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DEDI

CATEDFREI
GHTCORRI
DORCORPORATI
ONOFI
NDI
ALI
MITED

WDFCPHASE-2
SPECI
ALSTEELBRIDGE
CONTRACTPACKAGE–15B

METHODSTATEMENTOFMETALI
ZINGAND
PAINTI
NGFORUNDERSLUNGTYPESTEEL
STRUCTURE

DocumentNo.DOC/
CTP-
15B/
QAQC/
QSUB/
0174

TusharMohan
A 19.
12.
18
Nav
eenC Snehal Ur
ankar

Name Si
gn Name Si
gn Name Si
gn
Rev
. Dat
e Pr
epar
edby
: Rev
iewedby
: Appr
ovedby
:

Page1of1
METHODSTATEMENTOFMETALIZI
NGANDPAINTI
NG
FORUNDERSLUNGTYPESTEELSTRUCTURE

I
IS-
Larsen&Toubr
o DocumentNo:DOC/CTP-
15B/
QAQC/
QSUB/
174–RevA
Consor
ti
um DateofRev
.19.12.
18

METALI
ZING&PAI NTI
NGForUnderSlungType
Steel
Struct
ureatM/sEssarSt
eel
Indi
aLtd

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METHODSTATEMENTOFMETALIZI
NGANDPAINTI
NG
FORUNDERSLUNGTYPESTEELSTRUCTURE

I
IS-
Larsen&Toubr
o DocumentNo:DOC/CTP-
15B/
QAQC/
QSUB/
174–RevA
Consor
ti
um DateofRev
.19.12.
18

I
NDEX

Sr
.No. I
tem Descr
ipt
ion Pg.No.

1 I
NTRODUCTI
ON 4

2 SCOPE 4

3 REFERENCES 4

4 SURFACEPREPARATI
ON(
ONLYATHSFGBOLTEDAREA) 4

5 METALSPRAYI
NG(
ONLYATHSFGBOLTEDAREA) 5

6 METHODFORTHEDETERMI
NATI
ONOFLOCALTHI
CKNESS 5

7 I
NSPECTI
ON 6

8 ADHESI
ON 6

9 SHOPPAI
NTI
NG 6

10 SAFETYHEALTHANDENVI
RONMENT 7

Page3of3
METHODSTATEMENTOFMETALIZI
NGANDPAINTI
NG
FORUNDERSLUNGTYPESTEELSTRUCTURE

I
IS-
Larsen&Toubr
o DocumentNo:DOC/CTP-
15B/
QAQC/
QSUB/
174–RevA
Consor
ti
um DateofRev
.19.12.
18

1. I ON:
NTRODUCTI

I
IS–L&TConsor
ti
um hasbeenawar
dedDesi
gnandConst
ruct
ionofSpeci
alBr
idgesacr
oss
Nar
madaRi
verasCTP-
15BPackage,
locat
edi
nJNPTt
oVadodar
aSect
ionofPhase2oft
he
West
ernDedi
cat
edFr
eightCor
ri
dor
.
Themai
nscopeofPackageCTP-
15Bi
sDesi
gnandConst
ruct
ionofSpeci
alSt
eelBr
idge
acr
oss Nar
mada Ri
veri
nvol
vi
ng Br
idge St
ruct
ure,Appr
oaches (
of200m Lengt
hfr
om
Abut
ment
sonBot
hSi
des)i
nfor
mat
ioni
nEmbankment
swi
th01No.RUB,Gui
deBundsand
pr
otect
ionwor
ks.TheLengt
hoft
hePr
oposedNar
madaSt
eel
Bri
dgei
s1.
4Km.I
tisl
ocat
edi
n
JNPT-
Vadodar
aSect
ionofWest
ernDedi
cat
edFr
eightCor
ri
dorunderPhase-
2,i
ncl
udi
nga
boxt
ypeRUB,
whi
chi
sapar
tofBr
idgeAppr
oachonNor
thSi
deofAl
i
gnment(
Bhar
uchSi
de)
.

2. SCOPE:
Thi
sMet
hod st
atementdet
ail
sthemai
npar
ti
cul
ari
ti
esoft
heappl
i
cat
ionofAl
umi
nium
Met
ali
zi
ngatHSFG bol
tedar
eaandPai
nti
ngatpl
ainsur
facesf
orundersl
ungt
ypest
eel
st
ruct
urewhi
chwei
ntendt
ousef
ort
heconst
ruct
ionofSpeci
alBr
idgeatM/
sEssarWor
k
ShopFaci
l
ity
.

