page 9

5.4 For items fully coated in the shops, provisions must be made for the repair of handling damage to the coating after erection.

6. Site Painting 6.1 The applicator shall furnish the materials specified and ensure that they are applied in strict

accordance with this specification.

6.2 Unless otherwise specified, all finishing coats shall be applied on site. The finishing coats being used on site shall be sourced from the same manufacturer as the shop applied primer and intermediate coats.

6.3 All shop coated surfaces shall be inspected on arrival on site by the Engineer and examined for mechanical damage. If the damage is excessive it may be preferable to repair this transport damage before erection whilst access is easier. Alternatively all repairs can be carried out after erection.

6.4 The shop applied coats must be thoroughly washed to remove all traces of dust, dirt, grease, salts or any other forms of surface contamination. Where deemed necessary, detergent cleaners, as recommended by the respective coating manufacturers, may be used.

6.5 After cleaning, all areas of damaged coating shall be patch repaired as detailed in 4.8.

6.6 Where more than one coat is being applied on site, washing as per 6.4 shall be carried out between coats.

6.7 Where paint is allowed to age before the application of the finishing coat, the surface shall be prepared as recommended in the relevant manufacturer’s Product Data Sheet.

6.8 Field fabricated items shall be cleaned and coated as specified in the relevant coating system.

6.9 All coatings shall be given adequate time for curing prior to service.

7. Safety Precautions

7.1 General 7.1.1 The applicator shall ensure that he complies with all statutory regulations, municipal by-laws,

etc. concerning pollution and the health and safety of his personnel and members of the public who may be affected by his work.

7.1.2 The applicator shall provide for all necessary safety precautions.

7.1.3 The applicator shall advise the Engineer of all hazardous materials to be brought on site.

7.1.4 All painting materials on site shall be stored in designated areas in storage facilities that meet the storage requirements of the paint manufacturer and the safety requirements of the specific site.


H341803-2000-35-123-0003, Rev 0, Page 10

7.2 Safety Plan The loss control or safety officer shall prepare a safety plan for approval by the Engineer for the area to be worked in, which plan will be adhered to by the applicator.

7.3 Fire Hazards The applicator shall ensure that adequate precautions are taken to avoid fire hazards.

7.4 Storage of Hazardous Materials 7.4.1 Oily or solvent rags shall be kept segregated in closed containers and in minimum quantity.

Any spillage of volatile material shall be cleaned up immediately.

7.4.2 Solvents and volatile materials shall be stored in designated areas.

7.5 Scaffolds and Rigging The applicator shall provide and erect such scaffolds and rigging as may be required. All scaffolds and rigging shall comply with the requirements of the Occupational Health and Safety Act.

8. Inspection and testing

8.1 Inspection and Phase Clearance 8.1.1 Each phase of the corrosion prevention work will be inspected by the Engineer as detailed

under 9.3 ‘Quality Surveillance’.

8.1.2 Irrespective of the inspections carried out by the Engineer, the responsibility for the acceptability of each phase of the work shall remain with the contractor.

8.1.3 If a contractor accepts the works from another contractor, he shall do it in writing and in so doing assume responsibility for the works. The onus is on the contractor to bring to the Engineer’s attention, in writing, any faults or other defects which could render the works unsuitable for the operation to be carried out by the contractor. Such acceptance of responsibility shall occur at least in the following handover operations:

• Fabrication contractor/Coating application contractor

• Shop coating application contractor/Site coating application contractor.

8.2 Inspection of Fabrication Quality

The fabrication quality shall be checked prior to acceptance of the fabrication for coating in terms of rounded edges, smooth weld profiles, chamfered corners and any other relevant items.

8.3 Surface Preparation The blast profile shall be measured in accordance with SANS 5772 (ISO 8503-4).


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8.4 Visual Inspection Visual inspection for paint film defects shall be performed after each coat is applied. All defects including pinholes, runs, sags, dry spray etc shall be corrected before the next full coat is applied.

8.5 Dry Film Thickness (DFT) 8.5.1 DFT shall be measured in accordance SABS ISO 2808 and instruments shall be calibrated

using the smooth calibration disc supplied by the instrument manufacturer.

8.5.2 ISO 19840 recommends a correction factor to take into account the affects of the blast profile on the measurement of the film thickness when the thickness instrument has been calibrated on a smooth surface. If the coating manufacturer requires a correction factor to be applied to the thicknesses contained in his Product Data Sheet he shall advise the coating applicator before any coating application work is commenced.

8.5.3 The frequency of dry film thickness readings shall a minimum of one reading per square metre of coated surface or as agreed between the applicator and the Engineer at the start of the coating applications.

8.5.4 The DFT is given in the CPS systems as a minimum requirement. No individual thickness shall be less than 80% of this specified minimum thickness and not more than 20% of thickness measurements taken shall be less than the specified minimum thickness.

8.5.5 The maximum thickness requirements for each coat shall be as recommended in the manufacturer’s Product Data Sheet.

8.5.5 Where excessive film thickness can be detrimental to the integrity of the coating, the manufacturer shall advise on the critical maximum thickness for the system. Where the applied thickness exceeds the manufacturer’s critical maximum thickness, the over-thick coatings shall be totally removed and re-applied to the specified thicknesses.

8.5.6 The increase in thickness created by the application of the stripe coat shall not be used to justify recorded thicknesses that are in excess of the maximum specified thickness of the system.

8.5.7 All deficient film thicknesses shall be rectified to the approval of the Engineer at the coating applicator’s expense.

