AA CORROSION PROTECTION SYSTEM CPS_412

GALVANISED AND POLYURETHANE COATING ISSUE 1

(DUPLEX SYSTEM) COPYRIGHT

1 GENERAL
This system details the polyurethane coating of galvanised items.

2 REQUIREMENTS
This system shall be applied in accordance with AA Specification 164050. It is imperative
that this document has been read prior to the commencement of any application.

3 SURFACE PREPARATION
Remove all oil and grease by washing with an emulsifying detergent solution and rinsing
with clean potable water.

Abrasive blast clean using a non-metallic blast media i.e.: Garnet/Illmenite composition
with a particle size of 75 to 250µm to achieve a profile of not more than 20µm.

See Note 1.

3.1 ALTERNATIVE METHOD (SMALL AREAS ONLY)

Sand area using 80grit sandpaper to achieve a key. Apply by bristle brush a proprietary
brand (preferably the coating manufacturers') galvanised iron pre-cleaner scrubbing the
substrate. Leave in contact for 5 to 10 minutes, rinse well with clean potable water and
bristle brushes to achieve a 'water break' free surface. If this is not achieved repeat the
procedure, until this is achieved. The galvanised iron pre-cleaner shall not be allowed to
dry out on the cleaned steel surfaces before it is removed.

Allow to dry prior to applying the polyurethane coating.

4 APPLICATION
Prior to applying the polyurethane, take DFT readings of the galvanising and record.

Apply one complete coat of polyurethane. DFT shall be 50 to 70µm.

The total thickness over and above the DFT of the galvanised surface shall be 50 to
70µm.

AA_CPS_00041201.DOC APPROVED 26 May 2008 Page 1 of 3

For information or comments on this document please contact ATD QA

Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or
the information contained therein, irrespective of the cause and quantum thereof.
 AA CORROSION PROTECTION SYSTEM CPS_412

GALVANISED AND POLYURETHANE COATING ISSUE 1

(DUPLEX SYSTEM) COPYRIGHT

5 APPROVED CLEANERS

Brand Name Manufacturer

Aero Wash Stoncor

Aero Wash Sigma Coatings (Pty) Ltd

GIC Plascon

Galvanised Iron Cleaner Jotun Coatings (Pty) Ltd

6 APPROVED COATINGS

Brand Name Manufacturer

Primer finish : Sigmacover 256S (Tiecoat) Sigma Coatings (Pty) Ltd

Carbothane 136 Stoncor

Sigmafast 210 Sigma Coatings (Pty) Ltd.

Interguard 269 (Tie coat) Plascon

Polyester Polyurethane

Hardtop AS/Flexi Jotun Coatings (Pty) Ltd.

Note I : Sweep Blast Cleaning

Abrasion of hot-dip galvanised surfaces may be employed to create a profile

prior to painting. Normal blast cleaning will damage the galvanised layer and
is not recommended.

For sweep blast cleaning, the following parameters apply:

• Equipment and air supply free of oil and moisture.
• Nozzle pressure - not greater than 300kPa.
• Nozzle angle to the surface being cleaned - 30 to 60°.
• Sweeping distance 450 to 600mm.
• Abrasive - ultra fine non-metallic grit, not less than 0.2mm and not
greater than 0.8mm.
• Grit should not be recycled.
• The blasted zinc surface shall be free from all contaminants including
oil and dust.

AA_CPS_00041201.DOC APPROVED 26 May 2008 Page 2 of 3

For information or comments on this document please contact ATD QA

Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or
the information contained therein, irrespective of the cause and quantum thereof.
 AA CORROSION PROTECTION SYSTEM CPS_412

GALVANISED AND POLYURETHANE COATING ISSUE 1

(DUPLEX SYSTEM) COPYRIGHT

Note II : Individual coating materials as supplied from different manufacturers have

their own particular build characteristic.

It is the responsibility of the applicator to assure that he can achieve the

required dry film thickness (DFT) to any and all of the required coats in a
single application. If multi-coats are required, they shall be applied within the
recoat restrictions of that particular coating and all additional labour shall be
for the sole account of the applicator.

Note III : It is recommended that the galvaniser be notified that the galvanised items
are to be over coated.

7 SAFETY
The galvanised iron cleaner can be harmful. Contact with the skin, eyes and clothing
should be avoided. Wear goggles and rubber gloves when handling.

APPENDIX A: RELATED DOCUMENTS

AA Spec 164050 : Corrosion Protection of Steelwork with Coatings

APPENDIX B: RECORD OF AMENDMENTS

Issue 0 : Reviewed and amended (T Perham 28/04/06).

Issue 1 : Reviewed and Updated Clauses 5 & 6 (T Perham, May 2008); Appendix A added.

AA_CPS_00041201.DOC APPROVED 26 May 2008 Page 3 of 3

For information or comments on this document please contact ATD QA

Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or
the information contained therein, irrespective of the cause and quantum thereof.