Infrastructure Standard Specification Surface Protection

Infrastructure Standard Specification

Surface Protection

ACTEW Water Standard Specification – Surface Protection i

Document Authorisation

Author: Principal Engineer Infrastructure Standards Development

Signed:

Date:

20Jan14

Checked by: Manager Water Asset Planning Signed:

Date:

Approved by: Group Manager Water Signed:

Date:

Document Revision Control

Version Description of Revision

Person Making Issue

Date Approval

1 Draft issued as Document PB550-S01

Luke Belfield 24Feb12

2a Revised following ACTEW restructure and issued for review

Denis Baker 22Oct13

2b For reviewer workshop

Denis Baker 11Dec13

2c As amended in review workshop

Denis Baker 20Jan14

© ACTEW Corporation Ltd. This publication is copyright and contains information that is the property of ACTEW Corporation Ltd. It may be reproduced for the purposes of use while engaged on ACTEW commissioned projects. Disclaimer This document has been prepared for ACTEW Corporation Ltd and is used for its purposes. No warranty is given as to its suitability for any other purpose.

ACTEW Water Standard Specification – Surface Protection ii

Contents

Abbreviations iv 1 Purpose 1 2 Application .............................................................................................................. 1 3 Scope 1 4 Items to be left unpainted ........................................................................................ 1 5 Surfaces to be coated ............................................................................................. 2 6 Responsibilities ....................................................................................................... 2

6.1 Group Manager Water ......................................................................................................... 2 6.2 Manager Regulation Compliance and Quality ..................................................................... 2 6.3 Manager Water Operations ................................................................................................. 2 6.4 Manager Water Asset Planning ........................................................................................... 2 6.5 Project Manager .................................................................................................................. 3 6.6 External Designers, Contractors, Applicators, Manufacturers and Suppliers ..................... 3

7 Definitions ............................................................................................................... 3 8 Standards ............................................................................................................... 4 9 Health and Safety.................................................................................................... 6

9.1 General Requirements ........................................................................................................ 6 9.2 Thinners, Solvents and Coating Material Safety ................................................................. 6 9.3 Confined Spaces ................................................................................................................. 6 9.4 Working at Heights .............................................................................................................. 7 9.5 Physical Barriers .................................................................................................................. 7 9.6 Equipment ............................................................................................................................ 7 9.7 Personal Air Supply ............................................................................................................. 8

10 Environment ............................................................................................................ 9 10.6 Statutory Authorities ............................................................................................................ 9 10.7 Lead Coatings...................................................................................................................... 9 10.8 Asbestos .............................................................................................................................. 9 10.9 Polyaromatic hydrocarbons ............................................................................................... 10 10.10 General Wastage and Containment .................................................................................. 10

11 Quality Assurance and Control Requirements ....................................................... 11 11.1 Quality Control Documentation.......................................................................................... 11 11.2 Inspection and Test Plans ................................................................................................. 11

12 Supply of Materials and Equipment ....................................................................... 13 12.1 Coatings and Equipment ................................................................................................... 13

12.2 Material Approvals ................................................................................................ 13 12.3 Material in contact with Potable Water .................................................................. 14 12.4 Cathodic protection system compatibility ............................................................... 14 13 Coating Storage and Preparation .......................................................................... 14 14 Surface Preparation .............................................................................................. 15

14.1 Removal of surface or metal defects ................................................................................. 15 14.2 Precleaning ........................................................................................................................ 15 14.3 Abrasive blast cleaning ...................................................................................................... 15 14.4 Wet Abrasive Blasting ....................................................................................................... 16 14.5 High Pressure Water Cleaning and High and Ultra-high Pressure Water Jetting ............. 17 14.6 Hand and Power Tool Cleaning ........................................................................................ 17 14.7 Hot Dip Galvanised Steel .................................................................................................. 17 14.8 Aluminium Alloys Copper and Brass ................................................................................. 17 14.9 Plastics and FRP ............................................................................................................... 17 14.10 Concrete ............................................................................................................................ 17 14.11 Masonry ............................................................................................................................. 18 14.12 Concrete and Masonry Sealants and Primers ................................................................... 18

15 Coating Application ............................................................................................... 19

ACTEW Water Standard Specification – Surface Protection iii

15.1 Coating Application General Requirements ...................................................................... 19 15.2 Concrete Coating Application ............................................................................................ 20

16 Repairs to Existing Coating Systems..................................................................... 21 16.1 Spot Repairs ...................................................................................................................... 21 16.2 Renovation Repairs ........................................................................................................... 21 16.3 Refurbishment ................................................................................................................... 21

17 Inspection ............................................................................................................. 22 17.1 Inspection and Test Plans ................................................................................................. 22 17.2 Coatings Inspector ............................................................................................................. 22 17.3 Coatings Inspection Equipment and Data ......................................................................... 22 17.4 Coatings Inspection Reports ............................................................................................. 22 17.5 Coatings Inspection and Test Requirements .................................................................... 23 17.6 Concrete Moisture Test ..................................................................................................... 24

18 Coating of Proprietary Equipment ......................................................................... 24 19 Hot Dip Galvanising .............................................................................................. 24 20 Powder Coating .................................................................................................... 25 21 WAE Drawings ...................................................................................................... 25 Appendix 1: Surface Coating Systems for New Systems ........................................... 26 Appendix 2: Surface Coating Systems for Existing Systems ...................................... 39 Appendix 3: ACTEW Standard Coating Systems Correlation to AS 2312 and APAS

Specifications ......................................................................................... 43

ACTEW Water Standard Specification – Surface Protection iv

Abbreviations

Abbreviation Meaning

ACA means Australian Corrosion Association

ACTEW means ACTEW Corporation Ltd under the business name of ACTEW Water

APAS means Australian Paint Approvals Scheme (formerly Government Paint Committee)

DFT means dry film thickness (minimum)

HDG means hot dip galvanising

ITP means Inspection and Test Plan

NATA means National Association of Testing Authorities

PAH means polyaromatic hydrocarbons

PCCP means Painting Contractors Certification Program

PDF means portable document format

PPE means Personal Protective Equipment

SDS means Safety Data Sheet

SSPC means Society of Protective Coatings

WMS means Work Method Statement

ACTEW Water Standard Specification – Surface Protection 1

1 Purpose

The purpose of this infrastructure standard specification is to detail the requirements for the

surface protection of assets for use by ACTEW for facilities in the Water Network.

2 Application

This infrastructure standard specification applies to all of infrastructure assets in the

ACTEW Water Network. This standard specification applies to ACTEW personnel, contract

personnel engaged by ACTEW, developers including their consultants and construction

contractors contracted to handover assets to ACTEW and maintenance contractors

engaged by ACTEW.

3 Scope

This standard specification covers the ACTEW requirements for the following: 1. Coating systems

2. Supply of coating materials

3. Safety constraints

4. Surface preparation

5. Coatings application

6. Coatings testing

This standard specification is directed primarily to the supply and application of coating systems for ACTEW infrastructure projects by coating manufacturers and coating applicators.

Details of new coating systems required by this standard specification are given in Appendix 1 and maintenance coating systems in Appendix 2. APAS approved products are given in Appendix 3. For materials in contact with potable water refer section 12.3.

When adverse conditions exist for coating system application ACTEW shall be consulted prior to proceeding. A supplementary coating system will be supplied if appropriate e.g.:

1. Severely corrosive environment such as chemical or marine conditions; or

2. When equipment will be above ambient temperature during or after coating (unless such suitability is indicated in Appendix 1 or Appendix 2).

Where finish colours are specified they shall match AS 2700S colour reference cards.

Surface preparation, use of application equipment and methods of application shall be carried out in accordance with the requirements of this standard specification and the coating manufacturer’s requirements.

The scope of work for surface protection includes supply of all materials necessary for the finished coating system and includes supply all abrasives, cleaning and coating materials, tools, equipment, work platforms, product approvals and other specified documentation and labour to complete the work.

For coating systems which require coating applicator certification, work methods shall also comply with the certification requirements.

4 Items to be left unpainted

The following items shall be kept clean and free of paint and unless specified otherwise unpainted:


1. Nameplates, Information plates, scales and indicators fitted to equipment.

2. Asset numbering and barcode plates

3. Valve spindles, lubricators and positioners

4. Sight glasses

5. Gasket sealing faces on flanges

6. Stainless steel, aluminium and copper surfaces

7. Stud bolts and nuts for flanges

8. Air supply filters, regulators, gauges and air switches

9. Pressure gauges

10. Local temperature indicators

11. Field mounted transmitters and controllers

12. Cases of level instruments

13. Switches and backs of instruments mounted in control panels

14. Surface of running equipment which will be insulated

15. Plastic coated equipment

16. Galvanised surfaces

17. Relief valve colour-coded caps

18. Flexible hoses or flexible electrical conduits

19. Brickwork

20. GRP or polyethylene surfaces

21. ABS, PVC and FRP surfaces.

If ACTEW gives specific approval in writing, then the approved items supplied pre-coated

may be left unpainted. Care shall be taken to protect these items from blasting damage and

paint. Paint shall be immediately removed without damaging the original finish.

5 Surfaces to be coated

Surfaces which shall be coated as a minimum include: 1. Iron

2. Carbon Steel

3. Concrete and masonry exposed to corrosive or aggressive or submerged environment

4. Items specifically requiring a decorative or specific colour top coat or safety coating including non ferrous metals and building surfaces of interior or exterior exposure.

6 Responsibilities

6.1 Group Manager Water

The Group Manager Water shall be responsible for approval of this Water Network

infrastructure standard specification and any amendments to it.

6.2 Manager Regulation Compliance and Quality

The Manager Regulation Compliance and Quality shall be responsible for:

1. Ensuring that the quality framework for infrastructure surface protection is followed.

6.3 Manager Water Operations

The Manager Water Operations shall be responsible for:

1. Ownership of Water Network operations documents.

6.4 Manager Water Asset Planning

The Manager Asset Planning shall be responsible for:


1. Ownership of Water Network maintenance planning involving renewal of surface protection.

2. Acceptance of surface protection applied to Water Network infrastructure.

6.5 Project Manager

The project manager (both internal to ACTEW and external) for new assets and renewal

assets provision to ACTEW shall be responsible for ensuring that the design, selection,

application, inspection, testing and handover of infrastructure surface protection complies

with this standard specification. Refer also to section 7 “ACTEW representative responsible

for the contract”.

6.6 External Designers, Contractors, Applicators, Manufacturers and Suppliers

Designers, contractors, applicators, manufacturers and suppliers external to ACTEW Water

shall be responsible for ensuring that:

1. They follow the requirements of this standard specification in the design, selection, application, inspection, testing and handover of Water Network infrastructure surface protection.

2. They comply with the respective, specific responsibilities detailed in this standard specification.

7 Definitions

ACTEW representative responsible for the contract means Superintendent’s Representative for contracts directly with ACTEW under AS 2124 General Conditions of Contract or the ACTEW Project Manager for other contracts directly with ACTEW or means a member of ACTEW Asset Acceptance and Protection team for works other than directly contracted with ACTEW.

Applicator means the party engaged by the Contractor or ACTEW to carry out surface protection work.

Contractor means the party contracted to provide the respective infrastructure to ACTEW to which surface protection is required to be applied.

DFT means the minimum dry film thickness determined in accordance with AS 3964.3.

Manufacturer means the party which manufactures or supplies the protective coatings.

