Surface Preparation &

Painting Specification

XXXX XXXX
SDN BHD

Quality Management System

Company Manual

Document Title
Document No XXXX /JS001
Revision No 00
Effective Date 1 December 2016
Reviewed by General Manager
Approved by Managing Director

MASTER CONTROLLED COPY

UNCONTROLLED COPY
 Company Document No : XXXX /JS-
001
Manual Page No : 2 of 31
Revision No. : 00
Quality Management Effective Date : 1 Dec
System 2016

Title: Surface Preparation & Painting Specification

This document is the exclusive property of XXXX XXXX Sdn Bhd (XXXX ) and upon request, may
distribute on a confidential basis. Further distribution, copying, reproduction in whatever form is to be
done only with the express permission of XXXX . This document must be returned to XXXX at the
request of XXXX and no copies in whatever form of any part of this document is to be retained without
the permission of XXXX . XXXX will seek recourse should this notice be violated.

Revision History
Rev. No. Page Description Prepared by
No.
0 All New Issue
Table of contents
1. General........................................................................................................ 5
2. Definition..................................................................................................... 5
3. TECHNICAL DEFINITIONS and ABBREVIATIONS............................................6
4. Reference Documents................................................................................. 7
5. Painting Contractor Responsibility.............................................................11
5.1. General.........................................................................................11
5.2. Health, Safety and Environment...................................................11
5.3. Hazardous Coating Components...................................................12
5.4. Personnel......................................................................................13
5.5. Protection of Equipment and Structural Members........................13
5.6. Blasting and Spraying Equipment.................................................13
6. SURFACE PREPARATION AND CLEANING....................................................14
6.1. Pre-Cleaning..................................................................................14
6.2. Surface Preparation by Blast Cleaning..........................................15
6.2.1. General......................................................................................................... 15
6.2.2. Surface Preparation of Carbon Steel and Low Alloy Steel..............................16
6.2.3. Surface Preparation of Stainless Steel and High Alloy Surfaces....................16
6.2.4. Surface Preparation of Other Non Ferrous Surfaces......................................16
6.3. Alternative Surface Preparation (Power Tool Cleaning SSPC-SP11)
16
7. PAINTING APPLICATION.............................................................................. 17
7.1. General.........................................................................................17
7.2. Mixing and Thinning......................................................................18
7.3. Application Methods.....................................................................18
7.3.1. Spray Application.......................................................................................... 19
7.3.2. Brush Application.......................................................................................... 19
7.3.3. Roller application.......................................................................................... 20
7.3.4. Stripe coat.................................................................................................... 20
 7.3.5. Painting Under Insulation..............................................................................20
7.3.6. Thermal Spray Application (TSA) / Cold Spray Application (CSA)..................20
7.3.7. Hot Dip Galvanizing......................................................................................21
7.3.8. Fire Barriers / Passive Fire Protection (PFP) System......................................21
7.4. Repair of coating defects..............................................................22
7.4.1. Inadequate coating thickness.......................................................................22
8. INSPECTION AND TESTING.........................................................................23
8.1. Requirement.................................................................................23
8.1.1. Construction quality......................................................................................24
8.1.2. Climatic conditions........................................................................................24
8.1.3. Surface preparation......................................................................................24
8.1.4. Soluble salt contamination............................................................................24
8.1.5. Dry Film Thickness........................................................................................25
8.1.6. Appearance of coating..................................................................................25
8.1.7. Holiday (Pin-hole Detection)..........................................................................25
8.1.8. Adhesion Testing........................................................................................... 26
8.2. Painting Inspection........................................................................26
8.2.1. Painting Inspector......................................................................................... 26
8.2.2. Thermal Spray Coatings Inspector................................................................26
8.2.3. Responsibilities.............................................................................................27
9. Colour Scheme.......................................................................................... 27
10. Warranty.................................................................................................... 27

1. General

This specification is based on PETRONAS document PTS

30.48.00.31 Protective Coatings and Lining, dated
September 2012.
All paints and coating material shall be qualified by Client as per
paragraph 6.5 of PTS 30.48.00.31 Coating System Product
Approval Requirements when appropriate. Paint Manufacturer can
propose alternative paint systems. Alternative paint systems shall
be approved and tested as per ISO 20340. In case of any conflict
with this document or any referenced standard/code with any PTS,
this specification shall prevail. However, if deemed necessary, a
Technical Query can be generated to PETRONAS for resolution.
 This specification covers the minimum requirements for the design,
materials, application and inspection of coating systems to be
applied for any PETRONAS project that related with this
specification.
To achieve a long term service life of the protective coating system,
full attention shall be given to the quality of surface preparation and
application of the coating system. Quality assurance, quality control
and the professional skill of the painters are essential for this
process.
Specialised equipment supplied by vendors such as valves, pumps,
compressors, etc. will be coated in compliance with either the
User's respective functional specification or project painting
specification. Vendors shall submit the respective painting
procedure for Clients and CONTRACTORs approval.

2. Definition

The Contractor is the party which carries out all or part of the design,
engineering, procurement, construction, commissioning or management
of a projector operation of a facility.
The Supplier is the party which manufactures or s supplies equipment
and service to perform the duties specified by the Contractor.
The Principal is the party which initiates the project and ultimately pays
for its design and construction. The Principal will generally specify the
technical requirement.
Painting system is a term intended to include, with equal emphasis, not
only the well accepted components of a system such as surface
preparation and paint materials but also application, inspection and
safety functions.
Coating system is a term which refers to be applied and cured
multilayer film or to the components of a system based on non-paint type
coating.
Initial Painting is a term which refers to the painting of new facility or
complete re-coating of existing asset during major maintenance.
Maintenance Painting is a term which refers to the periodic painting
after initial painting (repair, touch up of corroded areas of deteriorated
paint work).
3. TECHNICAL DEFINITIONS and ABBREVIATIONS

The following abbreviations and definitions shall be used in this

specification.