8.5.8 Actual readings and not averages shall be recorded.

8.6 Adhesion Tests 8.6.1 Random pull-off adhesion tests shall be carried out on the applied coatings using the ASTM

D4541 test method. Adhesion (pull-off) values of the coating to the substrate (A/B) shall be a minimum of 5 MPa with no intercoat adhesion or cohesion failures.

8.6.2 The number and location of tests shall be agreed with the applicator at the start of the works.


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8.6.3 Repairs to the coating damaged by the tests shall be carried out in accordance with clause 4.8.

8.7 Pin-Hole Detection (EID) Tests All coatings intended for immersion service shall be tested for continuity in accordance with SANS 1217 or NACE RP0188-88, either low voltage ‘wet sponge’ or high spark techniques, depending upon the coating being used.

9. Quality Assurance

9.1 Applicator Qualification 9.1.1 The Engineer may, at his discretion, require a Quality Audit of the coating applicator to

ensure that he has the management, facilities and skilled staff to carry out the work in accordance with the specification.

9.1.2 The applicator shall accept full responsibility for the quality of his work and of materials used, irrespective of any quality surveillance or inspections that may be carried out by the Engineer.

9.2 Quality Control 9.2.1 Before the commencement of the contract, the coating applicator shall prepare and submit

the following for approval by the Engineer:

• A Quality Plan detailing each activity to be carried out during the execution of the works. Each activity shall be supported by a detailed Works Procedure for that activity. The Quality Plan will also detail the inspection requirements of each specific activity, listing whether it be a review, witness or hold point and defining the responsibilities of the various parties at each stage of the works

• The Safety Plan as required in 7.2.

• The location of the reference areas as required in 12.3.

9.2.2 The applicator shall have the necessary equipment and qualified staff to carry out the quality

control required to ensure compliance with the specification.

9.2.3 Quality control shall be carried out by a qualified inspector who is independent of the application activities. Quality control cannot be carried out by the site supervisor or any member of staff involved in production and programming.

9.2.4 The applicator shall provide the necessary documentation to be used during the quality control inspections. Such documentation shall be reviewed and approved by the Engineer beforehand.

9.2.5 The applicator shall keep at least the following records:

• Material batch records

• Product Data Sheets

• Psychrometric records (including steel temperatures)


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• Records of surface preparation

• Records of dates and times of the application of each coat

• Dry film thickness measurements per coat

• Records of specific tests as required by the Engineer

• Copies of inspection reports issued by the coating manufacturer

• Copies of inspection reports issued by the Engineer’s QA Surveyor.

9.2.6 These records shall be kept in a format that meets the approval of the Engineer.

9.2.7 The cost of quality control shall be included in the coating applicator’s tender price.

9.3 Quality Surveillance 9.3.1 The Engineer will carry out quality surveillance of the work or employ an independent

technically qualified organisation to carry out quality surveillance of the work on his behalf. The Engineer’s Quality Surveyor shall be qualified in accordance with 2.2.3 ‘Inspectors’.

9.3.2 The Quality Surveyor shall carry out independent measurements to verify the quality control inspection records of the applicator.

9.3.3 A report shall be compiled by the Quality Surveyor for each visit. A copy of the report will be given to the applicator on completion of each surveillance visit.

9.3.4 In the event of a dispute, the decision of the Engineer shall be final.

9.3.5 For the purpose of carrying out quality surveillance, the Engineer or his authorised representative shall be granted access to any part of the applicator’s premises relevant to the work being carried out, at any reasonable time. The applicator shall provide, at his own cost, any equipment or labour necessary to gain access to surfaces which are coated, to be coated or are in the process of being coated.

9.3.6 The Engineer or his authorised representative may remove any reasonable samples of materials to be used in the coating application. Rejection of the samples will place a hold on the use of material of the same batch number and may lead to rejection of all that batch of material and the reworking of any components that have already been coated with rejected material.

9.3.7 The Engineer or his authorised representative may carry out reasonable destructive tests to ascertain compliance with the specification. Areas thus damaged shall be repaired by the applicator to the satisfaction of the Engineer at no additional cost.

9.3.8 The cost of quality surveillance will be borne by the Engineer, except where surveillance results in rejection of the work or when notice by the applicator results in a fruitless trip, in which cases the cost of surveillance shall be carried by the applicator.


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9.4 Release Certificate 9.4.1 The shop applied coatings will be inspected by the Engineer or his authorised representative

at the applicator’s premises before releasing the coated items for delivery to site. A clearance certificate will be issued authorising the release.

9.4.2 The applicator shall notify the Engineer or his authorised representative at least 48 hours in advance of the date on which the coating activities will be complete and ready for inspection.

9.4.3 The coatings applied on site, including all repairs to transport, handling and erection damage, will be inspected by the Engineer or his authorised representative. A final acceptance certificate will be issued after the completion and final inspection and acceptance of each area or structure.

9.5 Data Book 9.5.1 Upon completion of the works, the applicator shall provide the Engineer with a Data Book

containing all the relevant Quality Control documents and records pertaining to the works.

9.5.2 This data book shall contain, as a minimum, the following:

• The relevant CPS specifications

• The Quality Plan

• Copies of all Batch Release Certificates from the paint manufacturer

• All relevant QC Records listed in clause 9.2.5

• Copies of all Quality Surveillance reports

• Copies of all Release Certificates.

