SECTION 09875 CORROSION RESISTANT COATINGS

PART 1 - GENERAL 1.1 A. DESCRIPTION OF WORK The extent of corrosion resistant coatings is as specified and shown on the drawings for materials requiring such coatings. Related Work: 1. 2. 3. Exhibit C-8 Finish Painting Requirements (End of Section-D4) Section 02610 Pipe and Pipe Fittings

B.

Section 02813 Underground Telecommunications Ductbanks and Jointing Chambers

1.2 A.

QUALITY ASSURANCE Source Quality Control: 1. Shop applied coatings on pipes, fittings, valves and other equipment of iron or steel shall be tested at the place of manufacture in accordance with the relevant standard specifications unless otherwise stated. Organic Coatings: The dry film thickness of the internal and external organic coatings on steel or iron pipes, fittings and valves shall be checked with the aid of a magnetic thickness gauge. The organic coatings shall furthermore be checked with the aid of an approved electric high-voltage spark tester to show that the coatings are free from holidays. The voltage used for spark testing of coatings on metal shall be 2,000 V at the requested 300 micrometers dry film thickness of the coating. Unavoidable sharp edges which cannot reasonably be rounded off at the manufacturing state, and which have been accepted by the MARAFIQ, may instead be tested with wet sponge tester operating at 90 V.

2.

B.

Standards: The latest editions of the following Standards shall apply: 1. American Society for Testing and Materials (ASTM): ASTM D117 ASTM D522 Electrical insulating oils, Testing. Elongation of attached organic coatings with conical Mandrel apparatus, Test for, Water absorption of plastics, Test for,

ASTM D570

P.O. Number : 7200018725

ASTM D1002

Strength properties of adhesives in shear by tension loading (metal-to-metal), Test for, Resistance of transparent abrasion, Test for, plastic materials to Polythene plastics moulding and extrusion materials, Spec. for, Moisture vapor permeability or organic coating films, Test for, Epoxy resins, Spec. for, Rubber property -durometer hardness, Test for, Indentation hardness of rigid plastics by means of a Barcol impresser, Test for, Resistance of organic coatings to the effects of rapid deformation (impact), Test for, Cathodic disbonding of pipeline coatings, Test for, Effects of outdoor weathering Test for, or pipeline coatings, Impact resistance of pipeline coatings (falling weight test), Test for, Disbonding characteristics direct soil burial, Test for, of pipeline coatings by Light-and water-exposure apparatus (Carbon-arc type) for exposure of nonmetallic materials, Rec. practice for operating.

ASTM D1044

ASTM D1248

ASTM D1653

ASTM D1763 ASTM D2240 ASTM D2583

ASTM D2794

ASTM G8 ASTM G11

ASTM G14

ASTM G19

ASTM G23

2.

American National Standards Organization (ANSI): ANSI A 21.5 Polythene encasement for gray and ductile cast-iron piping for water and other liquids.

3.

International Organization for Standardization (ISO): ISO 1461 Metallic coatings -Hot dip galvanized coatings on fabricated ferrous products -Requirements.

4.

National Association of Corrosion Engineers: NACE NO.1/SSPC-SP5 NACE NO.2/SSPC-SP10 White Blast Metal Cleaning Near-White Metal Blast Cleaning
P.O. Number : 7200018725

NACE NO.3/SSPC-SP6 NACE NO.4/SSPC-SP7 NACE NO.5/SSPC-SP12

Commercial Blast Cleaning Brush-Off Blast Cleaning Surface preparation of steel and other hard materials by high and ultra-high pressure water jetting prior to recoating. Application, performance, and quality control of plant-applied, fusion-bonded epoxy external pipe coating. Holiday detection of fusion bonded epoxy external pipeline coatings of 250 to 760 m (1030 mils)