Abrasive blast The impingement of a high-kinetic-energy stream of

cleaning blast cleaning abrasives onto the surface to be prepared

Anchor profile Contour of a blast-cleaned surface on a plane

perpendicular to the surface.

Application Application, drying and/or curing of a coating layer.

Dew Point The temperature of a given air/water-vapour mixture at

which under atmospheric pressure, condensation starts.

DFT Dry Film Thickness; the thickness of the dried or cured

paint or coating film.

WFT Wet Film Thickness; the thickness of the uncured or wet

paint or coating film

HSE Health, Safety and Environment.

Pot life The time interval, after mixing of paint or coating

materials, during which the mixture can be applied
without difficulty or loss of final coating quality.

Thinner Volatile liquid added to lower the viscosity of the paint to

ease application.

MSDS Material Safety Data Sheet

4. Reference Documents

ISO 9001 : 2008 : Quality management systems Requirements

ISO 8501-1 : 2007 : Preparation of steel substrates before application

of paints and related products -- Visual assessment of surface
cleanliness -- Part 1: Rust grades and preparation grades of uncoated
steel substrates and of steel substrates after overall removal of
previous coatings

ISO 8501-2 : 1994 : Preparation of steel substrates before application

of paints and related products -- Visual assessment of surface
cleanliness -- Part 2: Preparation grades of previously coated steel
substrates after localized removal of previous coatings

ISO 8501-3 : 2006 : 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 8501-4 : 2006 : Preparation of steel substrates before application

of paints and related products -- Visual assessment of surface
cleanliness -- Part 4: Initial surface conditions, preparation grades and
flash rust grades in connection with high-pressure water jetting

ISO 8502-3 : 1992 : Preparation of steel substrates before application

of paints and related products -- Tests for the assessment of surface
cleanliness -- Part 3: Assessment of dust on steel surfaces prepared for
painting (pressure-sensitive tape method)

ISO 8502-4 : 1993 : Preparation of steel substrates before application

of paints and related products -- Tests for the assessment of surface
cleanliness -- Part 4: Guidance on the estimation of the probability of
condensation prior to paint application

ISO 8502-6 : 2006 : 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 Brestle method
 ISO 8502-9 : 1998 : Preparation of steel substrates before application
of paints and related products -- Tests for the assessment of surface
cleanliness -- Part 9: Field method for the conductometric
determination of water-soluble salts

ISO 8503-1 : 2012 : Preparation of steel substrates before application

of paints and related products -- Surface roughness characteristics of
blast-cleaned steel substrates -- Part 1: Specifications and definitions
for ISO surface profile comparators for the assessment of abrasive
blast-cleaned surfaces

ISO 8503-2 : 2012 : Preparation of steel substrates before application

of paints and related products -- Surface roughness characteristics of
blast-cleaned steel substrates -- Part 2: Method for the grading of
surface profile of abrasive blast-cleaned steel -- Comparator procedure

ISO 8503-5 : 2003 : Preparation of steel substrates before application

of paints and related products -- Surface roughness characteristics of
blast-cleaned steel substrates -- Part 5: Replica tape method for the
determination of the surface profile

ISO 11125-3 : 1993 : Preparation of steel substrates before application

of paints and related products -- Test methods for metallic blast-
cleaning abrasives -- Part 3: Determination of hardness

ISO 11125-2 : 1993 : Preparation of steel substrates before application

of paints and related products -- Test methods for metallic blast-
cleaning abrasives -- Part 2: Determination of particle size distribution

ISO 11127-2 : 2011 : Preparation of steel substrates before application

of paints and related products -- Test methods for non-metallic blast-
cleaning abrasives -- Part 2: Determination of particle size distribution

ISO 2808 : 2007 : Paints and varnishes -- Determination of film

thickness

ISO 19840 : 2012 : Paints and varnishes -- Corrosion protection of steel

structures by protective paint systems -- Measurement of, and
acceptance criteria for, the thickness of dry films on rough surfaces
 ISO 16276-1 : 2007 : Corrosion protection of steel structures by
protective paint systems -- Assessment of, and acceptance criteria for,
the adhesion/cohesion (fracture strength) of a coating -- Part 1: Pull-off
testing

ISO 16276-2 : 2007 : Corrosion protection of steel structures by

protective paint systems -- Assessment of, and acceptance criteria for,
the adhesion/cohesion (fracture strength) of a coating -- Part 2: Cross-
cut testing and X-cut testing

ISO 4628-1 : 2003 : Paints and varnishes -- Evaluation of degradation

of coatings -- Designation of quantity and size of defects, and of
intensity of uniform changes in appearance -- Part 1: General
introduction and designation system

ISO 4628-2 : 2003 : Paints and varnishes -- Evaluation of degradation

of coatings -- Designation of quantity and size of defects, and of
intensity of uniform changes in appearance -- Part 2: Assessment of
degree of blistering

ISO 4628-3 : 2003 : Paints and varnishes -- Evaluation of degradation

of coatings -- Designation of quantity and size of defects, and of
intensity of uniform changes in appearance -- Part 3: Assessment of
degree of rusting

ISO 4628-5 : 2003 : Paints and varnishes -- Evaluation of degradation

of coatings -- Designation of quantity and size of defects, and of
intensity of uniform changes in appearance -- Part 5: Assessment of
degree of flaking

ISO 4628-6 : 2011 : Paints and varnishes -- Evaluation of degradation

of coatings -- Designation of quantity and size of defects, and of
intensity of uniform changes in appearance -- Part 6: Assessment of
degree of chalking by tape method