9.5.3 The applicator shall submit to the Engineer the number of copies of the Data Book as required by the contract. In addition, the applicator shall keep a copy of the Data Book for his own records.

10. Corrosion Protection System Selection 10.1 The Corrosion Protection Systems relevant to the respective areas of the plant are given in

Appendix A.

10.2 Appendix B details each Corrosion Protection System.

11. Alternative Coating Materials Should the applicator or manufacturer wish to propose alternative products or coating materials he shall submit a detailed motivation to the Engineer. The motivation shall include, but not be limited to, the following:

• Benefit to the Ngqura Manganese Terminal

• Product licensor and technical back-up available

• Location, experience and ISO quality rating of the production facility

• Detailed case histories


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• Performance guarantee offered

• Manufacturer's Product Data Sheets and Material Safety Data Sheets for each product.

Should the proffered case histories be deemed insufficient or inconclusive, additional testing may be required to confirm the adequacy of the alternative coating materials. The costs of such testing will be borne by the applicator or manufacturer.

12. Guarantees

12.1 Guarantee Type and Period The Ngqura Manganese Terminal requires performance guarantees for the applied coating systems. Such guarantees shall be provided jointly by the coating manufacturer and coating applicator. The minimum guarantee period will be 10 years and the criteria for failure will not exceed Ri 3 of ISO 4628-3.

This joint guarantee must be submitted at the time of tender.

12.2 Other Defects Although visible coating defects such as blistering, cracking, flaking and peeling are not always associated with visible rusting, they indicate defects that could either lead to substrate corrosion or are shielding substrate corrosion that has already taken place beneath the coating. Any such defects noted during the guarantee period shall be repaired.

12.3 Guarantee Reference Areas 12.3.1 The guarantee shall be subject to the application of Reference Areas as described in

Annexure B of ISO 12944-8 to assess the performance of the coating at any time after completion.

12.3.2 The Reference Areas shall be selected and agreed by the Engineer, the coating manufacturer and the coating applicator as being fully representative of the operating environment.

12.3.3 The coatings applied to the Reference Areas shall be the same as those specified and from the same manufactured batches of coatings used for the project. If more than one batch of coatings is used, the Reference Area coatings shall be from the same manufactured batches as the initial batches supplied at the start of the project.

12.3.4 The coatings in the Reference Areas shall be applied either by the coating manufacturer or the coating applicator under the strict supervision of the manufacturer. Where the coatings are applied under supervision by the coating applicator, the manufacturer shall issue a certificate confirming that the coatings have been applied in strict accordance with the manufacturer’s Product Data Sheets.

12.3.5 In the event of defect areas occurring during the period of the guarantee, the Reference Area and the rest of the defect areas shall be inspected by the coating applicator and the manufacturer.

12.3.6 If defect areas have occurred in the Reference Area the remedial costs for both material and application under this guarantee shall be recovered from the manufacturer.


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12.3.7 If defect areas have not occurred in the Reference Area but have occurred in the rest of the coated areas, the remedial costs for both material and application under this guarantee shall be recovered from the coating applicator.

13. Handling and Storage The following precautions shall be taken for the site storage of coated items.

13.1 Handling All coated components shall be handled using soft slings.

13.2 Loading All coated components to be transported shall be loaded with support blocks, packing between pieces and tight lashing to avoid chafing.

13.3 Off-Loading Off-loading at site shall be conducted using the same care and precautions for on-loading. Components shall not be tipped off the transportation.

13.4 Cover 13.4.1 Coated items shall be stored under cover where possible.

13.4.2 Items not stored under cover shall be stored in such a manner as to avoid retention of water and allow good air circulation.

13.4.3 Items shall be stored on baulks of timber to raise the lowest level above the rain splash zone.

13.5 Stacking Items shall be stacked using timber packing or other approved means to avoid coating to coating contact. Sufficient bearing area of packing shall be used to avoid damage to coatings.

14. Colour Codes Machinery and equipment shall be painted in the following colours:

Area Colour SABS 1091 and RAL Numbers

14.1 Mobile equipment (cranes, loaders etc.) a) Structure, machinery and electrical houses, operator’s cabins, chutes, hoppers etc. b) Undercarriage, travel bogies, rubber tyred rims

Transnet White Transnet Dark Grey

RAL 9016 RAL 7024 (Graphitgrau) SANS 1091 GO4 (Bluegrey)


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14.2 Industrial buildings, conveyor structures a) Roofs and canopies b) Painted walls c) Steel columns, rafters, trusses

Pantone Cool Grey 10 Pantone Cool Grey 3 Pantone Cool Grey 5

RAL 7037 (Staubgrau) RAL 7035 (Lightgrau) or SANS 1091 G62 (Pale Grey) RAL 7004 (Signalgrau)

14.3 General a) Guards b) Sheaves c) Cable reels (Stainless steel d) Machine buffers and parts of machine which could constitute a serious hazard e) Any exposed rotating part of machinery, electrical Switch-gear (other than starting and stopping devices and emergency stop control), electrical services e.g. conduit and allied fittings f) Low voltage switchgear panels where orange is not aesthetically acceptable g) Medium voltage cable trays, switchgear and motors (3,3 kV and up) h) Starting devices, low voltage cable trays and switchgear i) TPT Logo j) Parts of stationary machinery (Electrical, motors, gearboxes, brakes, transformers, etc.)