Water Network means the same as defined under the Utilities Act 2000 s12, namely:

(1) For this Act, a water network consists of the infrastructure mentioned in subsection (2) used, or for use, in relation to any of the following purposes:

(a) the collection and treatment of water for distribution by a person to premises of another person;

(b) the distribution of water by a person for supply to premises of another person. (2) For subsection (1), the infrastructure consists of the following: (a) water storages, mains and treatment plants;

(b) pumps, facilities and equipment for distributing water, or monitoring or controlling the distribution of water;

(c) pipes or equipment; (d) any other thing ancillary to any other part of the infrastructure.

In this standard specification, shall, must, is to, are to and will indicate a requirement and are all equally mandatory.


8 Standards

The following standards are referred to in this standard specification: AS 1192 Electroplated coatings, nickel and chromium AS 1214 Hot-dip galvanised coatings on threaded fasteners (ISO metric

coarse thread series) AS 1231 Aluminium and alloys - Anodic oxidation coatings AS 1281 Cement mortar lining of steel pipes and fittings AS 1318 SAA Industrial Safety Colour Code AS 1345 Identification of the contents of piping, conduits and ducts AS 1518 Extruded high-density polyethylene protective coatings for pipes AS 1580 Methods of test for paints and related materials AS 1627 Metal finishing – Preparation and pretreatment of surfaces Part 0: Method selection guide Part 1: Removal of oil, grease and related contamination Part 2: Power tool cleaning Part 4: Abrasive blast cleaning of steel Part 5: Pickling Part 6: Chemical conversion treatment of metals Part 9: Pictorial surface preparation standards for painting steel

surfaces AS 1678 Emergency procedure guide - Transport AS/NZS 1715 Selection, use and maintenance of respiratory protective equipment AS/NZS 1716 Respiratory protective devices AS 1789 Electroplated zinc (electrogalvanised) coatings on ferrous articles

(batch process) AS 1897 Electroplated coatings on threaded components (metric coarse

series) AS 1940 The Storage and Handling of Flammable and Combustible Liquids AS/NZS 2310 Glossary of paint and painting terms AS/NZS 2311 Guide to the painting of buildings AS/NZS 2312 Guide to the protection of structural steelwork by the application of

corrosion-resistant coatings AS 2700S Colour standards for general purposes AS 2855 Paints and related materials - micaceous iron oxide pigment AS 2865 Confined spaces AS 3730 Guide to the properties of paints for buildings AS/NZS 3750 Paints for steel structures Part 9: Organic zinc rich primer Part 13: Epoxy Primer (two-pack) Part 14: High Build Epoxy (two-pack) Part 15: Inorganic zinc silicate paint AS/NZS 3862 External fusion-bonded epoxy coating for steel pipes AS 3894 Site testing of protective coatings Part 1: Non-conductive coatings Continuity testing – High voltage

(‘brush’) method Part 2: Non-conductive coatings Continuity testing Wet sponge

method Part 3: Determination of dry film thickness Part 4: Assessment of degree of cure Part 5: Determination of surface profile Part 6: Determination of residual contaminants Part 7: Inspection report – Determination of surface temperature AS 3894 Site testing of protective coatings Part 0: Introduction and list of test methods


Part 1: Non-conductive coatings - Continuity testing - High voltage ('brush') method

Part 2: Non-conductive coatings - Continuity testing – Wet Sponge method

Part 3: Determination of dry film thickness Part 4: Assessment of degree of cure Part 5: Determination of surface profile Part 6: Determination of residual contaminants Part 7: Determination of surface temperature Part 8: Visual determination of gloss Part 9: Determination of adhesion Part 10: Inspection report – Daily surface and ambient conditions Part 11: Equipment report Part 12: Inspection report – Coating Part 13: Inspection report – Daily Part 14: Inspection report – Daily Painting AS/NZS 4020 Products for use in contact with drinking water AS 4049.3 Waterborne paint - For use with drop-on beads for Work on roads AS 4158 Thermal-bonded polymeric coatings on valves and fittings for water

industry purposes AS 4312 Atmospheric corrosivity zones in Australia AS 4321 Fusion-bonded medium-density polyethylene coating and lining for

pipes AS 4361 Part 1: Guide to lead paint management – Industrial Applications AS 4506 Metal finishing – Thermoset powder coatings AS/NZS 4680 Hot dip galvanised (zinc) coatings on fabricated ferrous articles AS 4791 Hot-dip galvanized (zinc) coatings on ferrous open sections, applied

by an in-line process AS 4792 Hot-dip galvanized (zinc) coatings on ferrous hollow sections,

applied by a continuous or a specialized process AS 4848 Part 1: Application specifications for coating systems, Part 1: Single

coat inorganic zinc silicate AS/NZ ISO 9001 Quality management systems – Requirements ASTM D4263 Standard Test Method for Indicating Moisture in Concrete by the

Plastic Sheet Method ASTM D5064 Standard Practice for Conducting a Patch Test to Assess Coating

Compatibility ISO 8501.3 Preparation of Steel Substrates Before Application of Paints And

Related Products – Visual Assessment of Surface Cleanliness – Part 3: Preparation Grades of Welds, Edges And Other Areas With Surface Imperfections

ISO 8502.6 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 6: Extraction of soluble contaminants for analysis – The Bresle method

ISO 11127 Preparation of Steel Substrates Before Application of Paints And Related Products – Test Methods For Non-Metallic Blastcleaning Abrasives

Part 6: Determination of Water-Soluble Contaminants by Conductivity Measurement

Part 7: Determination of Water-Soluble Chlorides ISO 12944 Paints and Varnishes


9 Health and Safety

9.1 General Requirements Contractors performing work under this specification shall conform to ACTEW construction safety rules and the Work Health Safety Act 2011 at all times. The Contractor shall seek prior approval of work procedures or clarification of safety rules from the Superintendents Representative. The contractor shall adhere to the requirements of ACTEW guideline Contractor Safety Management Guideline for the Provision of Works and Services.

On ACTEW property, material and equipment use and all abrasive blasting and protective coatings application shall include safety precautions necessitated by the presence of air and hydrocarbon mixtures or other flammable materials. All abrasive blasting shall conform to Safe Work Australia’s Model Code of Practice for Abrasive Blasting, particularly in relation to the requirements of environmental safeguards and personal protective equipment (PPE) including ‘dead man control’. Approval by the Superintendents Representative of procedures and detailed task analyses will be required prior to the commencement of work.

Eye, hearing and face protection shall be worn by all operators to comply with the requirements of the Workplace Health and Safety Act 2011, all relevant associated legislation, manufacturer’s recommendations and the Safety Plan and Work Method Statements (WMS).

“No Smoking” and “Flammable Liquid” signs shall be displayed by the Contractor and suitable fire fighting equipment shall be provided by the Contractor and be readily available at the work place.

First aid equipment is to include eye wash bottles and shall be available at the work site and located at or near the material pump, mixing area and paint storage point.

This standard specification does not purport to address all work health and safety issues associated with surface preparation and use of protective coatings. The Contractor will ensure that the users and operators establish appropriate health and safety practices, follow WMS and determine the applicability of regulatory limitations prior to commencing work.

9.2 Thinners, Solvents and Coating Material Safety All chemicals including coatings, solvents, thinners, clean-up materials and test materials must be accepted for use on ACTEW sites prior to their being taken onto an ACTEW site.

A physical copy of the Safety Data Sheet (SDS) and Emergency Procedure Guide as per AS 1678 shall accompany all chemicals during transport.

A copy of all relevant SDS shall be kept at each site and in all paint stores for reference.

All thinners, solvents, primers and coating materials shall be regarded as hazardous materials and their use and storage shall comply with WHS Hazardous Regulations (where applicable), AS 1940, Dangerous Goods Regulations and coating manufacturer's recommendations. All caution notices on the product containers and material labels shall be strictly observed.

Use of solvents shall be include correct precautions to ensure that solvent use is not be detrimental to health. For example adequate ventilation shall be provided and only non-sparking tools shall be used in the vicinity of flammable liquids or vapours.

9.3 Confined Spaces The Australian Standard AS 2865, other relevant standard provisions, ACTEW designation and specification of confined spaces and site requirements for confined space entry must be complied with.

When working in a confined space adequate ventilation shall be provided by the Contractor to:

1. remove and disperse solvent vapours;


2. avoid explosions;

3. ensure safety of personnel; and

4. provide a safe working environment.

Any Contractor or Applicator working in a confined space shall be qualified to operate in confined spaces and shall carry a card identifying them as qualified to satisfy any inspections or audits by the ACTEW personnel or nominated inspectors or WorkSafe ACT, WorkCover NSW or similar bodies.

Particular safety equipment and PPE required for working within confined spaces such as breathing apparatus, harnesses and gas detectors shall be supplied by the Contractor and provided as standard equipment on their plant. All equipment shall be in good working order and have records of maintenance and testing logs.

Note: Compliance to ACTEW site safety instructions will be in addition to regulatory requirements.

9.4 Working at Heights Any Contractor or Applicator working at heights shall be qualified to work at height and shall carry a card identifying them as qualified to satisfy any inspections or audits by the ACTEW personnel or nominated inspectors or WorkSafe ACT, WorkCover NSW or similar bodies.

Compliance to ACTEW site safety instructions will be in addition to compliance with regulatory requirements.

The Contractor shall be responsible for providing required scaffolding, elevating work platforms and harnesses and ensuring that these are inspected and properly maintained.

9.5 Physical Barriers Physical barriers and warning signs for fire hazards, dust, abrasive blasting operations, dangerous fumes and the like, shall be installed during blasting and coating activities.

Adjacent areas and equipment shall be protected from abrasive blasting and overspray by the erection of screens, hoardings, or drop sheets. Barriers and masking shall not prevent the operation of emergency response equipment. All materials used to mask areas requiring protection during blasting and painting operations shall be removed upon completion.

Barriers shall be erected around the exhaust of any equipment emitting hazardous gases.

9.6 Equipment All equipment used by the Contractor including, but not necessarily limited to, ladders, scaffold, compressors and electrical and pneumatic equipment shall conform to the requirements in force by the appropriate statutory Acts, regulations and by-laws. The equipment shall be properly maintained and used in strict accordance with any safety regulations or requirements pertaining to them.

All equipment that may or have the potential to develop an electrostatic charge shall be earthed.

All equipment including dust collectors, air compressors, lifting devices and work platforms shall conform to the relevant WHS Regulation, codes of practice and standards for safety and performance. Air supply hoses and couplings shall be of the anti - static type and shall be safety wired. Ladders shall not be used as work platforms.

The Contractor shall not use any ACTEW equipment. The Contractor shall provide all the necessary equipment required to complete the required works.

Any equipment used to exhaust hazardous gases shall be non-sparking and shall be suitable for hazardous area requirements.

Note: Compliance to ACTEW site safety instructions will be in addition to regulatory requirements.


9.7 Personal Air Supply Where personal breathing equipment is used the operator's hood or headgear shall be ventilated by clean, cool, oil and water free air served through a regulator filter. Air supplies must comply with Appendix A of AS/NZS 1715: Selection, Use and Maintenance of Respiratory Protective Equipment. Compliance must be assured through a measurement and certification program involving testing at intervals not exceeding every six months.


10 Environment

10.6 Statutory Authorities For work in the ACT, the Contractor must obtain all ACT Environment Protection Authority approvals and any other relevant approvals required to complete the work under this standard specification prior to commencing the work.

Likewise for work in NSW, the Contractor must obtain all NSW Environment Protection Authority approvals and any other relevant approvals required to complete the work under this standard specification prior to commencing the work.

Note: Compliance with ACTEW site safety instructions will be in addition to regulatory requirements.