ISO 4624 : 2002 : Paints and varnishes -- Pull-off test for adhesion

ISO 2409 : 2013 : Paints and varnishes -- Cross-cut test

 ISO 12944-7 : 1998 : Paints and varnishes --Corrosion protection of
steel structures by protective paint systems -- Part 7: Execution and
supervision of paint work

ASTM D 4541 : Standard test method for pull-off strength of coatings

using portable adhesion testers
ASTM D 4752 : Standard test method for measuring MEK resistance of
ethyl silicate (inorganic) zinc-rich primers by solvent rub.
ASTM E 337 : Standard method for measuring humidity with a
whirling hygrometer (the measurement of wet- and dry-bulb
temperatures).
NACE No. 1 : Surface preparation standard white metal blast cleaning.
NACE No. 2 : Surface preparation standard near-white metal blast
cleaning.
NACE No. 4 : Brush-off blast cleaning
NACE No. 5 : Surface preparation and cleaning of metals by water-
jetting prior to recoating.
NACE 6G198 : Wet abrasive blast cleaning
NACE RP0188 : Discontinuity (holiday) testing of new protective
coatings on conductive substrate.
SSPC-PA 2 : Measurement of dry coating thickness with magnetic
gauges.
SSPC-SP 1 : Solvent cleaning.
SSPC-SP 3 : Power tool cleaning.
SSPC-SP 5 : White metal blast cleaning.
SSPC-SP 7 : Brush-off blast cleaning.
SSPC-SP 10 : Near white blast cleaning.
SSPC-SP 11 Power tool cleaning to bare metal.
SSPC-SP 12 : Surface preparation and cleaning of metals by water-
jetting prior to recoating.
SSPC-SP TR 2 : Wet abrasives blast cleaning.
 SIS 05-59-00 : Swedish standard : Pictorial surface preparation
standard for painting steel surfaces.
PTS 30.48.00.31 : Protective Coatings and Linings, September 2012
PTS 30.10.02.11 : Metallic Materials Selected Standard, December
2010
PTS 30.48.40.31 : Thermal Spray Coatings Of Aluminum And 85/15
Zinc/Aluminum Alloy, December 2010
PTS 39.01.10.11 : Selection of Materials For Life Cycle Performance (EP)
Materials Selection Process, December 2010.
PTS 39.01.10.12 : Selection of Materials For Life Cycle Performance (EP)
Upstream Equipment, December 2010.
PTS 30.10.02.13 : Non-metallic Materials Selection And Application,
October 2009
5. Painting Contractor Responsibility

5.1. General
The Sub-Contractor or Vendor, in addition to his responsibilities
under the general conditions of the contract, is responsible for the
quality of the work which shall be performed in strict accordance
with this specification and all other relevant documents, such as site
regulations, safety rules and requirements, product data sheets,
referenced standards and codes.
The Sub-Contractor or Vendor is fully responsible for all Quality
Assurance and Control activities.
The Sub-Contractor or Vendor shall schedule a pre-job meeting to
ensure that job and quality requirements are fully understood.
Attendees shall include a representative of the CLIENT, the Sub-
Contractor/Vendors job superintendent and coating supervisor and
the coating inspector, and should also include the coating
Manufacturers representative.
For all coatings work, the Sub-Contractor or Vendor shall submit
appropriate work plans and a quality plan for implementing the
requirements of this specification for review by the CLIENT.
Copies of this specification, the work plans and the quality plan shall
be made available to the Painting Contractors representative at the
site and she/he shall be familiar with their contents.

5.2. Health, Safety and Environment

The Sub-Contractor or Vendor, as well as its/their Painting
Contractor(s) shall be responsible for all aspects of safety and
personal protection related to the painting work to be done.
Environmental regulations and rules shall be met.
Safe working is of the greatest importance particularly whilst
working in confined spaces such as tanks and vessels.
All personnel shall be provided with approved personnel protection
e.g. protective clothing, gloves, safety glasses, safety shoes, hard
hats, goggles, respirators, earplugs, fresh-air-fed hood and any other
necessary safety equipment. All safety equipment shall be
maintained to a good working condition.
Adequate warning signs shall be prominently displayed at all access
points to areas where abrasive blasting and painting is in progress.
Handling and disposal of hazardous waste resulting from the
Painting Contractor's activities shall be in accordance with
regulations and specific contract requirements. Moreover, the
CLIENTs regulations on chemical management or banned materials
shall also be strictly adhered to.
Paint products, solvents, diluents, etc. shall be stored in closed
dedicated room/container under controlled temperature.
Exposure of paint products, solvents, diluents to temperature equal
or above their flash point, exposure to heat source, flame source,
electrical arc or sparks, etc. shall be prohibited.
Material Safety Data Sheet of all coating products, solvent, diluents
shall be available at their place of use and shall be included in
Vendor/Subcontractor Data Book.
These are minimum safety requirements that are applicable to both
shop and field coating (including surface preparation).
Fire and Explosion Prevention
Smoking and/or the use of open flames shall be permitted only in
designated safe areas
Solvents and coatings shall not be applied to surfaces warmer
than 80C.
Mechanical (forced) ventilation shall be used in confined spaces
whenever abrasive blasting, solvent cleaning, and/or coating
application are in progress.
Forced ventilation shall continue until the coating is fully cured.
Natural ventilation (through opened man ways, etc.) shall not be
substituted for forced ventilation in confined spaces.
Respirable air-fed hoods shall be worn by all personnel inside
confined spaces whenever blast cleaning or spray coating is in
progress.
If alkaline catalysts (such as used in many epoxy coatings) come
in contact with the skin, they shall be immediately washed off
with water to avoid chemical burns. Follow the coating
manufacturer's materials safety data sheet and other safety
documents for washing off action.
 Adequate washing facilities shall be readily available so that
coatings and solvents splashed on the body or in the eyes can
be immediately removed.
Materials Safety Data Sheets for all coatings, solvents, and
cleaners in use shall be readily available on-site.