3. REFERENCES:
 Indi
anRail
waySpeci
fi
cat
ionf
orFabr
icat
ionandEr
ect
ionofSt
eelGi
rderBr
idgesand
Locomot
iveTur
n-Tabl
es(
IRS:
B1-
2001)
 I
S:6586Recommendedpr
act
icef
ormet
alspr
ayi
ngf
orpr
otect
ionofi
ronst
eel
 I
S:2590Pr
imar
yAl
umi
num i
ngot
sforr
e-mel
ti
ngf
orgener
alengi
neer
ingpur
poses
 Pai
nti
ngCl
auseNo10.
7ofCAPar
t-3
 Appl
i
cabl
eCodesasperCAofPar
t-3Cl
auseNo.10.
7.2
 Appendi
x–VI
IofI
RSB1-
2001

4. SURFACEPREPARATION(
ONLYATHSFGBOLTEDAREA) :
 Thesurfaceshoul
dbecl
ean,dr
yandf
reefrom contami
nant
sandi
tshoul
dber
ough
enought
oensur
eadhesi
onoft
hepai
ntf
il
m.Howev
er,i
tshoul
dnotbesor
ought
hatt
he
f
il
m cannotcov
ert
hesur
facepeaks.
 Thecl
eani
ngoft
hesur
faceshal
lbedonei
nit
ial
l
ywi
tht
heuseofemer
ypaper
,wi
re
br
ushes,scr
aper
set
c.f
orspotcl
eani
ngt
oremov
erust
,scal
eet
c.Subsequent
ly,sand
bl
ast
ing(
ManualPr
essur
eBl
ast
ing)oft
hesur
faceshal
lbedonet
oremov
erust
,mi
l
l
scal
eal
ongwi
thsomeoft
hebasemet
al.Thi
swi
l
lbeachi
evedbyhi
ghv
eloci
tyi
mpactof
abr
asi
vemat
eri
alagai
nstt
hesur
facei
naccor
dancewi
tht
hepr
ovi
sionsofI
S:6586,
whi
ch
wi
l
lal
socr
eat
eabasef
orgoodadhesi
on.Theai
rpr
essur
eatt
hesandcont
ainershoul
d
notl
esst
han4Kg/
cm2.
 Bl
ast
ingshoul
dsy
stemat
ical
l
ycov
ert
heent
ir
esur
facet
obet
reat
ed,byt
rav
ell
i
ngt
he
nozzl
e ata f
air
lyconst
antspeed i
n st
rai
ghtpat
hs,each succeedi
ng passpar
ti
all
y
ov
erl
appi
ngt
hepr
ecedi
ngoneandexposi
ngcl
eanmet
al.Thenozzl
edi
stancewhen
Page4of4
METHODSTATEMENTOFMETALIZI
NGANDPAINTI
NG
FORUNDERSLUNGTYPESTEELSTRUCTURE

I
IS-
Larsen&Toubr
o DocumentNo:DOC/CTP-
15B/
QAQC/
QSUB/
174–RevA
Consor
ti
um DateofRev
.19.12.
18

t
reat
ingmat
eri
alsl
i
kest
eelshoul
dbe150t
o250mm.Theangl
eofbl
ast
ingi
sgener
all
y
15°t
o30°f
rom nor
malt
othebl
ast
edsur
face.Thebl
astnozzl
eshoul
dber
epl
acedwhen
di
amet
eroft
heor
if
icehasbeeni
ncr
easedf
or25per
centbywear
.