10.7 Lead Coatings The Contractor is advised that existing ACTEW assets to be coated may contain coatings consisting of lead based paint. If the existence of lead based coating is disclosed in the contract document issued to the Contractor, then the Contractor shall be responsible for removal of the coating. If at any time the Contractor discovers the presence on the site of the work any coating containing or likely to contain lead, the Contractor shall not disturb the material but shall inform the ACTEW representative responsible for the contract who will have the material inspected and tested and shall issue directions to the Contractor in respect of further action to be taken.

The Contractor shall be responsible for the removal and disposal of all lead based coatings disclosed as at the sites. All work on sites where lead based coatings are disclosed in the contract document or later discovered shall conform to the following Safe Work Australia Standards:

1. National Standard for the Control of Inorganic Lead at Work (NOHSC:1012);

2. National Code of Practice for the Control and Safe Use of inorganic lead at Work (NOHSC:2015)

3. National Exposure Standard (NOHSC:1003)

All lead contaminated waste shall be collected in accordance with the requirements of AS 4361.1. Prior to commencement of the removal of lead based paint the Contractor must submit to the ACTEW representative responsible for the contract a WMS detailing the activities proposed to remove and dispose of the lead and provide satisfactory evidence of qualifications in handling lead based material.

All lead contaminated waste that is required to be disposed by the Contractor shall have a certificate indicating the type of waste, quantity of waste and location of where the waste is disposed and this shall be submitted by the Contractor to ACTEW.

All lead contaminated waste must be transported in compliance with the National Environment Protection Measure for Controlled Waste.

Note: New coatings containing lead or chromate shall not be used. 10.8 Asbestos The Contractor is advised that existing assets to be coated may contain asbestos. If the existence of asbestos is disclosed in the contract document issued to the Contractor, then the Contractor shall be responsible for removal of the asbestos material. If at any time the Contractor discovers the presence on the site of the work any material suspected of containing or likely to contain asbestos, the Contractor shall not disturb the material but shall inform the ACTEW representative responsible for the contract who will have the material inspected and tested and shall issue directions to the Contractor in respect of further action to be taken.

The Contractor shall ensure the workforce is protected from exposure to the material until the nature of the material has been competently determined.


Where the Contractor is responsible for the removal of asbestos material, he shall ensure that this is carried out by a licensed asbestos removal contractor.

All asbestos contaminated waste must be transported in compliance with the National Environment Protection Measure for Controlled Waste.

10.9 Polyaromatic hydrocarbons The Contractor is advised that existing assets to be coated may contain polyaromatic hydrocarbons (PAH). If the existence of PAH is disclosed in the contract document issued to the Contractor, then the Contractor shall be responsible for removal of the PAH material. If at any time the Contractor discovers the presence on the site of the work any material suspected of containing or likely to contain PAH, the Contractor shall not disturb the material but shall inform the ACTEW representative responsible for the contract who will have the material inspected and tested and shall issue directions to the Contractor in respect of further action to be taken.

Where the Contractor is responsible for the removal of PAH material, this work shall be subject to preparation by the Contractor, submission and approval by the ACTEW representative responsible for the contract of a WMS for this work.

All PAH contaminated waste must be transported in compliance with the National Environment Protection Measure for Controlled Waste.

10.10 General Wastage and Containment Removal of coatings, surface protection and cleaning of equipment shall not contaminate surrounding environment. All waste material or liquids shall be disposed of in an environmentally sensitive manner by the Contractor.

The Contractor is responsible for the design and erection of a suitable containment structure designed to prevent the escape of emissions into the environment, soils and waterways and to protect the public. Emissions include, but are not limited to, paint overspray, spills, wastewater, sludge or dust from abrasive blasting and other site discharges associated with the work.

The Contractor is responsible for ensuring that the design of the containment system complies with all relevant legislation and that no visible emissions escape to the environment from the contained work area.

The containment system may include, but is not restricted to, cover panels, screens, tarpaulins, hoardings and shrouds supported by scaffolding or other structures which when used separately or in combination will enclose the entire working area.


11 Quality Assurance and Control Requirements

11.1 Quality Control Documentation When requested by the ACTEW representative responsible for the contract, the Contractor shall submit for acceptance the following quality related documentation:

1. Contractor’s procedure for contract review.

2. Contractor’s method of identifying all work by marking, tagging or another method.

3. Contractor’s inspection and recording of all surface preparation and coating application activities identified by ACTEW as critical.

4. Contractor’s list of standards and test equipment required to carry out the required inspections.

5. Accreditation certificates (Coating Inspection Certificate issued by the Australasian Corrosion Association or other qualification listed in section 17.2) of the qualified and experienced person nominated for inspection.

6. Accreditation certificate (issued by the coating manufacturer) of the certified coating applicator for those coatings required to be applied by a certified applicator.

7. Statement on the current status of their quality system and that of significant sub-suppliers, in relation to their compliance with AS/NZS ISO 9001.

8. Inspection and test plans (ITPs) specifically related to the services being supplied. (includes identification, control and release of witness points and hold points). Work shall not commence until the ITPs have been accepted by the ACTEW representative responsible for the contract.

11.2 Inspection and Test Plans The ITPs shall address each of the inspection activities required and define where it is located in the work cycle. The following topics shall be addressed, such that the Contractor can clearly demonstrate how the quality of the work will be assessed:

1. Specification - criteria and scope.

2. Surface preparation - methods, degree of cleanliness, profile, equipment, abrasives, areas to be treated, ambient and surface temperature limitations.

3. Coating and application

- Coating system type (as in Appendix 1 and Appendix 2).

- Manufacturers generic coating types and identification of materials to be used on the project.

- Coating batch number.

- Coating expiry date.

- Location of coating with cross reference to batch number.

- Storage, mixing, thinning.

- Ambient and surface temperature limitations.

- Application methods.

- Drying times and recoating limitations.

- Coverage of edges, holes and other problem areas.

- Repairs and recoating procedures.

4. Inspection procedures

- Methods of measurement, e.g. surface profile, surface and ambient temperatures, relative humidity, wet film thickness, estimated thickness of each coat.

- Drying times between coats and prior to dry film thickness checks. Type of instruments and methods of calibration.

- Methods of obtaining dry film measurements. Test for cure and hardness, adhesion testing or holiday testing, when required.


- Holiday testing shall be performed in accordance with AS 3894.1 for coatings greater than 150 microns DFT and AS 3894.2 for coatings less than 150 microns DFT. Holiday testing shall be carried out for all internal coatings of tanks and vessels.

5. Handling procedures including suitable precautions to be taken in bundling, packing, crating and lifting to ensure that the protective treatment is not damaged during handling, transporting and installation. Soft slings shall be used unless adequate lifting lugs/eye bolts have been provided.

6. Stainless steel or nickel alloy equipment shall not come in contact with zinc containing paints and shall not be contaminated with carbon steel or cast iron particles.


12 Supply of Materials and Equipment

12.1 Coatings and Equipment Coatings shall conform to the requirements of this standard specification and be suitable for application in the local climate. Coatings shall only be selected from the approved lists contained in Appendix 3, unless otherwise approved in writing by the ACTEW representative responsible for the contract. All components of each coating system shall be compatible and shall be supplied from the same source unless otherwise accepted. Different brands or types of paint shall not be intermixed. Coatings to be applied over an existing coating shall be guaranteed by the Contractor and the new coating manufacturer as compatible with the existing coating.

All coatings shall be supplied in the manufacturer’s original containers, durably and legibly marked with a description of the contents. This shall include the specification number, colour reference number, method of application for which it is intended, batch number, date of manufacture, shelf life, expiry date, safety warnings and manufacturer’s name or trade mark.

The type and quantity of thinners and additives used shall conform to the manufacturer's recommendations.

The Contractor is responsible for: 1. The quality of workmanship, which shall be performed in accordance with this

standard specification and other relevant documentation including site regulations, safety rules, referred standards and codes;

2. Ensuring that the equipment is certified safe and available and that all appropriate tests have been completed before starting any work;

3. The protection of all equipment, structures and any other areas from mechanical damage, environmental damage, damage caused by abrasives during blast cleaning, coating droppings or overspray;

4. The earthing of electrical equipment;

5. Taking all necessary precautions to avoid interference with the execution of work of other contractors;

6. Maintenance of the coating work until completion of the contract including the repair of any damage caused by third parties;

7. The characteristics of the paint and materials obtained from the paint manufacturer. The characteristics of the paints shall be obtained via the provision of separate technical and health and safety data sheets;

8. Advising the ACTEW representative responsible for the contract when a change is made to the product causing it to cease to comply with the specification;

9. Control of waste resulting from the Contractor’s blasting and coating activities, in accordance with site regulations and specific contract requirements;

10. Maintaining facilities, tools and equipment in a good, clean condition including spray guns, brushes, rollers, paint pots and the like being regularly cleaned; and

11. Tools and equipment used in the work shall be suitable for the purpose.

12.2 Material Approvals

Materials shall meet the APAS or Australian Standard specifications or both, shown for each generic type in Appendix 3, unless specifically accepted by ACTEW. Where no specification is given, the manufacturer shall submit a written statement that the product is suitable for and compatible with the given application. Suppliers who have products which do not meet APAS or Australian Standard specifications or who wish to have a product approved shall submit the following information to ACTEW to support this application:

1. A written statement that the product complies with the relevant specification.


2. A National Association of Testing Authorities (NATA) test certificate confirming above.

3. Product data/application sheets.

4. Certified test results from independent test laboratories verifying the performance of the coating, including exposure test results and case histories.

12.3 Material in contact with Potable Water

Materials in contact with potable water shall adhere to the stated requirements of AS/NZS 4020. In addition approval will be required, for all coatings (primer, intermediate and top coat), from NATA including certification confirming approval for use in contact with potable water. Overseas products that have equivalent certification, such as ANSI/NSF 61 or BS 6920, may be used subject to prior written acceptance by ACTEW.

Potable water in this clause includes water that is at any stage of treatment and whilst in the distribution network and not just the final product. Materials include those that are immersed in the water, frequently splashed by the water, used in dosing equipment in the water treatment, embedded in the materials in contact with the water and where condensation may occur and the water enters the potable water network.

Colourants used in materials as defined above in contact with potable water shall comply with Council of Europe Resolution AP(89) 1 Resolution on use of colourants in plastics materials coming into contact with food.

12.4 Cathodic protection system compatibility

Where the coatings are nominated for surfaces of structures that have a cathodic protection system, a certificate of suitability from the manufacturer shall be provided.

13 Coating Storage and Preparation

The storage and preparation of coating materials shall be in accordance with the manufacturer’s instructions and accepted WMS.

All coatings, additives and thinners shall be stored in an enclosed weatherproof and well ventilated facility. Containers shall not be opened until immediately before they are required. Coatings shall not be used after 12 months from date of manufacture or such lesser time as recommended by the manufacturer. Prior to mixing or application the Contractor should provide copies of the manufacturer's delivery notes including the relevant batch numbers, date of manufacture and use-by date for each container of product.

All coatings shall be thoroughly mechanically stirred to give uniform consistency before use. The grade and quantity of thinners shall be agreed with the manufacturer, and excessive thinning will be cause for rejection of the work. Coatings supplied as more than one component shall be mixed in the proportions laid down by the manufacturer and applied within the specified time limit and coating temperature limit after mixing.

The Contractor shall not be permitted to remove or dispose of any coating container until the ACTEW representative responsible for the contract has inspected it and marked it, or given permission that they may be removed.

All flammable materials shall be handled and stored to minimise any fire risk.

Batches of coating material shall only be prepared in quantities sufficient for each work period.