5.3. Hazardous Coating Components

The Painting Contractor shall ensure that all layers of a painting
system and all blasting materials comply with any local and/or
regional standards or regulations on banned materials such as:
Heavy metals, such as arsenic, barium, cadmium, lead, mercury,
silver, chromium and selenium.
Substances recognized for being carcinogenic or hazardous, e.g.
asbestos, chromate, free crystalline silica, or coal tar.

5.4. Personnel
Only professional skilled blasters and painters shall be employed.
Blasters and painters working on every painting job should be
certified in accordance with a scheme approved by the CLIENT. A
certified foreman should supervise the blasters and painters. Before
any work is commenced, the certificates should be submitted to the
CLIENT. Certifying bodies shall comply with ISO 17024.
A skilled foreman shall supervise the blasters and painters.

5.5. Protection of Equipment and Structural Members

The Painting Contractor shall protect all equipment, structures and
any other areas from mechanical damage, environmental damage,
blockage or obstruction, damage caused by over blasting, dripping
paint, paint splashes and overspray.

5.6. Blasting and Spraying Equipment

The Painting Contractor shall demonstrate that blasting and
spraying equipment to be used is in good condition and well
maintained. Blasting and painting equipment shall fully comply with
any local and/or regional regulation.
Main CONTRACTOR and/or CLIENT shall be allowed to perform
periodical audit.
 The compressed air shall be free of water and oil. Adequate
separators and traps shall be provided, installed in the coolest part
of the system. The presence of oil and water shall be determined in
accordance with ASTM D 4285. In no case shall the temperature of
the compressed air be allowed to exceed 110C.

Blasting nozzles shall be discarded and replaced when the nozzle

diameter has increased through wear by more than 50 % of the
original diameter.

Blasting equipment, its operators and the equipment being blasted

shall be properly earthed to prevent the occurrence of electrostatic
discharges.

Abrasive blast cleaning equipment shall be an intrinsically safe

construction and equipped with a remote shut-off valve triggered by
the release of a dead man's handle at the blasting nozzle.
Where air-operated equipment is used, the operator's hood or
headgear shall be positive pressure fed by clean, cool air supplied
through a filter, to prevent blast cleaning residues from being
inhaled.
When working in confined spaces, adequate ventilation and spark-
proof lighting shall be used. As a minimum, ventilation shall ensure
sufficient air changes such that the threshold limit value (TLV) of the
various coating materials in use shall not be exceeded.

6. SURFACE PREPARATION AND CLEANING

6.1. Pre-Cleaning
All structures and equipment shall be designed according to ISO
12944 international standard for high durability painting systems. All
edges shall be ground to a minimum radius of 2 mm or otherwise
agreed with the CLIENT and flame cut areas should have been
ground flush. Weld spatter shall have been ground flush. The design
of the item to be painted shall be such that it creates no interstice
and inaccessible area.
 All welded areas and appurtenances shall be given special attention
for removal of welding flux in crevices. Welding splatter, slivers,
laminations and underlying mill scale which are not removed during
fabrication shall be removed prior to painting activities by the best
mechanical means and the edges smoothed or rendered flush.

All oil or grease shall be removed by washing the item to be painted

in accordance with SSPC, SP1 Solvent Cleaning before beginning
of blast-cleaning operations. This includes bolt holes in piping
assemblies. For the treatment of stainless steels, the level of free
halides in materials to be used shall be confirmed and reviewed by
CLIENT. Special attention shall be paid to avoid splashes of zinc
paint on equipment made of austenitic steels.

Before performing abrasive blast cleaning, all equipment which

could be damage by blast, dust or particular matter shall be suitably
protected by masking, wrapping, taping or other method to prevent
damage. Where required, the degree of contamination shall be
assessed in accordance with procedures described in ISO 8502-3.

All mating surfaces of equipment subject to outdoor exposure shall

be coated with the full coating system prior to assembly (saddles,
skirts, base plates, bolted components, flanges, etc.).
6.2. Surface Preparation by Blast Cleaning

6.2.1. General

To prevent dust and abrasive contamination, blast cleaning shall not

be done close to painting operations or wet coated surfaces.
Environmental restrictions shall be observed. Blast cleaned steel
surfaces shall not be touched by bare hands.

Blast cleaning shall not be carried out when the temperature of the
surfaces to be blasted is less than 3 degree C above dew point and
when the relative humidity of the air is greater than 85 %. For dew
point determination, refer to procedure described in ASTM E 337.

If the surface being cleaned lies adjacent to a coated surface, which

is not to be repaired, the blast cleaning shall overlap the coated
surface by at least 50 mm. The edges of the existing coating system
shall be feathered. The remainder of the existing coated surface
shall be properly protected with shields or screens to prevent any
over blast damage. Surface cleaning due to new weld or burn marks
shall be agreed with the Client.

If approved by the CLIENT, abrading with sandpaper or light

grinding with a suitable (flexible) disc may be used for surface
preparation where sweep blasting is impossible. In addition, when
aluminium or galvanised components have to be painted, zinc or
aluminium corrosion products (white rust) and/or rust present shall
be removed.
PFP and CSP surface preparation shall be done as per manufacturer
recommendations
Should Thermally Sprayed Aluminium be used to coat carbon steel,
low alloy steels and stainless steels, the surface profile shall be
between 70 m to 110 m.
The recognized surface finish grades are summarized in Table 7.1
below.

Table 9.1 Surface finish grades.

