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TECHNICAL SPECIFICATION

APPROVED PROTECTIVE COATING SYSTEMS

Document No.:

PMA-XT-SP0013

Rev No.

2

Xstrata Technology Pty Ltd

ABN 65 118 727 870

APPROVED PROTECTIVE COATING SYSTEMS 22-Aug-11 Page 2 of 47

TABLE OF CONTENTS

QUICK SELECTION CHART .......................................................................................................................................3

1 SYSTEM 01 .......................................................................................................................................................4

2

SYSTEM 02 .......................................................................................................................................................6

3

SYSTEM 03 .......................................................................................................................................................8

4

SYSTEM 04 .....................................................................................................................................................10

5

SYSTEM 05 .....................................................................................................................................................12

6 SYSTEM 06 .....................................................................................................................................................14

7

SYSTEM 07 .....................................................................................................................................................16

8

SYSTEM 08 .....................................................................................................................................................18

9

SYSTEM 09 .....................................................................................................................................................20

10

SYSTEM 10 .................................................................................................................................................22

11

SYSTEM 11 .................................................................................................................................................24

12 SYSTEM 12 .................................................................................................................................................26

13

SYSTEM 13 .................................................................................................................................................28

14

SYSTEM 14 .................................................................................................................................................30

15

SYSTEM 15 .................................................................................................................................................32

16

SYSTEM 16 .................................................................................................................................................34

17

SYSTEM 17 .................................................................................................................................................36

18

SYSTEM 18 .................................................................................................................................................38

19

SYSTEM 19 .................................................................................................................................................40

20

SYSTEM 20 .................................................................................................................................................42

21

SYSTEM 21 .................................................................................................................................................44

22

SYSTEM 22 .................................................................................................................................................46

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ABN 65 118 727 870


Quick Selection Chart

For service conditions other than listed contact corrosion engineer or technologist

Protective System Number 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22

Application

Equipment Exposed to Liquids or Slurries

Tank Internals Potable/Process Water X

Tanks and Thickeners Internals - Slurry X

Submerged Equipment - Slurry X X

Tanks and Thickeners External Surfaces X

Equipment in Wet Areas Mild Acid/ Alkaline X X

Hyperbaric filter vessel Internals - Slurry X

Mineral Processing Plant Launder Internals - Slurry X

MP Plant Launder Internals (Small Dia.) - Slurry X

Mineral Processing Plant Tank Internals - Slurry X

IsaMill Shell Liner - Primer X

Piping Coating SystemsSteel Piping External Surfaces X

Structural Steelwork Coating Systems

Structural Steel for Abrasive Service X

Structural steel in Wet Areas Mild Acid/Alkaline X

General Structural Steel (With Friction Grip Joints) X

General Structural Steel X

Handrails X

Mineral Processing Plant Structural SteelWet Plants X

General Equipment Coating Systems

General Equipment X

High Temperature Service Coating Systems

General Structural Steel & Equipment X

Coating Under Lagging X

Concrete and Masonry Coating Systems

Protective Coating of Masonary/Concrete X

Masonry/Concrete in Oily Environments X

Masonry/Concrete in Acidic Environments X

Galvanised Steel Coating Systems

Protection of Galvanised Steel in Acid Environments X

Protection of Galvanised Steel X X

Other Coatings

Sprayed Polyurethane Lining X

Hot Cast Polyurethane Lining X

Painting of Stainless Steel X

Non Flammable, Low Volatile Organic Compound X

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ABN 65 118 727 870


1 SYSTEM 01

1.1 System Designation

Life expectancy to first maintenance: Between 10 and 20 years, in an atmospheric environment.

To be used as an internal lining for potable/process water tanks.

1.2 Type of System

A two-component, solvent free, heavy-duty epoxy coating.

1.3 Surface Preparation

Remove all weld spatter and prepare equipment as required in its fabrication specifications. All sharp edgesmust be ground down to a minimum radius of 3 mm.

All joint and cavity sealants shall be used in accordance with Section 3.3.5.10 of AS/NZS 2312. All surface preparation shall be carried out in accordance with Section 4 of AS/NZS 2312.

Dirt and soluble salts must be removed by potable water washing as per Section 4.2.6 of AS/NZS 2312.

Oil & grease must be removed in accordance with AS 1627.1.

Abrasive blast, dry or wet, to AS 1627.4, Sa 3 (equivalent to NACE No.1; SSPC-SP 5).

The profile of the surface to be coated shall be within the 45-65 micron range.

All surfaces to be coated must be clean and dry.

1.4 Application

The coating shall be applied in conformance with Section 8 of AS/NZS 2312 and/or the coating shall beapplied in conformance with manufacturers recommendation.

Prepared surfaces shall be coated less than four hours after surface preparation, before flash rusting occurs.

For mixing instructions and re-coating application window, see manufacturers data sheet. For sharp, pitted, dimpled or rough surfaces, e.g. welds or plate edges, apply initial brushedstripe coat.

1.5 Limitations

Conditions required for painting shall be as per Section 8.5 of AS/NZS 2312, unless noted otherwise.

Note manufacturers data sheet.

Allow 15 minutes digestion after mixing

Apply with airless spray only.