14 Surface Preparation

Where possible surface preparation and coating shall be carried out off-site

14.1 Removal of surface or metal defects All concrete, welding slag, spatter and dags shall be removed and welds and other irregularities, such as cracks, laminations and pitting, shall be ground smooth prior to preparing the surface for coating. Sharp edges shall be deburred and bevelled. Any items to be holiday (spark) tested shall have edges rounded to a minimum radius of 3 mm to meet the requirements of Preparation Grade P2 as defined in ISO 8501.3. Welds shall be ground to a smooth surface free of peaks and sharp edges to a degree where they are paintable.

14.2 Precleaning The Contractor shall remove any oil, grease, dirt, bird droppings, algae, moss and other surface contamination in accordance with AS 1627.1

Where the substrate is heavily corroded, fresh water washing will be required to remove salt contamination. Such treatment may also be required after abrasive blasting. If a surface shows rapid formation of dark rust soon after blasting, salt contamination is likely. Such contamination shall be brought to the attention of the ACTEW representative responsible for the contract, who shall decide if further treatment is necessary before work is continued.

14.3 Abrasive blast cleaning Unless otherwise specified, all steelwork shall be dry abrasive blasted in accordance with AS 1627.4 to the class specified for the coating system to be applied. The surface profile shall be within the range given for the system in Appendix 1 or 2 and should be in the middle of the given range. Profile shall be measured using a method described in AS/NZS 3894 Part 5 and results recorded.

The abrasive used for blasting shall be non-metallic, clean, dry and free from oil and other contamination and of a type and size adequate to give the relevant surface profile amplitude and an angular profile shape. Slag or abrasives containing free silica shall not be used for blasting. Where stainless steel or galvanised surfaces are specified to be abrasive blasted garnet shall be used. All abrasives shall be approved with test certificates and batch numbers. Abrasives shall not be reused unless certified cleaned, resized and tested for contamination.

Blast cleaning shall only be carried out in conditions suitable for coating. Blast cleaning shall be permitted only during daylight, although preliminary blasting may be permitted at night providing all surfaces are blasted to the specified standard in daylight. Any out of hours work shall be submitted for prior acceptance by the ACTEW representative responsible for the contract. No abrasive blasting shall be carried out on metal surfaces which have a surface temperature of less than 3°C above dew point and/or when the local relative humidity is greater than 85%. The Contractor shall determine the relative humidity and dew point, as well as the ambient and steel temperatures. These shall be measured and recorded at least four times per day, especially before start of blast cleaning and before commencing coating. Abrasive blasting operations shall be suspended during inclement weather such as rain, fog or when wind may carry blasting dust to areas adjacent to those being coated.

Surface or fabrication defects (refer to clause 14.1) exposed following abrasive blasting, e.g. laminations, weld porosity, cracks or pitting considered to be detrimental to the performance of the coating system shall be referred to the ACTEW representative responsible for the contract before any coating work commences or repairs are undertaken.

After blast cleaning, the surface shall be cleaned. It shall be made completely dry, free from dust, dirt, loose scale, grease, weld spatter, and foreign matter before coat is applied. A blast cleaned and inspected surface shall never be left uncoated overnight.


Surfaces which have been abrasive blasted shall be primed before any discolouration occurs, normally within four hours of blasting. Flash rusting typically occurs within a few hours of blasting, unless dehumidification is provided. Surfaces which have discoloured or bloomed, or which have been cleaned and left overnight, shall be re-blasted to the specified standard of surface cleanliness and surface profile height and shape and shall exist at the time the primer is applied to any surface area.

During abrasive blasting, the following precautions shall be adhered to:

1. Persons not directly concerned with the operations will not be permitted in the work area.

2. Air compressors shall be fitted with adequate oil and water separators and in-line filters to ensure that the air supply used for blast cleaning is free from water and oil. Operators shall observe all safety precautions and wear the recommended safety clothing and breathing apparatus during abrasive blasting operations. All equipment shall be kept in good working order by the Contractor.

3. The abrasive blasting equipment will be electrically bonded to the item being blasted to the satisfaction of the ACTEW Representative responsible for the contract e.g. such connections will be 13 x 1.5 mm flat braided copper strip with crimped lugs and with solid mechanical connection to the hose nozzle, clipped to the hose and bolted to the abrasive hopper. The hopper and any eductors being used will be similarly connected to the item being blasted.

4. The Contractor shall take adequate steps to minimise the spread of abrasive and dust during abrasive blasting operations to protect the environment and adjacent equipment. Screens or a suitable containment shall be used to prevent the spread of emission if necessary. A vacuum blasting system may be used as an alternative to prevent the spread of emissions. Dust and spoil shall be removed from the surface immediately prior to coating or recoating by blowing with clean, dry air followed by either vacuum cleaning or careful brushing. All horizontal surfaces, e.g. tank bottoms, ledges, stiffeners, etc. shall be vacuumed before coating. Dust and spoil on vertical or overhead surfaces can be blown down with compressed air. Where nominated in the specification or the accepted ITP, tests for the presence of dust on the prepared steel surface shall be conducted in accordance with AS 3894.6, Method C, determination of surface dust. A rating of 2 or better is required for atmospheric service and a rating of 1 or better for immersion service.

5. Spent abrasive and blasting waste shall be contained and removed from the work site and disposed of in accordance with statutory regulations. Copies of dumping receipts are to be made available on request. All lead contaminated waste must be transported in compliance with the National Environment Protection Measure for Controlled Waste.

Where abrasive blasting is not possible, the Contractor may specifically submit other surface preparation methods for these areas to the ACTEW representative responsible for the contract for acceptance. This shall also apply to 'touch up' or repair systems. Mechanical cleaning shall only be used where abrasive blast cleaning is not permitted. Power tool or hand tool cleaning, where specifically permitted by ACTEW, shall comply with AS 1627.2.

14.4 Wet Abrasive Blasting Wet abrasive blasting (including slurry blasting and wet head processes) may be used where it is desirable to minimise dust or remove salts or both. An inhibitor shall not be added to the water unless specifically required and approved by the coating manufacturer. If added, the amount shall be strictly in accordance with the manufacturer’s recommendations. Primer shall be applied before excessive flash rusting occurs.


14.5 High Pressure Water Cleaning and High and Ultra-high Pressure Water Jetting Water jetting (pressures greater than 70 MPa (10,000 psi)) does not provide a profile, but can be used for maintenance coating work where there is an adequate pre-existing profile. Depending on the pressure used, cleanliness levels equivalent to Class 2 or 2½ as per AS 1627 Part 9 are possible. This form of preparation is acceptable if approved by the coating manufacturer. High pressure water cleaning (pressures less than 70 MPa (10,000 psi)) can be used to remove loose rust and paint and is recommended for maintenance work where cleanliness levels below Class 2 of AS 1627.9 are required. Primer shall be applied before excessive flash rusting occurs. Inhibitors for prevention of flash rusting shall not be used unless specifically accepted by the ACTEW Representative responsible for the contract.

14.6 Hand and Power Tool Cleaning For maintenance coating of steel substrates ACTEW may accept manual cleaning using hand tools as described in AS 1627.2 or using power tools as described in AS 1627.2 to remove rust and old paint if abrasive blasting is not possible or practical. Standards of preparation are given AS 1627.9.

A suitable containment shall be used to prevent the spread of emissions such as drop sheets and/or side tarpaulins. Dust and spoil shall be removed from the surface immediately prior to recoating by blowing with clean, dry air followed by either vacuum cleaning or careful brushing.

The prepared surface shall be coated with primer before any contamination or corrosion occurs.

Manual cleaning shall not be used for new construction painting.

14.7 Hot Dip Galvanised Steel If hot dip galvanised steel surfaces are required to be coated they shall be prepared by being given a light (sweep) blast cleaning using fine garnet to ensure proper adhesion of the subsequent coating system and then degreased preferably by high-pressure washing with suitable water detergents followed by rinsing with fresh, chlorine-free water in order to remove preservation agents, zinc salts and fluxing agent residues.

For maintenance coatings only and if galvanising has been welded or otherwise damaged, the damaged areas should be ground down taking care to feather or taper edges.

Preservation agents applied after galvanisation shall be completely removed by using suitable procedures.

14.8 Aluminium Alloys Copper and Brass If aluminium alloy surfaces are required to be powder coated they shall be prepared for powder coating in accordance with AS 4506 Appendix I.

If aluminium alloy other than for powder coating, copper and brass surfaces shall be prepared by cleaning with high-pressure washing with suitable water detergents followed by rinsing with fresh, chlorine-free water and then priming with metal etch primer complying with APAS specification AP-0035 subclass 0035/1 Two pack etch primer.

14.9 Plastics and FRP Plastic, GRP and FRP surfaces required to be coated shall be lightly hand or power tool abraded or low pressure brush blasted to remove all visible gloss from the surface. The surface profile shall not exceed 20 microns.

14.10 Concrete New concrete surfaces required to be coated (other than concrete fireproofing) shall have cured for at least 28 days or longer if specified by the coating manufacturer. New and existing concrete surfaces above grade shall be tested to determine the presence of an unsuitable amount of moisture as per the manufacturer’s requirements. On grade slabs and

surfaces below grade shall be tested to have a moisture vapour emission of 1.5 kg per 100


m2 per 24 hours. All air holes and other defects shall be rectified by bagging with sand and epoxy mortar and grinding as appropriate to ensure a smooth surface for coating.

The surface preparation for existing concrete surfaces to be coated shall remove any corroded concrete, oil, grease, chemical contaminants and existing coatings by using very high pressure water of 70 MPa or greater. Any drummy or delaminated concrete sections shall be broken out and removed so that only sound substrate remains. Sound concrete shall have pH 10 or greater. This may be indicated by testing with a phenolphthalein solution spray.

Concrete surrounding any corroded reinforcement bars shall be broken out beyond the limits of corrosion until clean bar is evident and at least 20 mm behind the bar. Where there is a potential for excessive removal of substrate material, or the reinforcement bar has more than surface corrosion, a direction from the ACTEW representative responsible for the contract shall be sought. Any exposed reinforcement shall be fully embedded with epoxy mortar without any air pockets being entrapped. The surface shall be steel trowelled and its profile shall be made to achieve optimum bond with the surface coating.

The broken out voids and lost concrete sections shall be restored back to the original surface level using an epoxy mortar with a compressive strength of no less than 20 MPa. Feathered edges shall be avoided by saw cutting to a minimum depth of 10 mm at the edges of the area to be patched.

Concrete must be at least free of contaminants, loosely adhering concrete and dust. Concrete shall provide a sound, uniform surface suitable for the application of protective coating or lining systems in strict compliance with this standard specification and the manufacturer’s recommendations.

Surface defects shall be patched with a material recommended by the coating manufacturer to provide a smooth surface suitable for the coating application.

Static cracks wider than 0.3 mm shall be repaired. The path along the crack shall be chased forming a wedge-shaped slot 20 mm wide x 20 mm deep. The slot is then to be filled with polymer modified repair mortar. The surface shall be struck flush with the cleaned concrete adjacent to the crack. Any active crack shall be treated as a joint and repaired using a waterproof joint sealant system. Any infiltration at the crack shall be stopped prior to undertaking crack repair.

Acid etching may only be used for horizontal surfaces. The concentration of hydrochloric acid (HCl) solution used for acid etching shall not exceed 10%. The etched surface shall be adequately washed with fresh water to remove any residual acid. This is indicated when the water used for washing has reached around pH 7.