Abrasive blast
cleaning SSPC ISO 8501-1 NACE
White metal blast cleaning SP5 Sa 3 No. 1
Near white clean cleaning SP10 Sa 2.5 No. 2
Commercial blast cleaning SP6 Sa 2 No. 3
Brush-off (Sweep) blast
cleaning SP7 Sa 1 No. 4
Power-tool cleaning to bare
metal SP11 - -
Power-tool cleaning SP3 St 3 -
Hand-tool cleaning SP2 St 2 -
Solvent cleaning SP1 - -

6.2.2. Surface Preparation of Carbon Steel and Low

Alloy Steel
The minimum degree of cleanliness shall be Sa 2.5 as per ISO 8501-
1 at the time of coating. The surface profile or anchor pattern for
carbon steel and low alloy steels to be coated with liquid organic
 coatings shall as per ISO 8503-2 or in accordance with the written
recommendation of the paint manufacturer. When not specified by
the paint manufacturer or when otherwise specified in this
document, the surface profile shall be between 40 m and 70 m.

6.2.3. Surface Preparation of Stainless Steel and High

Alloy Surfaces
The blast cleaning of stainless steel shall be carried out by sweep
blasting as per SSPC-SP7, using a fine abrasive not containing iron
(e.g. garnet, Aluminium Oxide, Aluminium Silicates), glass pearls or
stainless steel shots. To reduce the risk of unacceptably damaging
the substrate while sweep blasting stainless steel or hot dip
galvanized surfaces, it is recommended that a reduced nozzle
pressure be used in combination with a small size abrasive. Surface
roughness shall be in the range of 20 m to 30 m or shall be
agreed with paint manufacturer.

6.2.4. Surface Preparation of Other Non Ferrous

Surfaces
Non-ferrous surfaces to be painted shall be degreased and
preferably blast-cleaned with a non-ferrous and chloride-free
abrasive.
Except otherwise specified, surfaces roughness shall be Fine (G) as
per ISO 8503-2. Brush-off blasting as per SSPC-SP7 is also
considered as acceptable.
Other cleaning method, may be acceptable in some cases (e.g.
chemical etching of galvanized surfaces), subject to CLIENT
approval.

6.3. Alternative Surface Preparation (Power Tool

Cleaning SSPC-SP11)
Alternative surface cleaning is only acceptable after approval of the
CLIENT. Power tool cleaning should be confined to minor areas and
preferable to bare metal. It is not acceptable for areas difficult to
access such as under cellar and helidecks, areas exposed to water,
steelwork to be insulated, steelwork to be buried and internal
surfaces of equipment and tanks.
 Unless otherwise specified it shall be carried out in accordance with
the requirements of ISO 8504-3. Power-tool cleaning (grinding) to
bare metal shall be done in accordance with SSPC SP11. Stainless
steel surfaces shall not be treated with carbon steel cleaning tools or
any tools previously used on carbon steel.
If power-tool cleaning is not feasible, the surface cleanliness shall, as
a minimum, meet the visual standard St 3 in accordance with ISO
8501-2 at the time of coating. If the surface being prepared lies
adjacent to a coated surface, the power tool cleaning shall overlap
the coated surface by at least 25 mm and the coated surface shall
be feathered.

7. PAINTING APPLICATION
7.1. General
All paint material shall be qualified by Client as per Clients
specifications. The Manufacturers product data sheets and
specifications for mixing, application and curing shall be considered
an integral part of this specification. The Painting Contractor shall be
responsible for obtaining the product and safety data sheets of each
material from the Manufacturer.
All coating systems shall be applied in accordance with this
specification and the paint Manufacturer's instructions and data
sheets. Any conflicting requirements shall be brought to the
attention of the
CLIENT.
Each coat shall be applied uniformly over the entire surface. Skips,
runs, sags and drips shall be avoided. Each coat shall be free from
inclusions of foreign matters, lumps, pinholes, blisters and holidays.
Contrasting colour shall be used for each coat of paint so as to
ensure different coats are applied to meet the required dry film
thickness.
Surface which is inaccessible after assembly, including the surface
of lap joint flanges, nozzle necks, lap joint stub ends, lap rings, bolt
holds and some welded joints, shall receive the complete painting
system before being assembled. Contact surface of bolted
connection are to be primed only.
 On structural steel area subject to be assembled by high tension
bolts, contact surface shall be primed only with Inorganic Zinc Ethyl
Silicate. Intermediate and final coat shall not be applied.
Intercoat contamination shall be minimized by maintaining proper
cleanliness and by applying the intermediate and finish coats within
the over-coating time recommended by the manufacturer. Any
contamination shall be removed. Zinc rich primers shall be applied
over abrasive blast cleaned carbon and low alloy steel surfaces only.
Paints containing metallic zinc shall never be applied, over-sprayed
or dripped onto stainless steel components.

7.2. Mixing and Thinning

All paint spraying equipment including mixers shall be thoroughly
cleaned before the mixing of new materials. All painting materials
shall be mixed and thoroughly stirred in accordance with the
instructions of the paint Manufacturer. Sufficient agitation to
maintain good mixing shall be applied until the product is used. If air
is entrapped in the product during mixing/stirring, sufficient time
should be allowed for the air bubbles to escape before application.
Inorganic zinc coating products and other heavily metal-pigmented
paint such as Aluminium loaded paint shall be continuously stirred
during application by the mean of a pneumatic mixer.
Only thinners specified by the paint Manufacturer shall be used.
Mixing of different brands or generic types of paint material is not
permitted unless respective manufacturers consent has been
received.