1.6 Touch Up

Prepare and paint damaged surface as per SYSTEM 01

Prior to repairing existing coatings or substrates, test for chlorides (soluble salts) and pH.

1.7

Inspection & Testing

Inspection and testing shall be carried out in accordance with Section 11 of AS/NZS 2312.

Test compressor air for oil and/or water contamination before blasting and painting.

Carry out holiday detection as per AS 3894.

Measure and record prime coat and total coat DFT.

Execute Xstrata Technology approved quality control activities and documentation as per the applicablespecifications.

1.8 Health & Safety

All health and safety procedures shall be in accordance with Section 13 of AS/NZS 2312.

User to have copy of MSDS and comply with directions.

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1.9 SYSTEM 01 - Approved Products

Prime coatInternational (Akzo Nobel) Interline 982 DFT = 25-45 mWattyl Sigma EP universal primer DFT = 25-45 mOrica (Dulux) N/A N/AJotun Jotaprime 505 DFT = 25-45 m

Top coatInternational (Akzo Nobel) Interline 925 DFT = 400 mWattyl Sigmaguard CSF 75 DFT = 400 mOrica (Dulux) Durabild STP DFT = 400 mJotun Jotacote 412 DFT = 400 m

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2 SYSTEM 02


A Life expectancy to first maintenance: Between 10 and 20 years in an atmospheric environment.

To be used as an external coating for equipment to be submerged in liquids, or slurries.

2.2 Type of System

A two component, high solids, modified epoxy barrier coat designed to provide abrasive resistance and give

long term protection in a single coat application.

This system is compatible with sacrificial and impressed current cathodic protection systems.

Thickness of coating to be specified depending on application.

2.3

Surface Preparation


All joint and cavity sealants shall be used in accordance with Section 3.3.5.10 of AS/NZS 2312.

All surface preparation shall be carried out in accordance with Section 4 of AS/NZS 2312.



Abrasive blast, dry or wet, to AS 1627.4, Sa 2 (equivalent to NACE No 2; SSPC-SP 10), or for previouslyblasted steel use ultra high-pressure hydro blasting to AS 1627.4, Sa 2, provided that steel has acceptableprofile.



2.4

Application



For mixing instructions and re-coating application window, see manufacturers data sheet.

For sharp, pitted, dimpled or rough surfaces, e.g. welds or plate edges, apply initial brushedstripe coat.

2.5 Limitations

Conditions required for painting shall be as per Section 8.5 of AS/NZS 2312, unless noted otherwise. Note manufacturers data sheet.

Allow 15 minutes digestion after mixing.

2.6 Touch Up

Prepare and paint damaged surface as per SYSTEM 02


2.7 Inspection & Testing



Carry out holiday detection as per AS 3894. Measure and record prime coat and total coat DFT.


2.8

Health & Safety

All health and safety procedures shall be in accordance with Section 13 of AS/NZS 2312. User to have copy of MSDS and comply with directions.

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Holding primer:International (Akzo Nobel) Intergard 982 DFT = 25-45mWattyl Sigma EP universal primer DFT = 25-45 mOrica (Dulux) Luxapoxy 66 DFT = 25-45 mJotun Not Recommended N/A

Ultra high-build catalysed epoxy (Thickness to be as specified in the contract as it depends on desired service)

International (Akzo Nobel) Intertuff 485 DFT = 1000 to 3000m

Wattyl Sigmacover TCP compound DFT = 1000 to 3000mOrica (Dulux) Luxapoxy UHB DFT = 1000 to 3000mJotun Jotacote UHB DFT = 1000 to 3000m

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3 System 03


Life expectancy to first maintenance: Between 10 and 20 years in an atmospheric environment.

To be used as an internal lining for thickeners and slurry tanks.

3.2 Type of System

A two component, high solids, modified epoxy barrier coat designed to give long-term protection, for

thickeners or slurry tanks internal surfaces, in a single coat application.

This system is compatible with sacrificial and impressed current cathodic protection systems.


Remove all weld spatter and prepare equipment as required in its fabrication specifications. All sharp edges

must be ground down to a minimum radius of 3 mm. All joint and cavity sealants shall be used in accordance with Section 3.3.5.10 of AS/NZS 2312.





The profile of the surface to be coated shall be within the 45-65 micron range. All surfaces to be coated must be clean and dry.

3.4

Application





3.5 Limitations


Note manufacturers data sheet. Allow 15 minutes digestion after mixing.

3.6

Touch Up

Prepare and paint damaged surface as per SYSTEM 03.


3.7




Carry out holiday detection as per AS 3894.

Measure and record prime coat, Intermediate coats and total coat DFT. Execute Xstrata Technology approved quality control activities and documentation as per the applicable

specifications.

3.8 Health & Safety



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Holding primer: Prime coat is only to be used when conditions dictate e.g. to hold blast

International (Akzo Nobel) Intergard 982 DFT = 25-45m

Wattyl Sigma EP universal primer DFT = 25-45 m

Orica (Dulux) N/A N/A

Jotun Penguard Special DFT = 25-45 m

Two component, low volatile organic compound, high solids modified epoxy barrier coat.