Golden Yellow Orange Orange Golden Yellow (High Gloss) with Luminous Green Stripes in Chevron Pattern Light Orange (High Gloss) Light Grey Oxford Blue Mid Brunswick Green (high gloss) Transnet Blue Light Grey

SANS 1091-B49 RAL 1003 RAL 2008 RAL 2008 SANS B49 and Luminous Green SANS 1091 B26 SANS 1091-G29 SANS FO2 RAL5003 SANS1091-EO4 RAL6005 RAL 5002 (Ultramarine Blue) SANS G29


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k) Hand levers, hand wheels, oiling points, handrails on walkways, ladders l) Stopping devices, grease points, motor fan covers and danger signs (not symbolic safety signs for which see SANS 1186) m) Walkways (non slip surfaces) (Galvanised gratings not to be painted) n) Information signs and notices (not symbolic safety signs for which see SANS 1186)

Golden Yellow (High Gloss) Signal Red (High Gloss) Shop Floor Green White on Emerald Green (High Gloss)

SANS 1091 B49 SABS 1091 A11 BS 381C-537 RAL3001 SANS 1186) White on SABS 1091 E14

14.4 Pipe lines a) Reclaim water piping b) Slurry pipe lines c) Fire protection piping d) Washwater drain pipes e) Instrument air f) Plant air g) Potable water

Aluminium Dark Admiralty Grey Signal Red Light Grey White with Strong Blue Band White with Flag Blue Band Grass Green

SANS 1091-G12 SANS 1091-A11 SANS 1091-G29 White and SANS 1091- F11 White and SANS 1091- FO4 SANS 1091-D14

14.5 Colour bands for pipes shall be 75 mm wide for pipe sizes up to 150 mm diameter and

100 mm wide for 150 mm and above. The colour bands shall be applied to the pipe flanges, valves, junctions, walls or structures etc. in such a manner that the pipe may be easily identifiable. On straight sections the maximum spacing shall be 100 x the pipe diameter.


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15. Related Documents All national and international standards referred to in this document shall form part of this specification. Where reference is made to a code, specification or standard the reference shall be taken to mean the latest edition of the code, specification or standard, including addenda, supplements and revisions thereto.

15.1 South African Bureau of Standards (SANS) Codes of Practice, Specifications and Methods

Codes of Practice

SANS 10064 The Preparation of Steel Surfaces for Coating

SANS 121(ISO 1461) Hot-dip Galvanised Coatings on Fabricated Iron and Steel Articles – Specification and Test Methods

SANS ISO 2808 Paints and Varnishes – Determination of Film Thickness Specifications

SANS 780 Distribution Transformers

SANS 1091 National Colour Standards for Paint

SANS 1217 Internal and External Organic Coating Protection for Buried Steel Pipelines

SANS 1274 Coatings applied by the Powder Coating Process Methods

SANS 5159 Adhesion of Paints and Varnishes (Cross Cut Test)

SANS 5772 Profile of Blast Cleaned Surfaces for Painting (Determined by a Micrometer Profile Gauge)

15.2 International Organisation for Standardisation ISO 4628-3 Paints and Varnishes – Evaluation of Degradation of Paint Coatings –

Designation of Intensity, Quantity and Size of Common Types of Defects. Part 3: Designation of Degree of Rusting

ISO 8501-1 Preparation of Steel Substrates before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness

ISO 8502-3 Preparation of Steel Substrates before Application of Paint and Related Products – Tests for the Assessment of Surface Cleanliness-

Part 3: Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method)


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ISO 8503-4 Preparation of Steel Substrates before Application of Paint and Related Products – Surface Roughness Characteristics of Blast Cleaned Steel Substrates

Part 4: Method for the Calibration of ISO Surface Profile Comparators and for the Determination of Surface Profile – Stylus Instrument Procedure

ISO 8504 Preparation of Steel Substrates before Application of Paint and Related Products – Surface Preparation Methods

ISO 9001 Quality Management Systems

ISO 12944 Paint and Varnishes – Corrosion Protection of Steel Structures by Protective Paint Systems: Parts 1 to 8

ISO 19840 Paints and Varnishes – Corrosion Protection of Steel Structures by Protective Paint Systems – Measurement of and Acceptance Criteria for the Thickness of Dry Films on Rough Surfaces

15.3 RAL (Reichs Ausschuss fur Lieferbedingungen) RAL K1: Auxiliary Designation for RAL Colours

15.4 National Association of Corrosion Engineers RP0188-88: Discontinuity (Holiday) Testing of Protective Coatings

15.5 Hot-Dip Galvanisers Association Southern Africa

HDGASA01-1990 Code of Practice for Surface Preparation and Application of Organic Coatings

15.6 ASTM International ASTM D5451 Standard Test for Pull Off Test of Coatings using Portable Adhesion Testers.


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Appendix A: Corrosion Protection System Index


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Corrosion Protection System Index

Spec No

Description

CPS 01 Steelwork, piping and ducting inside buildings in dry non-corrosive areas that can be hot-dip galvanised. Applicable Areas/Equipment: workshops, warehouse, any structural steelwork in the architectural facilities including Admin building, Security and Induction building, Control building, Training Centre.

CPS 02 Steelwork, conveyor structures, base plates, piping and ducting inside and outside buildings in wet (spray) corrosive areas operating up to 80oC that can be hot-dip galvanised but require duplex coatings. Applicable Areas/Equipment: transfer stations, overland conveyors, overland conveyor housing, conveyor gantries and galleries, yard modules, elevated stringer modules, tipplers, tippler structures, stackers, reclaimers, shiploaders, any structural steelwork in the Change house and ablutions building.