14.11 Masonry Masonry surfaces required to be coated shall have all oil, grease and chemical contaminants removed from the masonry by chemical cleaning, high pressure water cleaned or abrasive blast to provide an anchor profile on masonry and to remove all surface coatings, foreign particles, chemical attack or unsound mortar. Loose masonry and voids in the mortar joints should be repointed. All active water leaks shall be stopped prior to surface coating application.

14.12 Concrete and Masonry Sealants and Primers Any concrete and masonry sealants and primer products shall be submitted for acceptance to the ACTEW representative responsible for the contract. Refer to 12.2.


15 Coating Application

15.1 Coating Application General Requirements No coating shall be applied until the surface preparation has been accepted by the ACTEW representative responsible for the contract.

Coatings shall be applied in accordance with manufacturer's instructions, including mix ratio, method of application, use of thinners, curing and over-coating times. The Contractor shall check with the Manufacturer's Data Sheet to ensure compliance with application requirements.

Where a primer is required, all welds, rivets, bolts, laps and edges shall be stripe coated by brush prior to spray or roller application.

Coatings shall be applied to the required wet film thickness using wet film thickness gauges during application.

When applying top coats to inorganic zinc coatings, the inorganic zinc shall be thoroughly cured before top coating. Cure testing shall be carried out according to AS 3894.4 Method C. Loosely adhered zinc particles should be removed with an aluminium wire screen or similar technique. In addition, a thin seal or mist coat should first be applied to displace air before building up to the specified thickness. Inorganic zinc exposed for long periods before top coating shall have white stains and zinc corrosion products removed before subsequent coating.

Metallic zinc-based coatings shall not be allowed to come into contact with stainless steels as this may cause zinc embrittlement.

The finished dry film thickness shall be as specified in Appendix 1 or 2. If the specified film thickness is not obtained in one pass, additional passes shall be applied. Areas with inadequate film thickness shall be thoroughly cleaned and if necessary abraded. Then additional compatible coats applied until they meet the required dry film thickness. Coatings with poor adhesion shall be removed and the coating reapplied. Measurement of the dry film thickness shall comply with AS 3894.3.

Coating shall not be applied under the following conditions (or any more stringent conditions recommended by the coating manufacturer) unless specifically accepted by ACTEW representative responsible for the contract:

1. When the temperature of the surfaces is less than 3°C above the dew point of the surrounding air, and/or the relative humidity is higher than 85%.

2. When air or surface temperature is below 5°C.

3. When surface temperature is 40°C or greater.

4. When there is the likelihood of an unfavourable change in weather conditions within two hours after coating.

5. When there is a deposition of moisture in the form of rain, dew, condensation, frost on the surface.

6. During fog, wind, dust, air pollution or other conditions unfavourable for application of paint.

The Contractor shall measure and record the relative humidity, dew point, ambient temperature and temperature of the structure or surface to be coated before commencing coating and at least four times during the day. The Contractor shall ensure that the equipment being used for such measurements is calibrated regularly, as specified in his Quality Manual or Quality Management Plan.

If ambient temperatures are expected to drop below 10OC during curing of two-pack coatings, a ‘winter’ catalyst may be used to aid curing times if approved in writing by the manufacturer.


The first coat shall be applied on the same day as the surface preparation, before degradation of prepared surface has commenced. After exposure of any painted surface in a polluted environment, thorough cleaning is required to remove contamination before over coating. The coating manufacturer shall be consulted as to the preferred method of removing the contaminants before over coating.

Spray application shall be employed where overspray damage can be prevented and for coatings that can only be applied by this method. Brush or roller application may be used for the coating of external surfaces if permitted by the coating manufacturer. Where the Contractor proposes to use a combination of roller and spray application within the same coating system, the coating manufacturer shall be consulted since mixed application may result in a finish which is not acceptable. Roller and spray equipment utilised in all work shall be that specified by the manufacturer of each product. When brush application is specified, the coating shall be well worked into the surface, corners, edges, welds and rivet heads.

When more than one coat of the same colour is applied, the first coat shall be slightly tinted to distinguish between coats.

Any defects which may occur in coating work shall be repaired before the application of further coats in accordance with the manufacturer’s recommendations or as instructed. The finish obtained on all equipment shall possess the correct shade and degree of gloss and be free from runs, sags, wrinkles, patchiness, dry spray, embedded debris, brush or roller marks or other defects which would detract from coating performance and aesthetics.

Pipework resting on supports shall be lifted and the contacting surfaces coated, unless specifically exempted by the ACTEW responsible for the contract. Pipe support brackets and instrumentation brackets shall be removed to allow coating of the surface underneath.

Removable gratings shall be lifted for coating of supports and re-attached on completion.

All items that are not required to be coated by this standard specification and in close proximity to coated surfaces shall be masked prior to application of any protective coating. These parts shall be cleaned on completion of the work.

The Contractor shall be responsible for protection of all adjacent equipment and structures from coating drops or overspray. If any such equipment is contaminated, it shall be fully cleansed by the Contractor at his own expense.

Pipework and equipment shall not be coated until after completion of all heat treatment, inspections and testing, including hydrostatic testing.

15.2 Concrete Coating Application Application of concrete coatings in direct sunlight and/or with rising surface temperatures is not permitted as this may result in blistering of the materials due to expansion of entrapped air or moisture (out gassing) in the concrete. In such conditions, it will be necessary to postpone the application until later in the day when the temperature of the substrate is falling. Concrete surfaces that have been in direct sunlight shall be shaded for at least 24 hours prior to coating application and remain shaded until the initial set of the coating has taken place. The coating manufacturer’s guidelines specific to temperature conditions and possible sealer application recommendations to reduce out gassing shall be complied with.


16 Repairs to Existing Coating Systems

Repairs to existing coating systems complying with the coating systems in Appendix 1 shall match the respective maintenance coating system in Appendix 2. The “M” prefix in Appendix 2 denotes a maintenance coating system and the maintenance coating system number corresponds with the new coating system number in Appendix 1.

Unless specified otherwise, the condition of the surface of existing coated surfaces shall be visually assessed for damage and tested for adhesion using AS 3894.9 – Method A (Knife Test) to determine whether spot repair, renovation or complete refurbishment is necessary. Alternatively, a pull-off bond strength test may be undertaken and the result shall be not less than 1 MPa.

All coated surfaces with intact, glossy and sound coating shall be lightly abraded to remove all visible gloss before over coating, unless the subsequent coating layer is tolerant of this condition.

16.1 Spot Repairs Spot repair includes the local restoration of an existing coating to a small area to a sound substrate. Spot repair shall be carried out where the coating, apart from the small local rust areas, is sound and adequate and will last for the 25 years life between recoating specified in AS/NZS 2312.

Surface Preparation - The areas that are corroded shall be degreased and cleaned and any fabrication defects removed. The local areas shall be spot blasted, with the coating at the borders of the areas feathered to at least 25 mm from the bare area. Any existing coating which separates from the surface shall be removed and the area re-blasted. If spot blasting is not required, then power tool or hand tool cleaning complying with AS 1627.2 shall be carried out. Coating Application - The area shall be cleaned and touched up to full thickness with specified types and number of coats and to the DFT specified for the respective surface coating system in Appendix 2.

16.2 Renovation Repairs Renovation includes the repair of an existing coating system to a sound substrate for a larger area then required by spot repair. Renovation also includes repair where the existing coating is assessed as inadequate or unsound or not expected short expected life.

Surface Preparation - The surface shall be thoroughly cleaned and lightly abraded (sweep blasted) to remove gloss. The surface shall be high pressure water cleaned unless required otherwise the ACTEW representative responsible for the contract. Coating Application - For renovation, repair shall be carried out to the existing coating system (as Appendix 2) and a full top coat applied. The existing primer coating shall be sound and adequate. If the generic type of old coating is unknown or in doubt, adhesion or compatibility testing shall be performed to ensure that planned finish coats are compatible with the existing coatings.

16.3 Refurbishment Refurbishment requires total removal of the existing coating system. Surface preparation shall comply with section 0 and new coating system details in Appendix 1. Application of coatings shall comply with new coating details in Appendix 1.


17 Inspection

17.1 Inspection and Test Plans Refer also to section 11.

Successful application of a surface protection system requires strict quality control of the surface preparation and coating operations. These aspects and the responsibilities for inspections shall be covered in the ITP and shall be strictly adhered to.

Witness and hold points required by the contract and the Quality Management Plan shall be included in the Contractor’s ITP.

17.2 Coatings Inspector A coatings inspector shall be nominated by the Contractor to carry out inspections and testing and to verify all works are performed in accordance with this standard specification. The Contractor’s coatings inspector should not be the Contractor’s work supervisor. The coatings inspector should be given adequate notice for carrying out inspections.

Note: It is expected that the work supervisor will initially inspect all work and carry out any necessary rectification before seeking inspection by the coatings inspector. The Contractor’s coatings inspector shall be certified by either:

1. Australian Corrosion Association (ACA);

2. Painting Contractors Certification Program (PCCP);

3. NACE International; or

4. Society of Protective Coatings (SSPC).

The Contractor shall arrange with the ACTEW representative responsible for the contract for inspection and acceptance on completion of each of the following work stages prior to proceeding to the next stage:

1. Surface preparation.

2. On completion of each coat.

3. During any holiday testing or additional tests that are specified.

4. Witness and hold points required by the Contract or Quality Management Plan. This shall be outlined in the Contractors ITP.

Inspections or waiver of any inspections, by the ACTEW representative responsible for the contract does not relieve the Contractor of their obligation to conduct his own supervision and inspection of the surface protection operations.

17.3 Coatings Inspection Equipment and Data The Contractor shall at all times, during surface preparations and coating applications have on site the following instruments and data.

1. Surface thermometer.

2. Relative humidity measuring device.

3. Dew point calculation charts.

4. Wet film thickness combs.

5. Electromagnetic dry film thickness gauge.

6. Product data sheets for all products used.

7. Safety data sheets for all products used.

All of the instruments and data shall be made available to the ACTEW representative responsible for the contract upon request.

17.4 Coatings Inspection Reports Inspection reporting, equipment reporting and itemised inspection reports such as AS 3894 Part 10 (daily surface and ambient conditions report), Part 11 (equipment report) and Part 12 (inspection report) shall be kept daily and copies shall be made available to the ACTEW representative responsible for the contract on request. The records shall also note any


unusual events or behaviour associated with the coating work or materials or both. Full documentation (including material certificates, inspection results) shall be supplied at completion of the surface protection work.

The ACTEW representative responsible for the contract shall have access to the work in progress at all times and reserves the right to inspect at any time for compliance with the requirements of this standard specification and the contract. This includes the right to halt work deemed to be improper or not in compliance with requirements and to require the Contractor to correct all improper practices and defective or deficient work promptly. Non conforming work shall be corrected to the satisfaction of the ACTEW representative responsible for the contract without extra cost to ACTEW.

17.5 Coatings Inspection and Test Requirements All surfaces, including previously and newly coated surfaces, shall be visually inspected for defects. The coating shall be free of lumps, bubbles, inclusions, ripples, sags, runs, air holes and other film faults.

Unless otherwise instructed, inspection or testing for the level of surface contamination shall be at a rate equal to one test per each 50 m2 of cleaned steel up to 200 m2, then one test per each subsequent 200 m2 up to the first 1,000 m2 and one test per each 500 m2 thereafter; all per structure. The frequency may be reduced by ACTEW when earlier results show low risk of contamination. Sites for surface contaminants inspection or testing are to be selected by, or agreed with, ACTEW.