RPO 394-94

RPO 490-95

1.3 A. B.

SUBMITTALS Samples: Submit samples of the polythene tube encasement. Product Data: The following information on composition of organic coatings shall be submitted. 1. Surface preparation to achieve a surface and profile depth suitable for coating. Name and manufacturer of proposed coating to be used. Composition of coating material: Contents of organic binder, filler and solvent. Type, grade and class of epoxy ASTM D1763. Results of mechanical, physical and chemical tests according to the following general list: a. b. Impact ASTM G14 or D2794. Abrasion resistance with CS 17 wheel of 1 Kg. weight 5000 cycles, ASTM D1044. Adhesion shear ASTM D1002. Hardness Shore D ASTM D2240. Hardness Barcol ASTM D2583. Elongation ASTM D522. Salt spray for 2000 hours ASTM D117.
P.O. Number : 7200018725

2. 3.

4. 5.

c. d. e. f. g.

h. i. j. k. l. m. n.

Weatherometer for 5000 hours ASTM G11 and/or G23. Resistance to different chemicals. Resistance to microbiological degradation. Temperature resistance in dry and wet conditions. Water absorbance ASTM D570. Water vapor permeability ASTM D1653. Permeability of oxygen, nitrogen, carbon dioxide and hydrogen sulfide. Cathodic disbonding ASTM G8 or G19.

o. 6. 7. 8. 9.

Method for application of coating. Method for field repair of coating. Precautions for shipping, handling and storage. Inspection of finished coating a. Dry film thickness not less than specified in paragraph 2.1.A.10, this Section. Testing for holidays, pinholes and other discontinuities with an electric spark tester using 2000 volts at a dry film thickness of 300 micrometers.

b.

PART 2 - PRODUCTS 2.1 A. MATERIALS Organic Coatings: 1. The type and quality of the coating must be chosen with regard to the corrosive properties of the water to be transported, and to the extreme climatic conditions. The coating shall have a high abrasion resistance, excellent adhesion and a low water and gas permeability. The materials used for the coating must be free from low temperature volatile solvents or other constituents which can cause evaporation and peeling during storage. The organic coatings used for internal and external insulation shall have a softening point (by the ring and ball method) higher than + 110 C.

2.

3.

P.O. Number : 7200018725

4.

The coating shall have a dry film thickness of not less than that specified in this Section. Primer materials shall be rust inhibitive and fully compatible with finish coat materials. Shop applied finish coatings shall consist of zinc galvanizing, alkyd enamel or epoxy paint systems. Paint applied over primed or previously painted surfaces shall cause no wrinkling, lifting or damage to underlying paint. Epoxy system coatings shall be applied without primer. The materials used for the coating of pipes used for transporting or equipment located in drinking water must be sufficiently free from low temperature volatile solvents or other constituents which can cause evaporation and peeling during storage or can cause taste or odor in the drinking water. The total paint film thickness including prime coat (if any), intermediate coats, and finish coat shall be not less than: Minimum dry film thickness 125 micrometers 500 micrometers 500 micrometers 300 micrometers

5.

6.

7.

8. 9.

10.

Type of paint Alkyd enamel Coal tar epoxy Epoxy enamel Organic coatings

Zinc layer thickness Hot dip galvanized steel Bolts and nuts 80 micrometers 80 micrometers

11.

The coatings shall be free from holidays, voids, missed spots, and pinholes. The type and quality of the coating must be chosen with regard to the corrosive properties of the water to be transported and to the extreme climatic conditions. In view of the presence of abrasive particles and conditions producing high water velocities, varying water pressures and the prevailing wind and sand conditions, the coating shall have a high abrasion resistance, excellent adhesion and a low water and gas permeability.
P.O. Number : 7200018725

12.