CPS 03 Steelwork, conveyor structures, base plates, platework located inside and outside buildings in wet (spray) corrosive areas operating at temperatures up to 80oC that cannot be hot-dip galvanised. Applicable Areas/Equipment: transfer stations, overland conveyors, overland conveyor housing, conveyor gantries and galleries, yard modules, elevated stringer modules, tipplers, tippler structures, stackers, reclaimers, shiploaders, any structural steelwork in the Change house and ablutions building.

CPS 04

Internal surfaces of box sections where access for future inspections is required. All areas.

CPS 05 Conveyor idler sets comprising rollers and cradles. Applicable Areas/Equipment: all conveyors.

CPS 06 Hand-railing and stanchions. All areas and equipment.

CPS 07

Stair treads and open grid floor grating and fixing systems. All areas and equipment.

CPS 08 Proprietary Equipment (pumps, motors, gearboxes etc) operating at temperatures up to 80oC. (To be applied over the manufacturer’s proprietary coating system where this is deemed inadequate for the site environment). All areas and equipment.

CPS 09 Cable ladders, cable trays and associated support structures. All areas and equipment.

CPS 10 Control panels, switchgear cabinets, power and lighting distribution boards internal and external to buildings. All areas and equipment.

CPS 11 Transformers. All areas.

CPS 12 Nuts, bolts, flat washers, spring washers, holding down bolts and packer plates. All structures and equipment.

CPS 13

Duplex protection of galvanised surfaces not covered in other CPS systems. All areas.

CPS 14 Sheeting and cladding. (Engineering note).


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Appendix B: Protective Coating Specifications


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CPS 01 Environment Atmospheric – ISO 12944 C3 Material Mild steel Temperature Ambient to 80oC Description Steelwork, piping and ducting inside buildings in dry non-corrosive areas Applicable Areas and Equipment

Workshops, warehouse, any structural steelwork in the architectural facilities including Admin building, Security and Induction building, Control building, Training Centre

Steel work shall be hot-dip galvanised in accordance with SANS 121 (ISO 1461). The zinc coating thickness achieved shall be based on article thickness in accordance with the standard, i.e. Steel ≥ 6 mm 85 micron Steel ≥ 3 mm to < 6 mm 70 micron Steel ≥ 1,5 mm to < 3 mm 55 micron Steel < 1,5 mm 40 micron Notes: 1. All structural steel components shall be designed to accommodate the process of hot dip galvanising without distortion or acid traps. 2. Uncoated areas for renovation by the galvaniser shall not exceed 0,5% of the total surface area of a component. Renovations at the galvanising works shall be by zinc metal spraying. The zinc thickness shall be 30 micron greater than the specified galvanising zinc thickness. 3. Repairs to transport and erection damage shall be by means of zinc metal spraying or epoxy zinc rich paint. The zinc rich paint shall contain a minimum of 80% zinc in the dry film and the thickness shall be 30 micron greater than the specified galvanising zinc thickness. The damaged area shall be thoroughly cleaned and the repair coating shall overlap onto the surrounding sound zinc for a distance of at least 25 mm. 4. The zinc rich paint for repairs will be as recommended by the HDGASA, i.e. either Zincfix (Speccoats) or Galvpatch (Drivelines and Sprayflow cc). 5. The use of aerosol spray repair coatings is not permitted.


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CPS 02 Environment Atmospheric – ISO 12944 C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Steelwork, conveyor structures, base plates, piping and ducting inside

and outside buildings in wet (spray) corrosive areas operating up to 80oC that can be hot-dip galvanised

Applicable Areas and Equipment

Transfer stations, overland conveyors, overland conveyor housing, conveyor gantries and galleries, yard modules, elevated stringer modules, tipplers, tippler structures, stackers, reclaimers, shiploaders, any structural steelwork in the Change house and ablutions building

Surface Preparation Sweep blasting Generic System Primer Intermediate Finishing

Hot-dip galvanising to CPS 01 70 – 85 micron

two component recoatable epoxy micaceous iron oxide intermediate coat 2 coats @ 100 micron/coat

two component recoatable polyurethane acrylic finishing coat @ 50 micron

Hempel Hempadur 15570 Hempathane 55210 International Paints Intercure 200HS

*Can be applied in 1 coat @ 200µm

Interthane 990

Jotun Penguard Midcoat MIO *May be applied in 1 coat @ 200 microns

Hardtop AS

Sigma SigmaCover 435 or 435 S

SigmaDur 550

Stoncor Carboguard 193 MIO Carbothane 134 Minimum Total Dry Film Thickness: 320 micron Notes: 1. The galvanised surface shall not be passivated. 2. The galvanised surface shall be sweep blasted in accordance with Clause 3.7 prior to the intermediate coat application. 3. Both intermediate coats are to be applied in the shops. 4. The two intermediate coats shall be of different colours.

5. Stripe coating to be carried out in accordance with Clause 4.3.8. 6. All site repairs to handling and erection damage shall be carried out in accordance with CPS 01 Notes 3, 4 and 5, Clause 4.3.6 and Clause 4.8. 7. Finishing coat to be applied on site after erection in accordance with Clause 6. 8. All nuts and bolts and packers to be patched with both intermediate coats prior to the application of the finishing coat.