Prior to the commencement of any surface preparation or coating application, areas of existing coating that have not experienced visible symptoms of deterioration shall be tested for the level of adhesion to the substrate. For substrates other than concrete, adhesion shall be determined in accordance with the requirements of AS 3894 Part 9 – Method A (Knife test). For concrete substrates, tests shall be in accordance with AS 3894 Part 9 – Method C (Pull-off test) using 50 mm diameter tests stubs. The tests shall be carried out at the same frequency as that described in the standard.

At the completion of surface protection application for any given area, the level of adhesion of the coating to the substrate shall be determined in accordance with the same requirements for existing coatings in the paragraph above. The number of tests shall be minimised so as to limit damage to the coating. All test locations shall be repaired after the test such that they blend in with the surrounding areas. Subject to ACTEW’s consent, test coupons made from the same or a similar substrate and sprayed at the same time and in the same manner as the area being inspected can be used for destructive evaluations of adhesion.

Wet film thickness measurements shall be made by the Contractor as specified or required to achieve a satisfactory dry film thickness. Wet film thicknesses are to be measured with wet film thickness combs. The wet film thickness required to obtain the specified dry film thickness shall be provided to the applicator. Wet film thickness measurements shall be taken as soon as practical after application.

Dry film thickness is to be measured by an electromagnetic instrument only. The Contractor is to calibrate the instrument at least once daily using calibration shims and the machined plate supplied with the instrument. A dry film thickness assessment shall be made as per the requirements of AS 3894 Part 3 and the following:

Three adjacent readings will be averaged to become a spot reading, five such spot readings taken over a 10 m2 area shall be taken. The average of five spot readings must not be less than the minimum dry film thickness specified. No single spot measurement shall be less than 90% of the minimum dry film thickness specified. No single spot measurement shall be more than 150% of the maximum dry film thickness specified.

All continuity testing shall be conducted in accordance with AS 3894.1. However, for high build systems and/or where high volume solids coating materials are used, the coating manufacturer shall be consulted to verify that the voltage suggested by the formula in


AS 3894.1 is appropriate for that coating. If the number of defects is greater than five and are spread randomly over an area of not less than 10 m2, the Contractor shall repair any defects. Where several defects fall within a circle of 100 mm radius they shall collectively be deemed to be a single defect. The entire area within the circumference shall then be repaired.

The Contractor, on completion of site work, shall visit area(s) with the ACTEW representative responsible for the contract for acceptance of site cleanliness and final inspection and acceptance of completed work. Scaffolds shall be made available, manned and moved by Contractor as required for inspection purposes.

The Contractor shall cooperate with the ACTEW representative responsible for the contract and the coating manufacturer in providing random samples of coating for test purposes.

17.6 Concrete Moisture Test Prior to surface protection application to concrete, the moisture content of concrete substrates shall be tested. Refer to section 14.10. Acceptable test methods are:

1. ASTM D4263: Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method

2. ASTM F1869: Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride

3. ASTM F2170: Standard Test Method for Determining Relative Humidity in Concrete Floor Slabs using in situ Probes

18 Coating of Proprietary Equipment

Subject to ACTEW specific written acceptance, the equipment manufacturer’s standard heavy duty coating system may be accepted provided that the performance of the standard coating system and the level of surface preparation can be demonstrated as being equal to or greater than the relevant system specified in this standard specification and the finish colour matches the specified requirements. If the equipment manufacturer’s coating system does not meet the requirements of this standard specification, then the equipment coating system on the item shall be fully replaced by or upgraded to the coating system specified.

Care shall be exercised to protect bearings, windings and all operational parts from contamination and damage when applying a coating system to equipment.

Coating shall not be applied to equipment within 50 mm of edges that are later to be welded. Such weld preparations shall be taped for a distance of 50 mm either side of the weld line.

Where the compatibility between an existing coating on equipment and a new coating system is unknown, the new coating system shall be applied to a small area and allowed to fully cure. A method for performing and evaluating a patch test to assess coating compatibility is detailed in ASTM D5064. The adhesion of the new coating system shall then be determined as described in Clause 4.4(2) of ASTM D5064.

19 Hot Dip Galvanising

Following completion of all fabrication, welding, cutting, drilling and grinding operations steel and iron work to be galvanised shall be degreased, pickled, washed, fluxed and dried before being hot dip galvanised (HDG) in accordance with AS/NZS 4680 to achieve at least the minimum zinc thickness and minimum zinc coating mass in Table 1 in AS/NZS 4680.

Hot dip galvanising shall be carried out in accordance with AS/NZS 4680. The zinc coating shall be continuous, adherent, as smooth and evenly distributed as possible and free from any defect such as uncoated or damaged areas, coating blisters, wet storage stains (white rust), sharp points, drainage spikes, ash or dross on the surface and flux residue. Transport and storage of galvanised articles shall be in accordance with Appendix F of AS/NZS 4680.


HDG articles which will be subsequently painted shall be allowed to air-cool rather than quenched.

Care shall be taken to prevent hydrogen damage (embrittlement) to high tensile and high carbon steels during the pickling process.

Galvanising shall be carried out to AS 1214 for coatings on threaded fasteners. All black bolts, nuts and washers to be HDG shall be spun galvanised and the threads of nuts re-run after galvanising.

HDG coating defects smaller than 50 mm2 in area repaired in accordance with AS/NZS 4680 section 8.2 (d) zinc alloy solder stick (such as CIGWELD Comweld Galvanising Bar applied in accordance with the manufacturer’s instructions) may be accepted by ACTEW if the application, adherence and thickness requirements of AS/NZS 4680 section 8.2 are met. Otherwise articles having HDG coating defects shall be regalvanised.

Articles specified as requiring an Architectural Galvanized Finish shall have superior surface quality requirements above those listed in AS/NZS 4680 and this clause. A process such as ‘INGAL HDG SSQ’ or equivalent which provides a smoother surface shall be used for such items. The design and steel chemistry of such items influence surface finish and shall be communicated to the galvanizer in advance to allow for special handling, inspection and dressing.

20 Powder Coating

Powder coating shall comply with AS 4506. Exposure classification requirements shall match classification D Industrial in Table 2.1 of AS 4506.

The powder coating system application shall be certified by the coating manufacturer and the requirements of the certification followed by the applicator.

The thermosetting powder shall comply with the requirements of Appendix 1 and Appendix 3.

21 WAE Drawings

Surface protection work as executed drawings shall be submitted in accordance with ACTEW Standard Specification WAE Drawings. The information recorded on the surface protection WAE drawings shall include:

1. Location and extent of areas of structures, equipment and pipework that have had asbestos containing surface protection removed;

2. Location and extent of areas of structures, equipment and pipework that have had PAH containing surface protection removed;

3. Location and extent of application of each coating material used including detailed listing of each coating by manufacturer, coating description or type, manufacturer’s product name and APAS approval held for each product.


Appendix 1: Surface Coating Systems for New Systems

All new coating systems shall comply with the previous sections of this standard

specification. Refer to Appendix 3 for coating designation as per the AS /NZS 2312 number

column in the below table. Refer to Table A1.2 for details.

Table A1.1 NEW COATING SYSTEM SUMMARY

System Application

AS/NZS 2312

Number1

Minimum DFT

(μm) New Coating or lining

S1 Structural Steelwork

- Hot dip galvanised after fabrication

HDG

XXX 2

Refer to section 19

Self finish 3

S2 Steelwork

- Indoor exposure

C06

C33

75

75

Epoxy zinc phosphate primer (2-pack) High Gloss Acrylic (2 pack)

S3 Steelwork and Ferrous Pipework

- Indoor and Outdoor exposure

C01a 125 Solvent borne inorganic zinc silicate

S4 Steelwork

- Outdoor Exposure

[Optional decorative finish (non chalking) and/or colour]

C02

C13

C26

75

200

50

Epoxy zinc primer (2 pack)

Epoxy (Medium build, 2 pack)

Optional - Polyurethane with the required colour

S5 Steelwork and Tank Linings

(suitable for potable water contact)

C13

C13

250

250

Epoxy (Medium build, solvent free, 2 pack)


S6 Electrical and Mechanical Equipment (excluding Electrical Panels) – Indoor exposure

C05

C33

75

75

Alkyd Primer

High Gloss Acrylic (2 pack)

S7 Electrical Panels

- Indoor exposure

C10

C13

C33

10

80

50

Etch primer (2 pack)


High Gloss Catalysed Acrylic

S8 Electrical Panels

- Outdoor exposure (and stainless steel)

-

-

60

25

Thermosetting Polyester Powder

Anti Graffiti permanent coating

S9 Ferrous Pipework and Equipment External Surfaces

– Indoor exposure

C02

C13

60

125

Epoxy zinc primer


S10 Ferrous Pipework and Equipment External Surfaces

- Indoor or Outdoor Exposure

-

-

400

635

Fusion Bonded Epoxy

Fusion Bonded Epoxy

S11 Steelwork, Ferrous Pipework or Equipment External Surfaces

- Buried Exposure

- Thermal bonded polymeric coating


System Application

AS/NZS 2312

Number1

Minimum DFT

(μm) New Coating or lining

S12 Steelwork, Ferrous Pipework or External Equipment Surfaces

- Submerged Exposure

C02 75

250

250

Epoxy zinc primer

Modified Epoxy

Modified Epoxy

S13 Ferrous Pipework External Surfaces

- Buried Exposure

C34 1000

Ultra High Build Epoxy

S14 Ferrous Pipework Internal Lining - Raw and Potable Water

-

Refer to AS 1281 Table 2

Cement Mortar Lining

S15 Ferrous Pipework Internal Lining (Alternative) - Raw and Potable Water

C32

C32

200

200

Epoxy Mastic

Epoxy Mastic

S16 Ferrous Pipework Internal Lining

- Aggressive Water (Alternative 1)

- Refer to AS 2280 Table 2.1

Calcium aluminate cement mortar

S17 Ferrous Pipework Internal Lining

- Aggressive Water (Alternative 2)

- Refer to AS/NZS

4158 Table D1

Thermal bonded polymeric coating

S18 Non-Ferrous Metallic Pipework

- External Surface

C10

C33

14

50

Etch Primer (2 pack)

Alkyd Gloss Finish (2 pack)

S19 Stainless Steel

- External Surface (Alternative 1 - Aesthetic purposes only)

C10

C33

14

50

Etch Primer (2 pack)

Alkyd Gloss Finish (2 pack)

S20 Stainless Steel

- External Surface (Alternative 2 - Aesthetic purposes only)

- 60 Thermosetting Polyester Powder 4

S21 Stainless Steel Pipework - - Passivation to ASTM A380

S22 Electroplated Metal Coatings - - Self Finish

S23 Concrete

- Aggressive water or chemicals

C13

C13

100

500

Medium Build Epoxy (Solvent free, 2 pack)

Medium Build Epoxy (Solvent free, 2 pack)

S24 Concrete

- exposed to non-aggressive environment

C13

C13

125

125

High Build Epoxy (2 pack)

High Build Epoxy (2 pack)

S25 Anti Graffiti Coating 25 Polyurethane clear 5

S26 Building Paint – gloss or semi gloss

B9 or B8 75 Water based

Notes: 1. AS/NZS 2312 System Designation Number or Paint Reference Number. 2. HDG designation varies with thickness of coating in accordance with basis metal

thickness. Refer to AS/NZS 4680 Table 1. 3. Refer to section 19 of this standard specification. 4. Refer to section 20 of this standard specification. 5. Anti graffiti coating to be compatible with underlying coating system.


Table A1.2 NEW COATING SYSTEM DETAILS

SYSTEM S1 - Structural Steel (Hot Dip Galvanised)

Application New structural steelwork

Location Normal industrial environment of ACTEW infrastructure

Surface preparation Refer to section 18 of this standard specification.