7.3. Application Methods

In general, paints shall not be applied when:
The surface temperature is less than 3oC above dew point.
The surface temperature is below 5 oC as it could adversely affect
the curing of paints.
The relative humidity is more than 85%, except for Inorganic
Zinc Ethyl Silicate which can go up to 90%.
The metal surface temperature is higher than that recommended
by Paint manufacturer for application.
Surface preparation has not been completed or oil, grease and
dust are present on the substrate to be painted.
 Poor weather conditions for painting exist or are expected within
two hours of application such as blowing sand or rain.
When there is a deposition of moisture in the form of rain,
condensation etc. on the surface. Probability of condensation
may be determined in accordance with procedures described in
ISO 8502-4.
Where the available light is less than 500 lux.

7.3.1. Spray Application

Spraying (Air or Airless) is the preferred method of application.
Paint shall always be applied to surfaces that are dry, clean and
degreased (substrate or previous coat).
The spray gun shall be held no closer than 300mm or more than
600mm from the surface to be coated. During application, the spray
gun shall always be held at a right angle (90 o) to the substrate. Each
pass shall overlap the previous one by 50%.
The completed coating shall be free from defects such as runs, sags,
pinholes, voids, bubbles, orange peel, grit, dust inclusions or other
deleterious anomalies and be of good visual appearance.
Different colours shall be used for all successive coats of the paint
system. The finishing coat of the required colour shall be sufficiently
opaque to cover the shade of the undercoat.

7.3.2. Brush Application

Brush application is acceptable under the following conditions,

subject to Client approval:

When spray application is difficult due to location of work

accessibility;
For touch-up or repair of localized damaged paint or areas of
incorrectly applied paint;
For painting of stripe coat e.g. when applying initial coat of
paint to corners, edges, cervices, holes, welds or other irregular
surface prior to spray application;
 Above ground level when it is considered that loss of paint
under prevailing conditions is excessive e.g. windy and progress of
work has to be maintained and personnel in or neat the work site or
requirement property, may be affected by spray particles.
Coatings applied by brush shall be smooth and even.

Material applied by brush shall be smooth, uniform in thickness,

without any apparent surface defect such as brush marks, runs,
sags, or curtains.

7.3.3. Roller application

Roller application shall only be used with written approval from the
CLIENT. However, it is allowed on steel floors and panels inside
climate-controlled areas.

7.3.4. Stripe coat

Stripe coating of primer coats may be carried out following spray

application of the full primer coat. This will minimize the time
between grit blasting and application of the primer coat.

7.3.5. Painting Under Insulation

For personal protection of equipment and piping for operating

temperatures above 70C, personal protection like physical barriers
are preferred. However, if it is not possible, like access to
instruments and pipe fittings, insulation shall be designed. Under
insulation painting shall be applied per the following painting
system.

7.3.6. Thermal Spray Application (TSA) / Cold Spray

Application (CSA)
TSA coating system shall fully comply with PTS 30.48.40.31, dated
December 2010.
 CSA coating system shall comply according to paint manufacturer
recommendation. General requirement for TSA:

Thermal spray coatings specified in this PTS 30.48.40.31 shall be

applied by arc or flame spraying, using a solid metal wire. Powder
consumables, high velocity oxy-fuel (HVOF) and plasma techniques
shall not be used.
TSA coatings only shall be used to protect stainless steel against
chloride stress corrosion cracking.
TSA coating is preferable. However, in case of TSA application is not
feasible, CSA coating can be considered.
The maximum service temperature for TSA coatings shall be 590 C
under dry conditions, and 200 C under wet, or immersed
conditions.
Sealers are designed to fill the porosity of the thermal spray coating,
and not to build film thickness.

Substrate must be cleaned completely. It shall be abrasive blast

cleaned by sharp edge abrasives to a degree of cleanliness of Sa 2.5
(ISO 8501-1) . It shall be free from grease, dust and other
contaminants. The specified cleanliness shall be maintained during
spraying process. The surface roughness shall be measured by
means of replica tape, in accordance with ISO 8503-5. Other,
proprietary testing techniques may be used, as agreed by the
Principal. The surface roughness for thermal spray coatings shall be
between 75 m and 110 m, in accordance with ISO 8503-5.

Aluminium used as TSA coating shall be in accordance with ISO 209,

Grade 1350 or Grade 1100.TSA coated surfaces shall not be in direct
contact with carbon steel, e.g. TSA coated pipe and steel support. A
non-metallic layer, e.g. PTFE, or elastomer strip should be used to
avoid direct contact between a TSA coated surface and its steel
counterpart. Testing, inspection and qualification shall be carried out
as per PTS 30.48.40.31.
Thermal spray aluminium coating shall not be sealed when applied:
To immersed components;
Under insulation (to protect against CUI); or
To buried components (e.g. buried piping).
 The sealer shall have sufficiently low viscosity to penetrate into the
pores and seal the surface of the thermal spray coating. The dry-film
thickness (DFT) of the sealer should not exceed 40 m.
TSA and zinc/aluminium (85/15) alloy coatings may be sealed when
used under atmospheric conditions, e.g. to prevent fouling of the
surface, or when a particular decorative finish, or safety colours are
required.
The following sealer materials shall be used:
Epoxy: to a maximum temperature of 120 C;
Silicone: to a maximum temperature of 450 C.

7.3.7. Hot Dip Galvanizing

Steel is coated with zinc by means of dipping into a molten zinc bath
keeping at a recommended temperature around 450 to 460 oC. The
recommended thickness is about 100 m.
7.3.8. Fire Barriers / Passive Fire Protection (PFP)
System
Approval of PFP System shall be the discretion of CLIENT. Fire test
report or certificate shall be submitted for validation.
The minimum standard curve temperature of PFP materials for rapid
rise fires follows either the following standards:
UL1709 standard for rapid rise fire test OR
BS 476 Parts 20 and 21 (High rise hydrocarbon type fire curve)
All hydrocarbon fire PFP coating system shall be capable of
preventing the passage of smoke and flame for at least 120 minutes
exposure to a hydrocarbon fire. A test report simulating this
capability shall be provided.