International (Akzo Nobel) Interzone 954 DFT = 600 m (2 @ 300)Wattyl Sigmaguard EHB DFT = 600 m (2 @ 300)

Orica (Dulux) Durabild STE DFT = 600 m (2 @ 300)

Jotun Jotazone DFT = 600 m (2 @ 300)

Catalysed Acrylic Topcoat

International (Akzo Nobel) Interfine 629 DFT = 1 x 60 mOrica (Dulux) Acrathane DFT = 1 x 60 m

Wattyl Paracryl IFC DFT = 1 x 60 m

Jotun Jotacote 371T DFT = 1 x 60 m

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4 SYSTEM 04



To be used as a general coating repair system, for repairs to surfaces that cannot be adequately prepared.

4.2 Type of System

Two pack surface tolerant epoxy mastic coating general repair system.

The service life is heavily dependant on the quality of substrate preparation.

4.3

Surface Preparation

If surface has been repaired, or modified, remove all weld spatter and prepare equipment as required in itsfabrication specifications. All sharp edges must be ground down to a minimum radius of 3 mm.




Abrasive blast, dry or wet, to AS 1627.4, Sa 2 (equivalent to NACE No 8; SSPC-SP 14), or for previouslyblasted steel use ultra high-pressure hydro blasting to AS 1627.4, Sa 2, provided that steel has acceptableprofile. This requirement may be varied by specific contract specification as a clean-up coating.



4.4 Application

The coating shall be applied in conformance with Section 8 of AS/NZS 2312 and/or the coating shall be

applied in conformance with manufacturers recommendation. Prepared surfaces shall be coated less than four hours after surface preparation, before flash rusting occurs.



4.5 Limitations

Conditions required for painting shall be as per Section 8.5 of AS/NZS 2312, unless noted otherwise. Do not apply when the temperature of the surface being coated is below 13C.



Minimum of 250 m to be applied when used to coat badly pitted steel.

4.6 Touch Up



4.7


Inspection and testing shall be carried out in accordance with Section 11 of AS/NZS 2312. Test compressor air for oil and/or water contamination before blasting and painting.

When used for encapsulation, measure and record average DFT to establish required final DFT readings.


4.8 Health & Safety



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Two pack epoxy mastic self primingInternational (Akzo Nobel) Interseal 670 DFT = 150 mOrica (Dulux) Durabild STE DFT = 150 mWattyl Epinamal Mastic STC DFT = 150 mJotun Jotacote 605 fast Cure DFT = 150 m

Catalysed Acrylic TopcoatInternational (Akzo Nobel) Interfine 629 DFT = 1 x 60 mOrica (Dulux) Acrathane DFT = 1 x 60 mWattyl Paracryl IFC DFT = 1 x 60 mJotun Jotacote 371T DFT = 1 x 60 m

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5 SYSTEM 05



General purpose coating system for use on outdoor steel in usual industrial/mining environments.

5.2 Type of System

Two pack, low volatile organic compound, high solids modified epoxy coating and catalysed acrylic top coat

where high gloss is desirable.







When painting over galvanised steel, prepare surface by abrasive sweep blasting according to Appendix D ofAS 1627.4, Sa 1 (equivalent to NACE No 4; SSPC-SP 7).



5.4

Application




5.5

Limitations




5.6 Touch Up



5.7



Test compressor air for oil and/or water contamination before blasting and painting. Carry out holiday detection, as per AS 3894, when specified.



5.8 Health & Safety



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Two component, low volatile organic compound, high solids modified epoxy coat.International (Akzo Nobel) Interzone 954 DFT = 2 x 200 mOrica (Dulux) Durabild STE DFT = 2 x 200 mWattyl Sigmaguard EHB DFT = 2 x 200 mJotun Jotazone DFT = 2 x 200 m

Catalysed Acrylic TopcoatInternational (Akzo Nobel) Interfine 629 DFT = 1 x 60 mOrica (Dulux) Acrathane DFT = 1 x 60 mWattyl Paracryl IFC DFT = 1 x 60 mJotun Jotacote 371T DFT = 1 x 60 m

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6 SYSTEM 06


Life expectancy to first maintenance: Between 10 year and 20 years in an atmospheric environment.

For use on new handrails for general purpose industrial/mining applications.

6.2 Type of System

Two pack epoxy zinc phosphate primer with intermediate coat of high build epoxy and topcoat of catalysed

acrylic.

For galvanised substrate; delete prime coat; prepare with compatible etch primer or brush blast .









6.4

Application




6.5 Limitations



6.6 Touch Up



6.7



Measure and record prime coat, Intermediate coat and total coat DFT.


6.8

Health & Safety



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Two pack epoxy primer contains non toxic zinc phosphate pigmentsInternational (Akzo Nobel) Intergard 251 DFT = 75 mOrica (Dulux) Durepon P14 Primer DFT = 75 mWattyl Sigmacover CM ZP DFT = 75 mJotun Jotaspeed ZP DFT = 75 m

High build high solids two pack epoxy intermediate coatInternational (Akzo Nobel) Intergard 475 DFT = 125 mOrica (Dulux) Duramax GPE DFT = 125 mWattyl Sigmacover CM DFT = 125 mJotun Jotacote 605 DFT = 125 m

Catalysed acrylic top coatInternational (Akzo Nobel) Interfine 629 DFT = 60 mOrica (Dulux) Acrathane DFT = 60 mWattyl Paracryl IFC DFT = 60 m

Jotun Jotacote 371 Isofree DFT = 60 m

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7 SYSTEM 07


Life expectancy to first maintenance: Between 10 and 20 years (possibly 20 years +)

For use as general structural steel coating. For Friction grip joints, only primer is required.