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CPS 03 Environment Atmospheric – ISO 12944 C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Steelwork, conveyor structures, base plates, platework located inside

and outside buildings in wet (spray) corrosive areas operating at temperatures up to 80oC that cannot be hot-dip galvanised


Transfer stations, overland conveyors, overland conveyor housing, conveyor gantries and galleries, yard modules, elevated stringer modules, tipplers, tippler structures, stackers, reclaimers, shiploaders, any structural steelwork in the Change house and ablutions building

Surface Preparation Abrasive blast clean to Grade Sa 2½. Surface profile as specified by the primer coating manufacturer.

Primer Intermediate Finishing Generic System two component

epoxy zinc primer (min 80% zinc in the dry film) @ 75 micron



Hempel Hempadur Zinc 17360

Hempadur 17410 Hempathane 55210

International Paints Interzinc 52 Intergard 475HS *Can be applied in 1 coat @ 200µm

Interthane 990

Jotun Barrier Penguard Express *May be applied in 1 coat @ 200 microns

Hardtop AS

Sigma SigmaZinc 109 HS SigmaCover 435 or 435 S

SigmaDur 550

Stoncor Carbozinc 859 Carboguard 893 MIO Carbothane 134 Minimum Total Dry Film Thickness: 325 micron Notes: 1. Primer and both intermediate coats to be applied in the shops with due cognisance being taken of the overcoating time requirements between the various coats. 2. The two intermediate coats shall be of different colours.

3. Stripe coating to be carried out in accordance with Clause 4.3. 4. All site repairs to handling and erection damage shall be carried out in accordance with Clause 4.3.6 and Clause 4.8. 5. Finishing coat to be applied on site after erection in accordance with Clause 6. 6. All nuts and bolts and packers to be patched with both intermediate coats prior to the application of the finishing coat.


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CPS 04 Environment Atmospheric – ISO 12944 C4 Material Mild steel Temperature Ambient to 80oC Description Internal surfaces of box sections where access for future inspections

is required Applicable Areas and Equipment

All areas

Surface Preparation Abrasive blast clean to Grade Sa 2½ Surface profile as specified by the primer coating manufacturer



two component recoatable epoxy micaceous iron oxide intermediate coat @ 125 micron/coat




International Paints Interzinc 52 Intergard 475HS Interthane 990 Jotun Barrier Penguard Express

MIO Hardtop AS


SigmaDur 550

Stoncor Carbozinc 859 Carboguard 893 MIO Carbothane 134 Minimum Total Dry Film Thickness: 250 micron Notes: 1. Primer and intermediate coats to be applied in the shops with due cognisance being taken of the overcoating time requirements between the various coats. 2. Stripe coating to be carried out in accordance with Clause 4.3.8 3. All site repairs to handling and erection damage shall be carried out in accordance with Clause 4.3.6 and Clause 4.8. 4. Finishing coat to be applied on site after erection in accordance with Clause 6. 5. All nuts and bolts to be patched with intermediate coat prior to the application of the finishing coat.


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CPS 05 Environment Atmospheric C4, C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Conveyor idler sets comprising rollers and cradles Applicable Areas and Equipment

All conveyors

System

All idler brackets and cradles to be hot-dip galvanised to SANS 121 (ISO 1461) followed by powder coating with an approved powder coating system in accordance with SANS 1274. The thickness of the powder shall be a minimum of 100 micron. The rollers shall be coated with a proprietary coating system as supplied by the roller manufacturer.

Notes: 1. The duplex coating shall comprise a minimum of two coats, i.e. either two coats of powder or a wet applied primer followed by the powder coating. 2. Textured or ‘structured’ powder coatings will not be acceptable due to variations in film thicknesses. 3. Fixing systems shall be hot-dip galvanised. Electroplated zinc coatings are not acceptable. 4. All site repairs to handling and installation damage shall be carried out in accordance with CPS 01 Notes 3, 4 and 5, Clause 4.3.6 and Clause 4.8. 5. The damaged powder coating shall be repaired with touch-up paint supplied by the powder manufacturer. 6. All nuts and bolts and packers shall be coated as per the conveyor steelwork, i.e. CPS 03.


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CPS 06 Environment Atmospheric C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Handrails and stanchions Applicable Areas and Equipment

In all areas and on all equipment

Systems

Hollow section tubular handrails and stanchions: To be coated as per CPS 02. Solid section (angle and bar) handrails and stanchions: To be coated as per CPS 03.

Notes: 1. The notes as per CPS 02 and CPS 03 shall apply. 2. Depending upon the fabrication and installation procedures, it may be necessary to apply all coatings on site in which case at least the primer coats should be applied before installation.


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CPS 07 Environment Atmospheric – ISO 12944 C3, C4, C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Open grid floor grating, stair treads and fixing systems Applicable Areas and Equipment

All areas and equipment

System

Open grid floor grating, stair treads and fixing systems shall be hot-dip galvanised to SANS 121 (ISO 1461)

Notes: 1. The zinc coating thickness shall be as specified for the section thickness. 2. The design and fabrication of the grating shall be appropriate for the process of hot-dip galvanising. 3. The fixing systems shall be hot-dip galvanised. Electro-plated zinc is not acceptable. 4. The flooring sections shall be made to measure before hot-dip galvanising so that site modifications that damage the galvanising are not necessary. 5. Kick plates shall be welded to the grating sections before galvanising. 6. Repairs to transport and erection damage shall be by means of zinc metal spraying or epoxy zinc rich paint. The zinc rich paint shall contain a minimum of 80% zinc in the dry film and the thickness shall be 30 micron greater than the specified galvanising zinc thickness. The damaged area shall be thoroughly cleaned and the repair coating shall overlap onto the surrounding sound zinc for a distance of at least 25 mm. 7. The zinc rich paint for repairs will be as recommended by the HDGASA, i.e. either Zincfix (Speccoats) or Galvpatch (Drivelines and Sprayflow cc). 8. The use of aerosol spray repair coatings is not permitted.