7.4. Repair of coating defects

Damages or defects shall be corrected in order to bring the coating
system back to its initial conditions.
Before application of any subsequent coat of material, all damages
from previous coats shall be repaired. All loose paint shall be
removed to a firm edge. All surface irregularities and contaminations
shall be removed. Hard, glossy surface may require abrading to
obtain a suitable surface for painting.
Re-cleaning may differ depending on the type and extent of the
defect or damage:
For defect with only aesthetical impact (runs, sags, etc. ),
corrective action shall be implemented where visual aspect is
important,
For defect or damage that leaves at least the primer coat on the
metallic substrate, re-cleaning shall include the removal of
foreign matters (oil, grease, dust, debris, etc.) by solvent
cleaning or lightly brush blasted. The coating around the
damaged area shall be chamfered by sanding to ensure
continuity of the patch coating. The full surface preparation and
coating system shall then be reapplied strictly in accordance
with this specification (hand tool- or power tool-cleaning, subject
to CLIENT approval),
For defect or damage that leaves the metallic substrate
uncoated, re-cleaning shall bring the initial surface cleanliness
and surface roughness back to the initial requirements either by
blast-cleaning or by an alternative method approved by CLIENT.
The surface preparation for repair coating shall be minimum St3
as per ISO 8501-1,

The re-cleaning shall carry over on to the secure surrounding coating

for not less than 50 mm all round and the edges shall be feathered
(over a width of at least 70 mm).
After the surface cleaning the specified coating system or the
required layers of the specified coating shall be re-applied. Any
additional coats shall blend in with the final coating on adjoining
areas. Paint Manufacturers shall be consulted if the existing coating
requires abrading before over-coating to obtain good bonding.

7.4.1. Inadequate coating thickness

For low and rejected coating DFT the coating system shall be
repaired in accordance with this specification. Areas with inadequate
coating thickness shall be thoroughly cleaned and if necessary,
abraded, and additional compatible coats applied until meeting the
specification. These additional coats shall blend in with the final
coating on adjoining areas.
 Regarding maximum allowable dry film thickness, the first
acceptance criteria will be the maximum nominal dry film thickness
as specified in this specification. When the dry film thickness
exceeds the specified maximum requirements, the maximum
allowable dry film thickness of the paint manufacturer may be
acceptable, on a case by case basis and when approved by Client.

8. INSPECTION AND TESTING

Prior to the commencement of any work, CONTRACTOR / CLIENT
shall approve all coating and inspection procedures.
Detailed procedures and plans for testing and inspection including
the methods and equipment to be used and the frequency of their
application and acceptance criteria shall be provided to
CONTRACTOR / CLIENT.

8.1. Requirement
All test equipment shall be regularly and routinely recalibrated. All
inspection and test results shall be recorded and shall be
maintained by SUBCONTRACTOR.
All materials, which will be used for painting, shall be properly
checked upon their delivery to the Sub-Contractor yard, in order to
verify that their containers are well preserved and to segregate
immediately any material that does not comply with the
Manufacturer Technical Data Sheet.
Inspection and testing during the coating application, and of the
finished applied coating, shall include the presenting of details of
the following variables as a minimum, with all results recorded on
test reports in an approved format (an example copy of proposed
daily log shall be attached in painting procedure):
Construction quality;
Environmental conditions;
Grading and cleanliness of abrasive;
Surface profile after blasting cleaning;
Visual cleanliness, surface contamination check and residual
dust test on blasted surfaces;
Coating equipment parameters and settings;
 Number of coating layer, DFT of each coat and interval time
between coating;
State of curing;
Coating adhesion strength;
Coating appearance, uniformity and final colour

8.1.1. Construction quality

A visual examination shall be carried out for sharp edges, corners,
weld spatter slivers, rust grade, etc.
Welds shall be free from porosity and shall have a smooth profile,
without sharp edges or recesses. All edges shall be ground to
minimum 2 mm radius.
All surface defects shall be repaired. Design consideration shall be
checked and approved in accordance with ISO 12944-3.

8.1.2. Climatic conditions

Relative humidity and air temperature shall be permanently checked
(as a minimum before start of each shift and twice per shift).
Substrate temperature shall also be tested in order to confirm that it
is more than 3C above the dew point. Relative Humidity shall be
less than 85%, ambient and substrate temperatures above 10C.

8.1.3. Surface preparation

The degree of surface cleanliness shall be checked in accordance
with ISO 8501-1 and shall not be less than Sa 2 .
The presence of dust before paint application shall be checked
according to ISO 8502-3, in such a way that the particle quantity
and particle size shall not exceed rating 2. If requirement is not
achieved, all surfaces shall be cleaned with a vacuum cleaner.
Surface profile shall be assessed with Testex Press-O-Film and a
calibrated micronmeter (according to ISO 8503) and be in range
40m to 70m (Rz) for carbon steel surfaces and 20m to 30m
(Rz) for Stainless steel surfaces.

8.1.4. Soluble salt contamination

Testing for chloride and soluble salt concentrations shall be done
after surface preparation using a Bresle sampler according to ISO
8502-6. The maximum content of soluble impurities of the blasted
 surface shall not exceed a conductivity corresponding to a NaCl
content of 30mg/m for atmospheric exposure and 20mg/m for
immersion (measured in accordance with ISO 8502-9). If the
requirements is not achieved surface shall be cleaned with fresh
water and re-prepared.