7.2 Type of System

Water based/non moisture curing high ratio inorganic zinc silicate primer and high build epoxy top coat

7.3

Surface Preparation



All surface preparation shall be carried out in accordance with Section 4 of AS/NZS 2312. Dirt and soluble salts must be removed by potable water washing as per Section 4.2.6 of AS/NZS 2312.




7.4

Application


Prepared surfaces shall be coated less than four hours after surface preparation, before flash rusting occurs. For mixing instructions and re-coating application window, see manufacturers data sheet. Friction grip contact areas are to be coated with the inorganic zinc silicate primer only. .

7.5 Limitations


Significant humidity is required to cure prime coat.

Note manufacturers data sheet. Allow 15 minutes digestion after mixing. Do not allow build up to cause mud cracking.

7.6 Touch Up

Prepare damaged surface and repair using epoxy primer, as per SYSTEM 07. The prime coat cannot be

recoated with inorganic zinc silicate primer. Do not use epoxy primer on friction grip contact areas.

Prior to repairing existing coatings or substrates, test for chlorides (soluble salts) and pH



Measure and record prime coat, Intermediate coat and total coat DFT. Execute Xstrata Technology approved quality control activities and documentation as per the applicable

specifications.

7.8

Health & Safety



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Water based /non moisture curing high ratio inorganic zinc silicateInternational (AkzoNobel)

Interzinc 225 DFT = 75 m

Orica (Dulux) Zincanode 304 DFT = 75 mWattyl HRZ 700 DFT = 75 mJotun Jotaprime 5 DFT = 75 m

High build epoxy/epoxy masticInternational (AkzoNobel)

Interseal 670 DFT = 150 m

Orica (Dulux) Duramax GPE DFT = 150 mWattyl Epinamel HSE 707 DFT = 150 m

Jotun Jotacote 605 Fast Cure DFT = 150 m

Epoxy prime coat repairInternational (AkzoNobel)


Orica (Dulux) Zincanode 402 DFT = 75 mWattyl Galvit EP 100 DFT = 75 mJotun Jotun Barrier DFT = 75 m

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8 SYSTEM 08


Life expectancy to first maintenance: Between 5 and 10 years.

For use on structural steel and equipment exposed to high temperatures (up to 600oC)

8.2 Type of System

A two-component water based alkali inorganic zinc silicate primer (non flammable) and a single component

temperature resistant top coat.









8.4 Application




Apply mist coat before the application of topcoat.

8.5 Limitations

Do not allow build up to cause mud cracking.

8.6 Touch Up

Prepare and paint damaged surface as per SYSTEM 08. Prior to repairing existing coatings or substrates, test for chlorides (soluble salts) and pH.



Measure and record prime coat and total coat DFT. Final DFT must not exceed specified DFT by more than 20%.

Execute Xstrata Technology approved quality control activities and documentation as per the applicablespecifications

8.8

Health & Safety



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Inorganic zinc rich ethyl silicate primerInternational (AkzoNobel)


Orica (Dulux) Zincanode 304 DFT = 50 mWattyl Galvit HRZ 700 DFT = 50 m

Jotun Jotaprime 15 DFT = 75 m

High temperature silicone acrylicInternational (AkzoNobel)

Intertherm 875 for temperatures to 260C DFT = 40 m

Akzo Nobel(International)

Intertherm 50 for temperatures to 540C DFT = 40 m

Orica (Dulux) Hi temp 600 DFT = 30 mWattyl Heatcote Aluminium DFT = 2*20

mJotun Solvalitt up to 600C Jotacote 710 up to

230CDFT = 2*25

m

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9 SYSTEM 09


Life expectancy to first maintenance: Between 1 and 10 years in an atmospheric environment (depending onquality of substrate preparation and micro environment).

Coating is non-flammable, when mixed, and has an extremely low solvent content to meet all current andproposed volatile organic compound legislation.

9.2 Type of System

Two component, water based, epoxy.

9.3

Surface Preparation




Oil & grease must be removed in accordance with AS 1627.1. Abrasive blast, dry or wet, to AS 1627.4, Sa 2 (equivalent to NACE No 2; SSPC-SP 10), or for previously

blasted steel use ultra high-pressure hydro blasting to AS 1627.4, Sa 2, provided that steel has acceptableprofile. If this is not possible, the substrate must be prepared as well as possible, keeping in mind thatservice life is dependent on substrate condition.


9.4

Application




9.5 Limitations


Significant humidity is required to cure prime coat.



9.6

Touch Up






Carry out holiday detection, as per AS 3894, when specified.



9.8 Health & Safety



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Two pack water based epoxyInternational (Akzo Nobel) Intergard 765 DFT = 120 (2X60 m)Orica (Dulux) Enviropoxy WBE DFT = 120 (2X60 m)Wattyl N/A N/AJotun N/A N/A

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10 SYSTEM 10



For protective coating of masonry or concrete.