System Hot dip galvanise in accordance with section 18 of this standard

specification

Coating Thickness Refer to section 18 of this standard specification

SYSTEM S2 - Structural Steel (Indoor Environment)

Application Structural steelwork - indoor

Location Atmospheric corrosivity category A of AS/NZS 2312 and C1 of AS 4312

Surface preparation Precleaning refer to section 14.2 of this standard specification.

Abrasive blast clean, refer to section 14.3 and to AS 1627.4 St 2.5 to 40-80 μm profile

First coat Epoxy zinc phosphate primer (C06, spray application only) to 75 μm DFT

Second coat Acrylic Gloss finish (C33, 2 pack, spray application only) to 75 μm DFT,

Total DFT 150 μm

SYSTEM S3 - Structural Steel and Above Ground Pipelines (Indoor and Outdoor

Exposures)

Application Structural steelwork and above ground ferrous pipelines. To be carried out to the requirements of AS 4848.1

Location Indoor and Outdoor except acidic, alkaline and hot water exposure. Atmospheric corrosivity categories B and C of AS/NZS 2312 and C2 and C3 of AS/NZS 4312.


Abrasive blast clean, refer to section 14.3 and to AS 1627.4 St 2.5 to 40-80 μm profile

Inspection Holiday testing according to AS 3894.1

First coat Inorganic zinc silicate – solvent borne (C01a) to 125 μm DFT

Total DFT 125 μm


SYSTEM S4 - Structural Steel (Outdoor Exposure)

Application Structural steelwork

Optional - where non-chalking or specific colour top coat is required.

Location Atmospheric corrosivity category C and D of AS 2312 and C3 and C4 of AS 4312 - exposed or damp conditions which can be abrasive blast cleaned


Abrasive blast clean refer section 14.3 and to AS 1627.4 St 2.5 to 40-80 μm profile

First coat Organic zinc primer 2 pack (C02) to 75 μm DFT

Second coat Medium build epoxy 2 pack (C13) to 200 μm DFT

Third coat

- Optional for decorative finish (non chalking) or for specific colour top coat

Recoatable polyurethane gloss (C26) to 50 μm DFT.

A second or thicker coat may be needed with some colours for opacity. This top coat must be applied within the recoat window of the second coat, as specified in second coat product data sheet. If the recoat window has elapsed, the second coat must have a lightly abrasive brush blasting with garnet abrasive for coating adhesion before the top coat is applied.

Total DFT 275 μm without third coat

325 μm (with Optional third coat)

SYSTEM S5 - Steel and Tank Linings (suitable for potable water)

Application Steelwork and tank linings (suitable for potable water)

Location Normal industrial environment in contact with potable water

Surface preparation Precleaning refer to section 14.2 of this standard specification

Abrasive blast clean refer section 14.3 and to AS 1627.4 St 2.5 to 40-80 μm profile

Approvals Coating approvals include certification of all coatings to AS/NZS 4020, refer to section 12.3


First coat Epoxy (C13, medium build, solvent free, 2 pack) - 250 to 300 μm DFT

Second coat Epoxy (C13, medium build, solvent free, 2 pack) - 250 to 300 μm DFT with colour if required

Total DFT 500 - 600 μm


SYSTEM S6 - Electrical and Mechanical Equipment (Indoor exposure)

Application Motors and mechanical equipment (excluding electrical panels)

Location Atmospheric corrosivity category A of AS 2312 and C1 of AS 4312


First coat Alkyd primer (C05) - 75 μm DFT

Second coat High gloss acrylic (C33, 2 pack) - 75 μm DFT

Total DFT 150 μm

SYSTEM S7 - Electrical Panels (Indoor exposure)

Application Electrical panels – carbon steel excluding stainless steel

NOTES: 1. Coatings applied by spray 2. Electrical panel equipment mounting plates (gear plates) shall be hot dip galvanised finish and unpainted.

Location Normal industrial environment indoor exposure not exposed to moist air


First coat Etch primer (C10, 2 pack) - 10 μm DFT

Second Coat Epoxy (C13, medium build, 2 pack) - 80 μm DFT

Third coat Acrylic (C33, isocyanate free, high gloss, catalysed, 2 pack) - 50 μm DFT

Total DFT 140 μm

SYSTEM S8 - Electrical Panels (Outdoor exposure external surfaces)

Application Electrical panels – stainless steel

NOTES: 1. Electrical panel equipment mounting plates (gear plates) shall be hot dip galvanised finish and unpainted. 2. If powder coated then System S20 applies.

Location Normal industrial environment, outdoor exposure, only external surfaces coated

Surface preparation Refer to System 19

First coat Refer to System 19

Top Coat Spray applied , clear, exterior class, permanent, anti graffiti top coat complying with APAS 1441/1 to 25 μm DFT

Total DFT 85 μm


SYSTEM S9 - Steel or Cast Iron Pipes and Equipment External Surfaces (Indoor

exposure)

Application New steel or cast iron pipes and equipment external surfaces

Location Atmospheric corrosivity category A of AS 2312 and C1 of AS 4312


Abrasive blast clean refer to section 14.3 and to AS 1627.4 St 2.5 to 40 to 80 microns profile

First coat Epoxy zinc primer (C02) - 60 μm DFT

Second coat Epoxy (C13, medium build, 2 pack) - 125 μm DFT

Total DFT 185 μm

SYSTEM S10 - Steel, Cast Iron and Ductile Pipes and Equipment External Surfaces

(Indoor or Outdoor exposure)

Application Steel, cast iron and ductile iron pipes or equipment with fusion bonded epoxy external surface to AS/NZS 3862

Location Normal industrial environment. Atmospheric corrosivity category A to EI of AS 2312 and C1 to C5I of AS 4312.


Abrasive blast clean to section 14.3 of this standard specification, to AS 1627.4 St 3 and to the coating manufacturer’s written instructions using abrasive material complying with AS 3862 section 2.2


First coat Fusion bonded epoxy first layer - 400 μm

Second Coat Fusion bonded epoxy abrasion resistant second Layer - 635 μm DFT

Total DFT 1035 μm


SYSTEM S11 - Steel or Cast Iron Pipes and Equipment External Surfaces Thermal

bonded polymeric coatings (Buried Exposure)

Application Steel, cast iron or ductile iron pipework or equipment external surface with thermal bonded polymeric coating to AS/NZS 4158

Location Buried underground or where thermal bonded polymeric internal lining is provided


Abrasive blast clean to section 14.3 of this standard specification and to AS 1627.4 St 3 and to the coating manufacturer’s written instructions using abrasive material complying with AS 3862 section 2.2


First coat Pipes, fittings and specials shall be coated with thermal bonded polymeric coating in accordance with AS/NZS 4158.

Total DFT Thickness in accordance with Table D1 in AS/NZS 4158.

SYSTEM S12 - Steel, Cast Iron Castings, Cast Iron and Ductile Iron Pipes for

Submerged Service

Application Steel, cast iron castings, cast iron and ductile iron pipes submerged surfaces

Location Normal industrial environment submerged or in contact with sewage including 1 m freeboard


Abrasive blast clean to section 14.3 of this standard specification and to AS 1627.4 St 2.5 to 40 to 80 profile

First coat Epoxy zinc primer (C02) - 75 μm DFT

Second coat Modified epoxy - 250 μm DFT

Third coat Modified epoxy - 250 μm DFT

Total DFT 575 μm

SYSTEM S13 - Steel, Cast or Ductile Iron Pipework Buried (External Surface)

Application Steel, cast iron and ductile iron pipes external surface

Location Buried underground

Surface preparation Abrasive blast clean to section 14.3 of this standard specification and to AS 1627.4 St 2.5 - 60 to 100 microns profile


Single coat Ultra high build epoxy (C34, 2 pack) - 1000 μm DFT

Total DFT 1000 μm


SYSTEM S14 - Steel, Cast Iron or Ductile Iron Pipes, Fittings and Specials for Raw or

Potable Water (Internal Lining)

Application Steel or cast iron pipes and specials internal surface

- cement mortar lined

Location Normal industrial environment in contact with raw water or potable water



Approvals Refer to section 12.3 of this standard

Cement lining Pipes and specials shall be lined with Portland cement mortar to a finished thickness as specified in AS 1281. Cement shall comply with AS 3972 Type SR. Materials for lining, methods of application and curing of the lining shall be in accordance with AS 1281.

Total dry film thickness

Lining thickness in accordance with Table 2 in AS 1281

SYSTEM S15 - Steel, Cast Iron or Ductile Iron Pipes, Fittings and Specials for Raw or

Potable Water (Internal Lining)

Application Steel or cast iron pipes and specials internal surface

- epoxy mastic lined (Alternative to System S14 – for larger diameter pipework)

Location Normal industrial environment in contact with raw water or potable water



Approvals Refer to section 12.3 of this standard

First coat Epoxy mastic (C32) - 200 μm DFT

Second coat Epoxy mastic (C32) - 200 μm DFT


400 μm


SYSTEM S16 - Steel, Cast Iron Pipes for Aggressive Water (Calcium aluminate

Internal Lining)

Application Steel or cast iron pipes (Internal Lining)

Location Normal industrial environment in contact with aggressive non potable water or sewage


Abrasive blast clean to section 14.3 of this standard specification and to AS 1627.4 St 2.5 - 60 to 100 microns profile

Cement Lining Pipes and specials shall be lined with calcium aluminate cement mortar in accordance with AS 2280.


Refer to Table 2.1 in AS 2280.

SYSTEM S17 - Steel, Cast Iron Pipes for Aggressive Water Thermal bonded polymeric

coatings (Internal Lining)

Application Steel or cast iron pipes (internal lining)

Location Normal industrial environment in contact with aggressive non potable water or sewage


Abrasive blast clean to section 14.3 of this standard specification and to AS 1627.4 St 2.5 - 60 to 100 microns profile

Internal Lining Pipes, fittings and specials shall be lined with thermal bonded polymeric coating in accordance with AS/NZS 4158.


Lining thickness in accordance with Table D1 in AS/NZS 4158.

SYSTEM S18 - Aluminium, Copper, Brass and Galvanised Steel (External Surface)

Application Minor pipework manufactured from aluminium, copper, brass, stainless steel or galvanised steel. (External Surface)

Location Normal industrial environment

Surface preparation Abrasive sweep blast to section 14.3 of this standard specification - 10 to 20 μm profile

First coat Etch primer (C10, 2 pack) to 50 - 75 μm DFT

Second coat Acrylic two pack (C33) to 75 μm


150 μm


SYSTEM S19 - Stainless Steel - Aesthetic reasons only (External Surface)

Application Stainless steel (external surface)



First coat Epoxy mastic (AS 2312 System C32) to 125 μm DFT

Second coat Acrylic two pack (AS 2312 System C33) to 50 μm DFT


175 μm

SYSTEM S20 - Aluminium or Stainless Steel – Aesthetic reasons only (External

Surface)

Application Aluminium or stainless steel (external surface) - Powder Coating alternative to System S19 on stainless steel

Location Normal industrial environment. Atmospheric classification D in Table 2.1 of AS 4506.


First coat Thermosetting polyester resin certified to APAS 0155/2.

Inspection Holiday testing according to AS 3894.1. Other tests required by AS 4506 Table 2.1 for classification D.


60 μm


SYSTEM S21 - Stainless Steel passivation

Application Stainless steel passivation to ASTM A380


Surface preparation The surface of the stainless steel shall be thoroughly degreased by

solvents and if necessary rubbed down with a fine grade abrasive

cloth or pumice stone.