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CPS 08 Environment Atmospheric – ISO 12944 C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Proprietary Equipment (pumps, motors, gearboxes etc) operating at

temperatures up to 80oC. (To be applied over the manufacturer’s proprietary coating system where this is deemed inadequate for the site environment)



Surface Preparation Hand clean, abrade and degrease as per coating manufacturer’s recommendations.

Primer Finishing Generic System two component epoxy

barrier/tie coat @ 100 micron


Hempel Hempadur Quattro 17634 Hempathane 55210 International Paints Interseal 670HS

* subject to confirmatory adhesion check

Interthane 990

Jotun Jotamastic 90 –colour similar to finishing colour

Hardtop AS

Sigma SigmaCover 350 SigmaDur 550 Stoncor Carbomastic 15 Carbothane 134 Notes: 1. Conduct an adhesion test on the proprietary coating in accordance with SANS 5159. If the adhesion coefficient is less than 8, return item to manufacturer for replacement. If the adhesion coefficient is 8 or 10, apply upgrade system as above. 2. Confirm compatibility between the proposed tie-coat and proprietary coating. 3. All upgrade coatings to be applied at suppliers shops prior to shipment to site and installation unless otherwise instructed in the equipment order. 4. All site repairs to handling and installation damage shall be carried out in accordance with Clause 4.8. 5. When motors, gearboxes etc are supplied on base plates, the base plates shall be coated to either CPS 02 or CPS 03.


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CPS 09 Environment Atmospheric C3, C4, C5-M and C5-I Material Mild steel or stainless steel Temperature Ambient to 80oC Description Cable ladders, cable trays and associated support structures internal

and external to buildings Applicable Areas and Equipment


Systems

Inside clad areas C3 and C4: All components to be hot-dip galvanised to SANS 121 (ISO 1461) followed by powder coating with an approved powder coating system in accordance with SANS 1274. The thickness of the powder shall be a minimum of 100 micron. Externally exposed areas C5-M and C5-I. All components to be powder coated stainless steel.

Notes: 1. The duplex coating shall comprise a minimum of two coats, i.e. either two coats of powder or a wet applied primer followed by the powder coating. 2. Textured or ‘structured’ powder coatings will not be acceptable due to variations in film thicknesses. 3. Fixing systems shall be hot-dip galvanised. Electroplated zinc coatings are not acceptable. 4. All site repairs to handling and installation damage shall be carried out in accordance with CPS 01 Notes 3, 4 and 5, Clause 4.3.6 and Clause 4.8. 5. The damaged powder coating shall be repaired with touch-up paint supplied by the powder manufacturer. 6. Fixing systems for stainless steel components shall be stainless steel.


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CPS 10

Environment Atmospheric C3, C4, C5-M and C5-I Material Mild steel or stainless steel Temperature Ambient to 80oC Description Control panels, switchgear cabinets, power and lighting distribution

boards internal and external to buildings Applicable Areas and Equipment


Systems

Inside clad areas C3 and C4: All panels, cabinets and boards to be hot-dip galvanised to SANS 121 (ISO 1461) followed by powder coating with an approved powder coating system in accordance with SANS 1274. The thickness of the powder shall be a minimum of 100 micron. Externally exposed areas C5-M and C5-I: All panels, cabinets and boards to be powder coated stainless steel.

Notes: 1. The duplex coating shall comprise a minimum of two coats, i.e. either two coats of powder or a wet applied primer followed by the powder coating. 2. Textured or ‘structured’ powder coatings will not be acceptable due to variations in film thicknesses. 3. Fixing systems shall be hot-dip galvanised. Electroplated zinc coatings are not acceptable. 4. All site repairs to handling and installation damage shall be carried out in accordance with CPS 01 Notes 3, 4 and 5, Clause 4.3.6 and Clause 4.8. 5. The damaged powder coating shall be repaired with touch-up paint supplied by the powder manufacturer. 6. Fixing systems for stainless steel components shall be stainless steel.


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CPS 11 Environment Atmospheric – ISO 12944 C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Transformers Applicable Areas and Equipment

All areas

System Transformers shall be coated in accordance with SANS 780 Clause 4.17.4 ‘Coatings of exterior surfaces of transformers for use in corrosive environments’, i.e. hot-dip galvanising in accordance with SANS 121 (ISO 1461) or zinc metal spray in accordance with BS EN 22063 followed by the appropriate organic coating system as specified in the standard. The following epoxy/polyurethane coating system may be used as an alternative:

Surface Preparation Abrasive blast clean to Grade Sa 2½. Surface profile as specified by the primer coating manufacturer.







International Paints Interzinc 52 Intergard 475HS *Can be applied in 1 coat @ 200µm

Interthane 990

Jotun Barrier Penguard Express MIO *May be applied in 1 coat @ 200 microns

Hardtop AS


SigmaDur 550

Stoncor Carbozinc 859 Carboguard 893 MIO Carbothane 134 Minimum Total Dry Film Thickness: 325 micron Notes: 1. All coats to be applied in the shops. 2. The two intermediate coats shall be of different colours.