10.2 Type of System

A single two pack surface tolerant epoxy mastic coat, with a catalysed acrylic top coat, where a high gloss

finish is desirable.


For cracks and/or rough surfaces: repair with epoxy filler before application of coatings.

Dirt and soluble salts must be removed by potable water washing.

Oil & grease must be removed in accordance with AS 1627.1. To ensure that the masonry or concrete has an acceptable profile use abrasive blasting (dry or wet, with non

metallic abrasive), ultra high-pressure hydro blasting or another method as specified in the contract.

The surface condition of the masonry or concrete must be free of curing compounds, forming lubricants,laitance or other loose materials.


10.4 Application


Prepared surfaces shall be coated within 3 days of surface preparation, before surface contamination occurs.

10.5

Limitations

Conditions required for painting shall be as per Section 8.5 of AS/NZS 2312, unless noted otherwise. Do not apply coat if surface temperature is less than 130C or if the surface temperature is less than 60C

above the dew point temperature.

Note manufacturers data sheet, especially for mixing instructions.

Allow 15 minutes digestion after mixing. The re-coat window is 3 weeks.

The concrete moisture content should be less than 6%.

10.6 Touch Up





When used for encapsulation, measure and record average DFT to establish required final DFT readings. Measure and record total coat DFT.


10.8 Health & Safety



Note: the use of dry blasting may produce hazardous dust- proper hazrd management is required.

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Two pack epoxy mastic self primingInternational (Akzo Nobel) Interseal 670 DFT = 200 mOrica (Dulux) Sigma Cover CM ZP DFT = 200 mWattyl Epinamal Mastic DTM DFT = 200 mJotun Jotacote 605 Fast Cure DFT = 200 m

Catalysed acrylic top coat (use only when high gloss retention finish is required)International (Akzo Nobel) Interfine 629 DFT = 60 mOrica (Dulux) Acrathane DFT = 60 mWattyl Paracryl IFC DFT = 60 mJotun Jotacote 371 Iso Free DFT = 60 m

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11 SYSTEM 11


Life expectancy to first maintenance: Between 10 year and 20 years in an atmospheric environment.

For use on equipment that will have lagging installed. This coat protects the surfaces during transportation.

11.2 Type of System

Two pack epoxy zinc phosphate primer.

11.3

Surface Preparation







11.4

Application


Prepared surfaces shall be coated less than four hours after surface preparation, before flash rusting occurs. For mixing instructions and re-coating application window, see manufacturers data sheet.

11.5

Limitations



11.6 Touch Up



11.7



Measure and record total coat DFT.





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Two pack epoxy primer contains non toxic zinc phosphate pigmentsInternational (Akzo Nobel) Intergard 251 DFT = 75 mOrica (Dulux) Durepon P14 Primer DFT = 75 mWattyl Sigmacover CM ZP DFT = 75 mJotun Jotaspeed ZP DFT = 75 m

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12 SYSTEM 12


Life expectancy to first maintenance: Between 5 and 10 years in an atmospheric environment (service life isdependant on the quality of substrate preparation).

This system is used for the protection of galvanised steel in acid environments, for example galvanised cabletrays in a Cu smelter fume.

12.2 Type of System

Two pack surface tolerant epoxy mastic coating.

12.3

Surface Preparation




Abrasive sweep blast according to Appendix D of AS 1627.4, Sa 1 (equivalent to NACE No 4; SSPC-SP 7).


12.4 Application


applied in conformance with manufacturers recommendation.



12.5

Limitations

Do not apply below 13C or if relative humidity exceeds 85%.

Re-coat window three weeks.


Surface temperature must always be a minimum of 3C above dew point.

For mixing instructions and re-coating application window, see suppliers date sheet.

12.6

Touch Up

Abrade damaged surface to provide mechanical key and paint as per SYSTEM12


Test compressor air for oil and/or water contamination before blasting and painting For repair to existing coatings on steel, test for chlorides

For repair to existing coatings steel located in an adverse environment, test pH

When used for encapsulation, measure and record average DFT to establish final DFT readings

Measure and record total coat DFT on XT approved quality control documentation.

12.8 Safety


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Two pack epoxy mastic self primingInternational (Akzo Nobel) Interseal 670 DFT = 150 mOrica (Dulux) Durabild DTM DFT = 150 mWattyl Epinamal Mastic STC DFT = 150 mJotun Jotacote 605 Fast Cure DFT = 150 m

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13 SYSTEM 13


Life expectancy to first maintenance: Greater than 15 years.

This is a high durability protective coating for masonry/concrete in oily environments, for example oil bunds,

etc. This coating is suitable for use in an environment classed as C5-I (very high corrosivity (industrial)) in ISO12944-2.

13.2 Type of System

Two pack chemical resistant Polyamide Cured Epoxy.

13.3

Surface Preparation

Concrete must be allowed to cure for 28 days prior to preparations for coating.

For cracks and/or rough surfaces: repair with epoxy filler before application of coatings. Dirt and soluble salts must be removed by potable water washing.


To ensure that the masonry or concrete has an acceptable profile use abrasive blasting (dry or wet, with nonmetallic abrasive), high-pressure hydro blasting (70MPa) or another method as specified in the contract.