8.1.5. Dry Film Thickness

Based on PTS 30.48.00.31, the dry film thickness of the coating
systems specified herein is the minimum requirement to achieve the
desired system performance.
The dry film thickness of individual paint coatings and the total
system shall be checked in accordance with ISO 19840 and shall
comply with all following criteria:
The average of all measurements shall be equal or above NDFT.
Maximum dry film thickness shall not exceed the recommendations
of the Coating Manufacturer.
If the required DFT is not achieved, an additional coat of the same
product and colour will be applied to meet the DFT requirement.
If the overall thickness is higher than the maximum thickness
allowed by the Coating Manufacturer, then the system shall be
blasted off and re-applied.
DFT and WFT measurement shall be comply with SSPC-PA 2 and
ASTM D4414 respectively.

8.1.6. Appearance of coating

For each coat, the curing shall be checked by assessing the solvent
resistance.
Test shall be performed according to ASTM D5402 for organic
coatings or according to ASTM D4752 for inorganic zinc (zinc
silicate) primers.
The topcoat shall completely cover the colour of the underlying
layers.
Final appearance of paint film shall be approved by careful visual
inspection of the fully coated surfaces, to ensure that they are free
from runs, sags, orange peeling, fish eyes, overspray, dirt and grit
entrapment, wrinkles, open joints and mechanical damage. 100% of
coating surface shall be verified. In case the defect is detrimental to
 anti-corrosion properties (i.e. lake of thickness, pin holing, etc.), it
shall be repaired.

8.1.7. Holiday (Pin-hole Detection)

Coating systems intended for immersion or splash zone service,
shall be tested for porosity, pinholes and holidays in accordance
with ASTM D5162.
100% of surface shall be tested and in case of presence of holidays,
coating systems shall be repaired and re-tested.
Low tension equipment (wet sponge) shall be used on coating
systems with thickness up to 500m. For coating systems with
thickness above 500m, high tension testing will be performed.

8.1.8. Adhesion Testing

The tests shall be carried out only when the system is completely
dry and fully cured.
The coating system (DFT less than 200 m) shall be examined for
adhesion between coats and for adhesion of the first coat to the
substrate by tape test according to ISO 2409 or ASTM D3359, Test
Method A.
For painting system with a total DFT above 200m, the adhesion
pull-off test shall be carried out, in accordance with ISO 4624 or
ASTM D4541 after 7 days cured period from the final coat. The
minimum mechanical pull-off test value shall be 500 psi for splash
zone and 300 psi for atmospheric zone.
The above destructive testing may be performed on referenced
sample panels to avoid damaging the equipment coated surface.
This shall be applied at the same time and under the same
conditions as the item surface.

8.2. Painting Inspection

All painting inspection shall be carried out by certified personnel
described below.

8.2.1. Painting Inspector

The painting inspector shall be certified under either one (1) of the
following certification institutes:
 Institute of Materials, Malaysia (IMM) Level II
NACE International Certified Coating Inspector Level III
Other reputable Institutes e.g. SSPC, FROSIO, ICorr, etc.
He shall have at least three (3) years of experience in painting
inspection, and good working knowledge on all aspects of painting:
procedures, specification, paint performance, and application as well
as inspection. He shall be able to use paint inspection tools which
are normally associated with the works.

8.2.2. Thermal Spray Coatings Inspector

Thermal Spray Coatings Inspector shall be certified to Institute of
Materials, Malaysia (IMM) Level III or equivalent.
He shall have at least three (3) years of experience in thermal spray
coating inspection, and a good working knowledge on all aspects of
thermal spray application: procedures, specification, paint
performance, and application as well as inspection. He shall be able
to use thermal coating inspection tools which are normally
associated with the works.

8.2.3. Responsibilities
The Painting Inspector is held responsible for ensuring that the
quality of all aspects of a painting programme is correct and
according to this specification. Painting Inspector shall be
responsible for witnessing, verifying, and documenting the work at
various inspection points:
Pre-surface preparation inspection.
Measurement of environmental conditions.
Evaluation of compressor (Air cleanliness) and surface
preparation equipment.
Determination of surface preparation cleanliness and profile.
Inspection of application equipment.
Witnessing paint mixing.
Inspecting paint / application.
Determination of wet film thickness.
Determination of dry film thickness.
Evaluating cleanliness between coats.
Pinhole and holiday testing.
Adhesion testing.
 Evaluating the curing of applied paints.
Any other coating related activities

9. Colour Scheme
General requirements of colour scheme are extracted from PTS
30.48.00.31.

10. Warranty
Contractors, undertaking painting and/or coating work, which are to
be carried out in accordance with this project specification, shall
guarantee the quality of their coating work. Before any painting or
coating work shall commence, warranty period and coating
condition shall be agreed with the Principal.
A minimum warranty period of five (5) years for conventional
painting system and ten (10) years for special coatings such as
Thermally Sprayed Aluminium is required. A final inspection shall be
carried by a party to be agreed between the Contractor and the
Principal before expiry of the coating work warranty period.
Five years after the acceptance date of the completed coating work:
The degree of rusting shall be in accordance with ISO 4628-3 and
shall not be worse than Ri 2 (0.5 % rusting). This degree of rusting
shall only be allowed in localized areas and not be scattered 2.5%
over the total surface area coated;
Visual cracking, mud-cracking or flaking of the coating systems is
not allowed. Full attention shall be given to areas such as corners
where overlaps are difficult to avoid;
No conspicuous discoloration or excessive loss of gloss shall be
observed in the topcoats specified for the atmospheric zone. The
topcoat on steel floors is not included. The requirements on colour
retention as agreed with the CLIENT shall be observed.
In all cases, SUB-CONTRACTOR who carried out the painting work
shall fully comply with the warranty requirement specified in PTS
30.48.00.31 Section 3.1