3. Stripe coating to be carried out in accordance with Clause 4.3.8. 4. All site repairs to handling and installation damage shall be carried out in accordance with Clause 4.3.6 and Clause 4.8.


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CPS 12 Environment Atmospheric – ISO 12944 C3, C4, C5-M and C5-I Material Mild steel Temperature Ambient to 200oC Description Nuts, bolts, flat washers, spring washers, holding down bolts and packer

plates Applicable Areas and Equipment


System All nuts, bolts, flat washers, spring washers, holding down bolts and packer plates shall be hot-dip galvanised in accordance with SANS 121 (ISO 1461): Minimum zinc thicknesses shall be as follows: Articles of diameter less than 12 mm 45 micron Articles of diameter of 12 mm or greater 55 micron

Notes: 1. After installation all nuts, bolts and packer plates shall be degreased and shall be fully coated in accordance with the specification for the respective area of the plant. 2. Electro-plated zinc shall will not be accepted as an alternative to hot-dip galvanising.


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CPS 13 Environment Atmospheric – ISO 12944 C4, C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Duplex protection of galvanised surfaces not covered in other CPS

systems Applicable Areas and Equipment


Surface Preparation Sweep blasting or cleaning with galvanised iron cleaner as recommended by the coating manufacturer


galvanised iron epoxy primer @ 100 micron

two component recoatable epoxy micaceous iron oxide intermediate coat @ 100 micron


Hempel Hempadur 15570 Hempadur 17410 Hempathane 55210 International Paints Interseal 670HS Intergard 475HS Interthane 990 Jotun Penguard Primer @

50 microns Penguard Express MIO @ 150 microns

Hardtop AS

Sigma SigmaCover 280 SigmaCover 435 or 435 S

SigmaDur 550

Stoncor Carboguard 193 Carboguard 193 MIO Carbothane 134 Minimum Total Dry Film Thickness over galvanising: 250 micron Notes: 1. Depending upon the requirements, the coatings can be applied in the shops or on site. 2. Stripe coating to be carried out in accordance with Clause 4.3.8. 3. All site repairs to handling and erection damage shall be carried out in accordance with Clause 4.3.6 and Clause 4.8. 4. All nuts and bolts to receive the full coating system.


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CPS 14 Environment Atmospheric – ISO 12944 C5-M and C5-I Material Mild steel Temperature Ambient to 80oC Description Sheeting and cladding (Engineering Note) 1. Introduction This engineering note is a guide to the selection of sheeting and cladding materials. There are a number of sheeting and cladding materials available from various suppliers. As cladding is difficult to maintain it is preferable to select a material that will last for the service life of the plant with minimum or no maintenance. All suppliers offer guidance as to initial material selection with respect to the corrosivity of the micro-environment and required service life. It is therefore recommended that cladding requirements are discussed with the suppliers at the design stage of the plant. 2. General Considerations Cladding is deemed to have failed when the sheet or membrane is perforated and allows access of the external environment, e.g. rain. The longevity or service life of a cladding material is therefore the sum of the life of the coating and the life of the base metal to perforation. Obviously, once the coating is spent, corrosion of the substrate metal is unsightly and although the cladding membrane has not perforated, it is considered to have failed. This point must be taken into account when selecting a material for a corrosive environment where aesthetics are also of concern. Where a performance guarantee is offered by the suppliers, clarification on the interpretation of the guarantee must be sought with respect to ‘life to perforation’ and/or ‘life to recoating’. 3. Fasteners Fasteners should have equal or better corrosion resistance than the cladding materials which they support and care should be taken to avoid galvanic effects between the two materials. Electroplated coatings should be avoided as they are generally too thin to provide effective long term protection in aggressive environments. When inherently resistant materials such as stainless steel fasteners are used, due regard to galvanic corrosion should be given. Quite often stainless steel fasteners used with less noble metals such as aluminium fail due to the galvanic corrosion of the aluminium around the hole in contact with the stainless steel causing enlargement of the hole and lifting of the sheeting. In aggressive environments where protective coatings have been applied to the structural steelwork, hook-bolts rather than screws that pierce the steelwork should be considered. These latter fasteners damage the coating on the steelwork and create isolated areas of corrosive attack to the steelwork. 4. Sealing of Laps The areas of overlap created at the ends and sides of the sheets provide ideal sites for accelerated crevice corrosion. These areas are narrow enough to draw in moisture by capillary action but not wide enough to allow ventilation. The concentration effects caused by alternative wetting and drying create highly corrosive environments that lead to rapid corrosion and perforation of the sheets. Such areas should be protected by sealants or coatings applied to both of the mating surfaces. When sealing beads only are used, these beads should be positioned at the external edge of the lap in order to prevent moisture ingress. If they are incorrectly positioned they can actually create crevice areas.


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5. Corrosion At Cropped Ends The coil coated mild steel cladding materials suffer from corrosion at cropped ends where the coated sheet has been cut or cropped. This operation exposes the steel to the corrosive environment. In the milder inland environments the galvanised zinc layer does afford some protection. However in aggressive marine environments this protection is short lived. To avoid the necessity of patch repairing cut ends, the cladding should be rolled to length so that end laps are eliminated. 5.1 Typical Material Selections Stainless Steel – coated Stainless Steel – uncoated Aluminium – coated Aluminium – uncoated Mild steel – galvalume – coated

Mild steel – galvalume - uncoated Mild Steel – Galvanised – coated Mild Steel – Galvanised – uncoated