13.4

Application


Prepared surfaces shall be coated within 3 days of surface preparation, before surface contamination occurs. First coat of Intergard 475 should be thinned 25% to aid penetration.

13.5 Limitations


Do not apply coat if surface temperature is less than 60C above the dew point temperature. Note manufacturers data sheet, especially for mixing instructions.


The re-coat window is 16 hours to 5 days at 250C.


13.6

Touch Up



13.7



Measure and record total coat DFT.




User to have copy of MSDS and comply with directions. Note: the use of dry blasting may produce hazardous dust- proper hazard management is required.

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Two-pack polyamide cured epoxy.International (Akzo Nobel) Intergard 475 DFT = 1X100 - 2X200 - Total 500 mOrica (Dulux) TBAWattyl TBAJotun Jotacote 418 DFT = 1X100 - 2X200 - Total 500 m

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14 SYSTEM 14


Life expectancy to first maintenance: Greater than 15 years.

This is a high durability protective coating for masonry/concrete in acidic environments, for example acid

bunds, etc. This coating is suitable for use in an environment classed as C5-I (very high corrosivity(industrial)) in ISO 12944-2.

14.2 Type of System

Two pack chemical resistant Vinyl Ester.

14.3

Surface Preparation

Concrete must be allowed to cure for 28 days prior to preparations for coating.

For cracks and/or rough surfaces: repair with a paste of clean sand added to Interline 811 and apply by trowel. Dirt and soluble salts must be removed by potable water washing.


To ensure that the masonry or concrete has an acceptable profile use abrasive blasting (dry or wet, with nonmetallic abrasive), high-pressure hydro blasting (70MPa) or another method as specified in the contract.



14.4

Application


Prepared surfaces shall be coated within 3 days of surface preparation, before surface contamination occurs. Where applicable roll strips of fibreglass matting over wet Interline 811 and topcoat with interline 871.

14.5 Limitations


Do not apply coat if surface temperature is less than 60C above the dew point temperature. Note manufacturers data sheet, especially for mixing instructions.


The re-coat window for Interline 811 is 16 hrs to Ext at 250C and for Interline 871; it is 4 hrs to EXT at 250C.


14.6

Touch Up



14.7



Measure and record first coat DFT and then final coat DFT.




User to have copy of MSDS and comply with directions. Note: the use of dry blasting may produce hazardous dust- proper hazard management is required.

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Two pack Vinyl EsterInternational (Akzo Nobel) Interline 811 DFT = 50m.Orica (Dulux) TBAWattyl TBAJotun Chemflake Clear DFT = 100m.

Two pack Vinyl EsterInternational (Akzo Nobel) Interline 871 DFT = 1000 m.Orica (Dulux) TBAWattyl TBAJotun Chemflake II DFT = 1000m.

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15 SYSTEM 15


This System is intended for painting the internal surfaces of mineral processing plant tank launders (width of350mm plus) and is suitable for use in wet areas.

15.2

Type of System

Epoxy, two coat system.

15.3

Surface Preparation



All surface preparation shall be carried out in accordance with Section 4 of AS/NZS 2312. Dirt and soluble salts must be removed by high pressure potable water washing as per Section 4.2.6 of

AS/NZS 2312.


Abrasive blast, dry or wet, to AS 1627.4, Sa 2 (equivalent to NACE No 2; SSPC-SP 10), or for previouslyblasted steel use ultra high-pressure hydro blasting to AS 1627.4, Sa 2, provided that steel has acceptableprofile. Note: extend launder surface blast coverage into the tank interior by at least 200mm.



1stcoat is an optional blast holding primer.

15.4

Application




15.5 Limitations



15.6 Touch Up





Carry out spark testing, as per AS 3894, to check the continuity on the hard cured final coat. Measure and record prime coat and total coat DFT.





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15.9 Extent of Coverage

When SYSTEM 15 is applied to the internal surfaces of the launders, there is a need to consider theinterfacing of this system with respect to other coating systems applied to adjacent tank surfaces (e.g. maintank internal surfaces coated with SYSTEM 20). Where multiple coating systems are to be used on the tank,the Applicator must strictly adhere to all notes and recommendations given by XT.

15.10Notes

International Protective Coatings require the spark testing of tank lining coatings be limited to coatingswhere the dry film thickness is in excess of 500m and where a suitable pulsating type holiday detectorvoltage is set to the equivalent of 100V per 25m of dry film thickness (i.e. 2kV at 500m DFT). Excessivevoltage may produce a holiday in the coating film.

15.11SYSTEM 15 - Approved Products

1stcoat: Polyamide Adduct Cured Epoxy (Optional)Dulux TBA DFT = 40mJotun Tankguard HB DFT = 40mInternational Intergard 269 DFT = 40mWattyl TBA DFT = 40m

2ndcoat: High Solids High Build EpoxyDulux TBA DFT = 450 to 500mJotun Marathon XHB DFT = 450 to 500mInternational Interzone 954 DFT = 450 to 500mWattyl TBA DFT = 450 to 500m

Total DFT = 500m

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16 SYSTEM 16


This system is intended for painting any structural steel work associated with the mineral processing plants.