PART 3 - EXECUTION 3.1 A. FABRICATION AND MANUFACTURE General: 1. This section covers the shop priming and painting of equipment including surface preparation, materials, workmanship, protection of surface, and other appurtenant work. The Contractor shall furnish all materials, tools, equipment and labor and do all painting work specified herein. Unless otherwise stated, all cast iron, ductile iron and steel surfaces shall be protected by suitable paint or coatings applied in the shop. Surfaces to be field painted after equipment installation shall be shop painted with one or more coats of a primer which will adequately protect the equipment until finish coats are applied. Electric motors, pumps, speed reducers, starters, and other self-contained or enclosed components shall be shop finished with a high grade, oil resistant enamel. Steel equipment not in contact with the water such as framework, pipe supports, hangers, support structures for equipment, anchor bolts for machines, loose flanges for piping, bolts, nuts etc., shall be hot dip galvanized before delivery to the site. Machined, polished, and non-ferrous surfaces which are not normally painted by the Supplier shall be coated with corrosion preventive compound. Except as otherwise required or directed, the following surfaces are to be left unpainted: a. b. c. d. e. B. 1. Exposed surfaces of aluminum. Polished or finished stainless steel. Nickel or chromium. Galvanized surfaces, except piping and conduit. Rubber and plastics, including fiberglass reinforced plastics.

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5.

Surface Preparation: Prior to being coated, the internal and external surfaces shall be prepared by mechanical grinding and shot blasting to NACE No.1/SPCC-SP5. All surfaces shall be free of substances such as oil, grease, moisture, dust, rust etc. When necessary, surfaces shall be ground to remove slag inclusions or other surface protuberances and to reduce the profile depth of cast surfaces.

2.

P.O. Number : 7200018725

3.

Grinding shall also be used to smooth off all sharp edges and rough welding seams and to remove spatters on welded details. The metal surface shall be shot blasted to NACE No.1/SPCC-SP5. The profile depth of the blasted surface on cast materials shall be less than 150 micrometers. The corresponding value for blasted steel surfaces shall be less than 80 micrometers. After grinding and blasting, dust shall be removed from all surfaces with the aid of either some form of vacuum cleaner or by compressed air. The compressed air used for cleaning shall be free from condensed water, oil, dust, etc. Surface cleaning after possible grinding and degreasing prior to hot dip galvanizing shall be made by pickling and washing in water. When applying touch-up paint, or repairing previously painted surfaces, the surfaces to be painted shall be cleaned and sanded or wire brushed in such a manner that the edges of adjacent paint are feathered or otherwise smoothed so that they will not be noticeable when painted. All paint made brittle or otherwise damaged by the heat from welding shall be completely removed. COATING APPLICATION General: 1. Paint shall not be applied, except under shelter, during wet, damp, or foggy weather or when wind blown dust, dirt, debris or insects will collect on freshly applied paint. Paint shall not be applied at an air temperature below 10oC or to surfaces of metals which have a temperature below 10oC, regardless of the air temperature, or when metal temperature and atmospheric conditions cause condensation on the surface of the metal. The coating is to be applied in accordance with the manufacturer's specification. Information about the proposed application technique and repair methods to be used on site shall have prior approval of the MARAFIQ. Paint films showing sags, checks, blisters, teardrops or flat edges will not be accepted. Paint containing any of these defects shall be entirely removed and the surface repainted.

4. 5.

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8.

3.2 A.

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4.

B.

Alkyd Enamel: Alkyd enamel coatings shall be applied by brush or by a liquid spray method. Zinc Coating: Steel shall be zinc coated by hot dip galvanizing. Epoxy or Polyurethane Systems: Coatings of epoxy, epoxy bitumen or polyurethane may be applied either by liquid spraying, electrostatic powderspraying or by dipping the part to be coated in a fluidized bed of coating powder, according to the coating manufacturers recommendation.
P.O. Number : 7200018725

C. D.

E.

Repairing Damaged Paint on Equipment: 1. Painted surfaces of equipment which have become damaged prior to acceptance by the MARAFIQ shall be repainted with the same or equivalent paint as that used in the original application. The system of repairing proposed by the Contractor shall be approved by the MARAFIQ.

2.

F.