The item to be passivated shall be treated by swabbing with a nitric

acid solution.

First coat Simple equipment correctly used should be adequate: a plastic

bucket, hand brush, rubber gloves and eye protection.

Acid concentration shall be from 15% minimum to 30% maximum. A

solution containing 25% nitric acid at 38°C will passivate stainless

steel in 10 minutes.

The area being treated shall be scrubbed with the brush until the acid

film completely covers the surface.

The reaction of the solution should produce fierce gassing for some

minutes after application. The solution shall remain on the surface for

a minimum of 10 minutes to a maximum of 15 minutes after gassing

has ceased. At this stage passivation is complete.

After passivation, the items shall be thoroughly hosed with clean water. Solvents or alkalis shall not be used to neutralise the acid on the stainless steel.

SYSTEM S22 - Electroplating

Application Electroplating where specified by ACTEW

nickel plus chromium plating

zinc plating

as stated in the relevant specification

Surface preparation AS 1192 Electroplated coatings, nickel and chromium (includes stainless steel)

AS 1789 Electroplated coatings, zinc on iron or steel

AS 1897 Electroplated coatings on threaded components (metric coarse series)


SYSTEM S23 - Concrete (Aggressive Environment)

Application Concrete surfaces

- exposed to feed, desalinated and potable water splash, brine

splash, mild acid splash, mild alkali splash and other concrete

surfaces exposed to chemicals which do not damage the coating


Approvals Refer to section 12.3 of this standard specification

Surface preparation In compliance with section 14.10 of this standard specification and the

manufacturer’s recommendations.

First coat Thin coat(s) 10 - 15% Medium Build Epoxy (C13) to give 100 μm

DFT.

If required for large surfaces, a holding primer compatible with the top

coat and approved by the coating manufacturer applied to the

manufacturer’s recommended thickness.

Second/Third coat Medium Build Epoxy (C13).

Two coats shall be applied to give 500 μm DFT.


600 μm

SYSTEM S24 - Concrete (Non-Aggressive Environment)

Application Concrete surfaces

- exposed to non-aggressive environments



Abrasive sweep blast to section 14.3 of this standard specification - 30

to 60 μm profile

First coat Thin coat(s) 10 - 15% High Build Epoxy to give 125 μm DFT

Second/Third coat High build epoxy (C13) to give 125 μm DFT


250 μm


SYSTEM S25 - Anti Graffiti Coating

Application Permanent graffiti barrier to coated surfaces, concrete or masonry

Location Normal industrial environment subject to potential of graffiti

Surface preparation Manufacturer’s recommendations which might include light abrasion of

the top coat for adherence of anti graffiti coating

Coat Spray applied clear polyurethane certified to APAS 1441/1


30 μm

SYSTEM S26 – Building Paint (Indoor or Outdoor exposure)

Application Waterbased paint for buildings

- exposed to non-aggressive environments

Location Normal building environment

Surface preparation Preclean and dry

First coat Primer or sealer to manufacturer’s requirements

Second and Third coat

Gloss (B9) or Semigloss (B8) or Low Gloss (B7)


75 μm


Appendix 2: Surface Coating Systems for Existing Systems

Refer to section 15 of this standard specification.

Table A2.1 MAINTENANCE COATING SYSTEM

Refer to Table A2.2 for details of each maintenance system that is not cross referred to

Appendix 1.

System Application Maintenance Coating or Lining - DFT

M1 Structural steel work - HDG repair HDG coating defects smaller than 50 mm2 in area repaired in accordance AS/NZS 4680 section 8.2 (d) zinc alloy solder stick (such as CIGWELD Comweld Galvanising Bar applied in accordance with the manufacturer’s instructions) if the application, adherence and thickness requirements of AS/NZS 4680 section 8.2 are met.

Otherwise articles having HDG coating defects shall be regalvanised.

Alternatively, if specifically accepted by ACTEW in writing:

Epoxy zinc primer (C02) – 60 μm

Medium build epoxy (C13) – 125 μm

M2 Steelwork

- Indoor Exposure

Refer to System S2 Appendix 1

M3 Steelwork and Ferrous Piping

- Indoor and Outdoor Exposure


M4 Steelwork

- Outdoor Exposure [Optional decorative finish (non chalking) and/or colour]


M5 Steelwork and Tank Linings

(suitable for potable water contact)


M6a Electrical and Mechanical Equipment (excluding Electrical Panels)

- Indoor Exposure - where abrasive blast is not possible

Epoxy mastic (C32) - 150 μm


Optional second coat: Acrylic Gloss (C33, 2 pack) – 75 μm

M6b Electrical and Mechanical Equipment (excluding Electrical Panels)

- Indoor Exposure - where abrasive blast is possible or original coating system is unknown

Epoxy zinc phosphate primer (C06) - 75 μm


Alternative top coat for colour matching: Acrylic Gloss (C33, 2 pack) - 75 μm

M7 Electrical Panels

- Indoor Exposure


M8 Electrical Panels

- Indoor Exposure



System Application Maintenance Coating or Lining - DFT

M9 Ferrous Pipework and Equipment External Surfaces

- Indoor Exposure


M10 Ferrous Pipework and Equipment External Surfaces

- Indoor and Outdoor Exposure (Fusion Bonded Epoxy)

Refer to System S10 Appendix 1 and to AS 3862 section 4

M11 Steelwork, Ferrous Pipework or Equipment External Surfaces

- Indoor and Outdoor Exposure (Thermal Bonded Polymeric Coating)

Refer to System S11 Appendix 1 and to AS 4158 section 3.5 and Appendix D

M12 Steel, Cast or Ductile Iron Pipework External Surfaces

- Submerged Exposure


M13 Ferrous Pipework External Surfaces

- Buried Exposure


M14 Ferrous Pipework Internal Lining Raw and Potable Water (Cement Lining)

Refer to System S14 Appendix 1 and to AS 1281 section 9.3.

M15 Ferrous Pipework Internal Lining Raw and Potable Water (Epoxy Lining)


M16 Ferrous Pipework Internal Lining Aggressive Water (Calcium Aluminate Cement Mortar Lining)

Refer to System S16 Appendix 1 and to AS 2280 Appendix D clause D8.

M17 Ferrous Pipework Internal Lining Aggressive Water (Thermal Bonded Polymeric Lining)

Refer to System S17 Appendix 1 and to AS 4158 section 3.5 and Appendix D

M18 Non Ferrous Pipework External Surface


M19 Stainless Steel External Surface (Alkyd Finished)


M20 Stainless Steel External Surface (Powder Coated)

Refer to System S20 Appendix 1 and to AS 4506 Appendix E

M21 Stainless Steel Passivation Refer to System S21 Appendix 1

M22 Electroplated Metal Coatings Refer to System S22 Appendix 1

Electroplated articles showing defects should be rejected

M23 Concrete Aggressive Environment Refer to System S23 Appendix 1

M24 Concrete Non Aggressive Environment


M25 Anti Graffiti Coating Refer to System S25 Appendix 1

M26 Building Paint Refer to System S26 Appendix 1


Table A2.2 NEW COATING SYSTEM DETAILS

SYSTEM M1 - Structural Steel (Hot Dip Galvanised)

Application Structural steel.

Refer to Table A2.1 System M1.

Touch up paint system for System S1 only if specifically accepted by

ACTEW in writing as detailed below


Surface preparation High pressure water cleaning (see section 14.5 of this standard specification)

Hand or power tool clean to AS 1627.2 (See section 14.6 of this

specification standard)

If second touch-up coat is applied by brush, additional coats may be

necessary to build up the specified coating thickness.

First Coat Organic zinc primer (C02, 2 pack) to 60 μm DFT

Second Coat High build epoxy (C13) to 150 μm DFT

Total dry film

thickness

210 μm

SYSTEM M6a - Electrical and Mechanical Equipment excluding Electrical Panels -

Indoor Exposure

Application Electrical and mechanical equipment (excluding electrical panels) - Indoor exposure - where abrasive blast is not possible

Location Indoor.

Atmospheric corrosivity category A of AS/NZS 2312 and C1 of AS 4312

Surface preparation High pressure water cleaning (Refer to section 13.5 of this standard specification)

Spot blasting to AS 1627.4 St 3 or

Hand or power tool clean to AS 1627.2 St 2 if specifically accepted by ACTEW

First coat Epoxy mastic (C32) to 150 μm DFT

Second coat Epoxy mastic (C32) to 150 μm DFT

Optional Second coat

- If colour required

Acrylic Gloss (C33, 2 pack) 75 μm DFT


300 μm

If Optional Second Coat: 225 μm


SYSTEM M6b - Electrical and Mechanical Equipment excluding Electrical Panels -

Indoor Exposure

Application For repainting of proprietary equipment where blast cleaning is possible and original coating is of unknown type. Mechanical and electrical equipment e.g. pumps, motors.

Location Indoor.

Atmospheric corrosivity category A of AS/NZS 2312 and C1 of AS 4312

Surface preparation Precleaning to AS 1627.1 (see section 9.2 of this standard specification)

Abrasive blast clean to AS 1627.4 St 2.5 to 50 to 60 μm profile

First coat Etch primer (C10) to 10 μm DFT

Second coat Epoxy mastic (C32), to 150 μm DFT

Optional Second coat

- If colour matching required

Acrylic Gloss (C33, 2 pack) to 75 μm DFT


160 μm

If Optional Second coat: 85 μm


Appendix 3: ACTEW Standard Coating Systems Correlation to AS 2312 and APAS Specifications

All paints used shall have APAS approval against the relevant specification and when requested by the ACTEW representative responsible for the contract, the contractor shall submit evidence of the coating approval by APAS.

ACTEW Standard Systems

Generic Description AS 2312 Paint Ref No

APAS Specification

Additional AS requirements

S3 Inorganic zinc silicate - Solvent borne

C01a APAS 2908 AS/NZS 3750.15

Type 4

S4, S9, S12, M1

Organic zinc primer (2 pack)

C02 APAS 2916 AS/NZS 3750.9

Type 2

S6 Alkyd Primer C05

APAS 2921 or APAS 0032

AS 4089 Type 2

S7, S18, M6b

Etch Primer (2 pack) C10 APAS 0035/2, 4 AS/NZS 3750.17

S4, S5, S7, S9, S23, M1


C13 APAS 2974P AS/NZS 3750.14

S24 Epoxy (High Build, 2 pack) C13 APAS 2973 AS/NZS 3750.14

S4 Recoatable Polyurethane gloss

C26 APAS 2911 AS/NZS 3750.6

S15 Epoxy Mastic (2 pack)

C32 APAS 0156 AS 3750.1

S2, S6, S7, S18, S19, M6a, M6b

Acrylic Gloss (2 pack) C33 APAS 2917 AS/NZS 3750.5

S13 Epoxy Ultra High Build C34 APAS 2975 AS 3750.2

S8, Thermosetting Polyester Powder

- APAS 0155/2 AS 4506

S10 Fusion Bonded Epoxy - - AS/NZS 3862

S14 Cement Mortar Lining - - AS 1282

S16 Calcium Aluminate Cement Mortar Lining

- - AS 2280

S11, S17 Thermal bonded polymeric coating

- - AS 4158

S25 Clear Polyurethane (Anti Graffiti Coating)

- APAS 1441/1 -

S26 Building Paint - gloss B9 APAS 0280/1 AS 3730.10

S26 Building Paint - semigloss B8 APAS 0280/2 AS 3730.9

S26 Building Paint – low gloss B7 APAS 0280/3 AS 3730.8

Infrastructure Standard Specification Surface Protection

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