16.2 Type of System

Aliphatic Acrylic Polyurethane Paint System.





Dirt and soluble salts must be removed by high pressure potable water washing as per Section 4.2.6 ofAS/NZS 2312.





16.4

Application


Prepared surfaces shall be coated less than four hours after surface preparation, before flash rusting occurs. For mixing instructions and re-coating application window, see manufacturers data sheet.

16.5 Limitations



16.6 Touch Up

All damaged surfaces shall be blast cleaned to AS 1627.4 Class 21/2and feathered into existing coating. Thecoating must then be reinstated with Zinc Rich Epoxy Primer to achieve a dry film thickness of 75m andsecond coat applied as per SYSTEM 16.


16.7




Measure and record prime coat, intermediate coat and total coat DFT.





Aliphatic Acrylic Polyurethane paint systems generally contain isocyanate. Refer to MSDS for handling and

coating requirements.

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16.9 Notes

1.

Wattyl Australia recommends 50m DFT maximum for their primers.2. Aliphatic Acrylic Polyurethane paint systems are best used as a shop applied new construction coating, where

exposure to isocyanate can be strictly controlled. The Aliphatic Acrylic Polyurethane paint system can later becoated over with an isocyanate free catalysed acrylic (Interfine 629 or Paracryl IFC) paint system, if anisocyanate free site applied maintenance coatis required.

3. Subject to prior approval, an alternative to the 3rdcoat system would be an isocyanate free catalysed acrylic,such as Interfine 629 or Paracryl IFC.


Alternative 1stcoat: Zinc Rich Epoxy PrimerDulux TBA DFT = 50-75m

Jotun Barrier DFT = 50-75mInternational Interzinc 52 DFT = 50-75mWattyl (see note 1) Galvit EP102 DFT = 50-75m

2ndcoat: High Build Polyamide Epoxy

Dulux TBA DFT = 150 to 200mJotun Jotacote Universal DFT = 150 to 200mInternational Interplus 1180 DFT = 150 to 200mWattyl (see note 1) Epinamel HSE 707 DFT = 150 to 200m

3rdcoat: Aliphatic Acrylic PolyurethaneDulux TBA DFT = 50 to 75m

Jotun Hardtop XP DFT = 50 to 75mInternational Interthane 990 (see notes 2 & 3) DFT = 50 to 75mWattyl (see note 1) Poly-U 400 (see notes 2 & 3) DFT = 50 to 75m

Total DFT = 250 to 350

m

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17 SYSTEM 17


This System is intended for painting the internal surfaces of the mineral processing plant tank launderswhich are less than 350mm wide (use only when specified).

17.2

Type of System

Solvent free, ultra high build, high solids paint system.

17.3

Surface Preparation




AS/NZS 2312.





17.4

Application




Stripe coating of corners and weld areas is mandatory.

17.5 Limitations



This paint system is suitable for areas where access for removal of all weld spatter and sharp edges is

limited, but grit blasting to AS1627, Class 3, is possible.

17.6 Touch Up





Carry out spark testing, as per AS 3894, to check the continuity on the hard cured final coat.





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1stcoat: Non Inhibitive, Two Pack Epoxy PrimerAmeron Amercoat CC22 Red Oxide DFT = 40-100mJotun N/A DFT = 40-100mInternational TBA DFT = 40-100mWattyl TBA DFT = 40-100m

2ndcoat: High Solids High Build EpoxyAmeron CC703/2 DFT = 1 to 2.5mmJotun Jotacote UHB DFT = 1 to 2.5mmInternational TBA DFT = 1 to 2.5mmWattyl TBA DFT = 1 to 2.5mm

Total DFT = 1 to 2.5mm

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18 SYSTEM 18


This system is intended for painting of steel work that has been hot dipped galvanised, or for final colourcoats over stainless steel.

18.2

Type of System

Catalysed Acrylic paint system.

18.3

Surface Preparation




AS/NZS 2312.


Abrasive sweep blast (see note 1) according to Appendix D of AS 1627.4, Sa 1 (equivalent to NACE No 4;SSPC-SP 7).


18.4

Application



For mixing instructions and re-coating application window, see manufacturers data sheet.18.5

Limitations



18.6

Touch Up

All damaged surfaces shall be blast cleaned to AS1627.4, Class 21/2(see note 1) and feathered into existingcoating. Coating must then be reinstated as per SYSTEM 18.


18.7





18.8

Health & Safety



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18.9 Notes

1.

For stainless steel substrates, grit must be unused and non metallic (garnet or equal). Recycled grit previouslyused on mild steel must not be used on stainless steel.

2. For stainless steel, in lieu of Intergard 251, International recommends Intergard 269 @ 40m DFT, over asuitably prepared surface.

3. In lieu of Epoxy Zinc Phosphate primer, Wattyl Australia nominates a two pack adhesion promotingpolyamide cured epoxy primer.

4. For strong contrasting colours (such as bright reds and yellows), 2 coats at 30 to 50m DFT is recommendedin lieu of 1 coat at 60 to 75m DFT.