Organic Coatings: 1. The coating shall have a total dry film thickness of not less than 300 micrometers and be applied at the place where the pipe material is manufactured either by liquid-spraying, electrostatic powder-spraying of by dipping the part to be coated in a fluidized bed of coating powder. The coating shall be applied in accordance with the manufacturer's specification. The coatings shall be free from holidays and flaws such as blisters, cracks, voids, missed spots and pinholes, etc. All flaws shall be carefully repaired. Parts which are to be installed above ground shall be given a white or light-colored coating in order to keep down surface temperature on exposure to sunlight.

2.

3.

4.

G.

Polythene Encasement: 1. Straight DCI pipes shall be provided with a polythene encasement as an extra corrosion protection. This shall be done by enclosing the pipe in loose polythene tubes. The film thickness of the polythene tube shall be not less than 250 micrometers. Both the polythene film and the raw materials used in its manufacture shall fulfill the requirements stated in ASTM D1248 and ANSI A21.5. The polythene encasement on straight DCI pipes shall be applied during the course of pipe laying, in accordance with method A of ANSI A.21.5, in order to prevent direct contact between the coated pipe and the surrounding water, soil, backfill and bedding material. Overlaps shall be secured by the use of adhesive tape or plastic strings. Rips, punctures or other damage to the polythene encasement shall be repaired with adhesive tape or with short lengths of polyethene tube cut open, wrapped around the pipe and secured in place. The polythene tubes during storage and transport shall be protected from direct sunlight.

2.

3.

4.

P.O. Number : 7200018725

H.

Pressure Sensitive Tape Wrapping: 1. Polyethylene or polyvinyl chloride pressure sensitive tape, with a hightack adhesive surface, shall be used to wrap metal conduit and pipe, field joints and pipe fittings. All pipe and fittings to be tape wrapped shall be primed using a specially formulated thixotropic fast drying primer as specified by the tape manufacturer. Priming material and tape shall be purchased from the same manufacturer. The primer shall be applied in one coat in accordance with the recommendations of the manufacturer. Irregular contours shall be filled with filler mastic acceptable to the MARAFIQ before taping. The Contractor, using the following suggested tapes, tape primers, shall coat and wrap the exposed surface:
Tape Primer Scotchrap Scotchrap Tape Thickness (Microns) 250 (10 Mils) 500 (20 Mils) Tape Width

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5.

6.

Suggested Tape Scotchrap No. 50 (for girth welds only) Scotchrap No. 51 Pipe sizes (for field shop coating only) 50 mm (2) to 200 mm (8)

Tape Supplier 3M Co. & Harco 3M Co. & Harco

51 mm (2) to 153 mm (6) 153 mm (6) to 916 mm (36)

250 mm (10) to 1200 mm (48)

The Contractor may provide an alternate coating and wrapping material provided it is equal to or exceeds the specified material. English language technical literature and samples of Contractor recommended material shall be furnished to the MARAFIQ for review and approval. 7. Sharp burrs shall be removed and smoothed with a file or ball peen hammer. The shoulders of fittings and all other irregular surfaces and weld beads at fittings shall be wire brushed prior to coating and wrapping application. Exposed metal pipe, field joints and fittings which are to be buried, shall be wire brushed (except zinc galvanized) conduit, double-layered, halflapped field-wrapped.

8.

9.

P.O. Number : 7200018725

10.

A minimum of 50 percent overlap (between inner and outer wrap) shall be performed. All tape wrapping shall be inspected with a holiday detector. All holidays or flaws shall be repaired in accordance with this specification and to the satisfaction of the Owner at Contractors expense. A calibrated holiday detector shall be supplied by the Contractor. The calibration of the holiday detector shall be checked regularly at the start of work and the end of such work and after the re-commencement of work. All inspections shall be duly recorded and submitted to the MARAFIQ.

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+ + END OF SECTION 09875 + +

P.O. Number : 7200018725