1stcoat: Epoxy Zinc Phosphate primerDulux Durepon P14 DFT = 50 - 75m

Jotun Penguard Special DFT = 50 - 75mInternational Intergard 251 (see 2nd

note)DFT = 50 - 75m

Wattyl EP Universal Primer (see3rdnote)

DFT = 50 - 75m

2ndcoat: High Solids High Build EpoxyDulux Acrathane IF (see 4thnote) DFT = 60 - 75mJotun Jotaproof Topcoat of

Jotacoate 371TDFT = 60 - 75m

International Interfine 629 (see 4thnote) DFT = 60 - 75mWattyl Paracryl IFC (see 4thnote) DFT = 60 - 75m

Total DFT = 110 to 150m

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19 SYSTEM 19


This system is intended for painting the internals of the mineral processing plant tanks (slurry, process andgland water tanks - see note 2), where the surface is not polyurethane lined.

19.2

Type of System

Abrasion resistant, Amine cured, Epoxy system.

19.3

Surface Preparation




AS/NZS 2312.





19.4

Application




19.5 Limitations



19.6

Touch Up/Repairs



19.7

Inspection & Testing Inspection and testing shall be carried out in accordance with Section 11 of AS/NZS 2312.


Carry out spark testing, as per AS 3894, to check the continuity on the hard cured final coat.

Measure and record prime coat, intermediate coat and total coat DFT. Execute Xstrata Technology approved quality control activities and documentation as per the applicable

specifications.

19.8

Health & Safety


This system is not suitable for tanks containing potable water.

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19.9 Notes

1.

Wattyl Australia recommends 75m DFT maximum for their primers.2. It must be noted that this system is not suitable for potable water.


1stcoat: Two pack Epoxy Primer (suitable for anti-abrasive top coat)Dulux Luxepoxy 66 DFT = 40mJotun Tankguard HB DFT = 40mInternational Interline 908 DFT = 40mWattyl (see note 1) EP Universal Primer DFT = 75m

2ndcoat: Abrasion Resistant Amine Cured EpoxyDulux Durebuild TSP (Black) DFT = 150m

Jotun Marathon DFT = 150mInternational Intershield 912 (Black) DFT = 150mWattyl (see note 1) Multiguard Black DFT = 150m

3rdcoat: Abrasion Resistant Amine Cured EpoxyDulux Durebuild TSP (White) DFT = 150mJotun Marathon DFT = 150mInternational Intershield 912 (Red) DFT = 150mWattyl (see note 1) Multiguard Grey DFT = 150m

Total DFTs:

Dulux, Jotun, international: 340m

Wattyl: 375m

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20 SYSTEM 20


This system is used to line the internal working surfaces of mineral processing plant slurry tanks.

20.2 Type of System

This is a sprayed polyurethane lining system.





Dirt and soluble salts must be removed by high pressure potable water washing as per Section 4.2.6 ofAS/NZS 2312.



The profile of the surface to be coated shall be within the 50-75 micron range for the Chemtura products

and 75 to 100 micron range for the Chemind and Dulux products. A reduced surface profile of 50 to 75microns is acceptable for the Chemind and Dulux products, provided that the abrasive blast class isincreased from Sa 2, to Sa 3.


20.4

Application

The coating shall be applied in conformance with best industry practice and/or the coating shall be appliedin conformance with manufacturers recommendation.


20.5 Limitations




Sprayed polyurethane lining to be applied by approved applicators only.

20.6 Touch Up

Preferred Method (for repairs with 48 hours of original coating): Recoat as required over the existing surface

within 48 hours of application (e.g. under-thickness or failure during spark testing) Alternative Method (for repairs after the 48 hour recoat window has been exceeded): Light abrasion of the

defective area followed by a solvent wash (MEK) and the application of a trowelable polyurethane system(WRM 80t or equal).



Test compressor air for oil and/or water contamination before blasting and painting. Carry out spark testing, as per AS 3894, to a maximum of 13.5kV in order to check the continuity on the

hard cured final coat.


Execute Xstrata Technology approved quality control activities and documentation as per the applicable

specifications.

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20.9

Extent of Coverage

When SYSTEM 20 is applied to the internal surfaces of tanks, there is a need to consider the interfacing ofthis system with respect to other coating systems applied to adjacent tank surfaces. Where multiple coatingsystems are to be used on the tank, the Applicator must strictly adhere to all notes and recommendationsgiven by XT.

20.10Approved Applicators

Hunter Urethane Spray Technology Pty Ltd, Unit 4/44 Munibung Road, Cardiff, NSW, 2285,phone: (02) 4961 1077

Glindemann Industrial Coatings Pty Ltd, 37 Darnick Street, Underwood, QLD, 4119Phone: (07) 3219 0419


1stcoat: Two Pack Epoxy Primer

Chemtura International Intergard 348 DFT = 15 - 25mChemind Chemspray 117 Clear Primer DFT = 15 - 25mDuluX Durepon P14 DFT = 15 - 25mTBA TBA TBA

2ndcoat: Part A & B Sprayed Polyurethane Lining System

Chemtura Vibraspray EP1690 DFT = 3mm plusChemind Chemspray 690 DFT = 3mm plusDuluX Flexituff PC 390 DFT = 3mm plusTBA TBA TBA

Total DFT = 3mm plus

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21 SYSTEM 21


Documents

Pma Xt Sp0013