5. METALSPRAYING(ONLYATHSFGBOLTEDAREA) :
 Metalspr
ayi
ngshal
lbef
oll
owedasperAppendi
x-VI
IofI
RSB1-
2001
 Themet
alspr
ayi
ngshal
lbecar
ri
edoutassoonaspossi
bleaf
tersur
facepr
epar
ati
onbut
i
nanycase,
wit
hinsuchper
iodt
hatt
hesur
facei
sst
il
lcompl
etel
y.Cl
ean,
dryandwi
thout
v
isi
bleoxi
dat
ion.I
fdet
eri
orat
ioni
nthesur
facet
obecoat
edi
sobser
vedbycompar
ison
wi
thaf
reshl
ypr
epar
edmet
alsur
faceofsi
mil
arqual
i
tywhi
chhasunder
gonet
hesame
pr
epar
ati
on,
thepr
epar
ati
ont
reat
mentshoul
dber
epeat
edont
hesur
facet
obecoat
ed
 Thewi
remet
hodshal
lbeusedf
ort
hepur
poseofmet
all
i
zingt
hedi
amet
eroft
hewi
re
bei
ng3mm or5mm.Speci
fi
edt
hicknessofcoat
ingshal
lbeappl
i
edi
nmul
ti
plel
ayer
sand
i
nnocasel
esst
han2passesoft
hemet
alspr
ayi
nguni
tshal
lbemadeov
erev
erypar
tof
t
hesur
face.Atl
eastonel
ayeroft
hecoat
ingmustbeappl
i
edwi
thi
n4hour
sofbl
ast
ing
andt
hesur
facemustbecompl
etel
ycoat
edt
othespeci
fi
edt
hicknesswi
thi
n8hour
sof
bl
ast
ing.
5.
1Pur
it
yofAl
umi
num:
 The chemi
calcomposi
ti
on ofal
umi
num t
o be spr
ayed shal
lbe 99.
5% al
umi
num
conf
ormi
ngt
oIS:
2590.
5.
2Appear
anceoft
heCoat
ing:
 Thesur
faceoft
hespr
ayedcoat
ingshal
lbeofuni
for
mtext
ureandf
reef
rom l
umps,
coar
sear
easandl
oosel
yadher
entpar
ti
cl
es.
5.
3Thi
cknessofCoat
ing:
 The nomi
nalt
hickness oft
he coat
ing shal
lbe 150μ (
micr
ons)
.The mi
nimum l
ocal
t
hickness,
shal
lbenotl
esst
han110μ(
micr
ons)
,asperI
RSB1:
2001Appendi
x-VI
I.

6. METHODFORTHEDETERMI
NATI
ONOFLOCALTHI
CKNESS:

 Equi
pment
:Anymagnet
icorel
ect
ro-
magnet
ict
hicknessmet
ert
hatwi
l
lmeasur
elocal
t
hicknessofaknownst
andar
dwi
thanaccur
acyof±10per
cent
.
 Cal
i
brat
ion ofI
nst
rument
:Cal
i
brat
e and check t
he met
eron one oft
he f
oll
owi
ng
st
andar
ds(
asappr
opr
iat
e)
 Appl
i
cabl
etomagnet
icandel
ect
ro-magnet
icmet
ersot
hert
hant
hepul
l
-of
fty
pe:Asof
t
br
assshi
m,f
reef
rom bur
rs,i
ncont
actwi
tht
hegr
it
-bl
ast
edsur
faceoft
hebasemet
al
pr
iort
oit
sbei
ngspr
ayed.Thet
hicknessoft
heshi
m shal
lbemeasur
edbymi
cromet
er
andshal
lbeappr
oxi
mat
elyt
hesameast
het
hicknessoft
hecoat
ing
 Aspr
ayedmet
alcoat
ingofuni
for
m knownt
hicknessappr
oxi
mat
elyt
hesameast
he
t
hicknessoft
hespr
ayedcoat
ingt
obet
est
ed,appl
i
edt
oabaseofsi
mil
arcomposi
ti
on

Page5of5
METHODSTATEMENTOFMETALIZI
NGANDPAINTI
NG
FORUNDERSLUNGTYPESTEELSTRUCTURE

I
IS-
Larsen&Toubr
o DocumentNo:DOC/CTP-
15B/
QAQC/
QSUB/
174–RevA
Consor
ti
um DateofRev
.19.12.
18

andt
hicknesst
othear
ti
cl
ebei
ngspr
ayed,
gri
t-
blast naccor
edi dancewi
thCl
ause4.
 Pr
ocedur
e:Foreachmeasur
ementofl
ocalt
hickness,makeanappr
opr
iat
enumberof
det
ermi
nat
ions,
accor
dingt
othet
ypeofi
nst
rumentused,
Wit
hinst
rumentmeasur
ingt
he
av
eraget
hicknessov
eranar
eaofnotl
esst
han0.
645Sq.cm,
thel
ocalt
hicknessshal
lbe
t
her
esul
toft
heoner
eadi
ng,Wi
thI
nst
rument
shav
ingoneormor
epoi
ntedorr
ounded
pr
obes,t
hel
ocalt
hicknessshal
lbet
hemeanoft
hreer
eadi
ngswi
thi
naci
rcl
eof0.
645
cm2ar
ea,
wit
hmet
ershav
ingt
wosuchpr
obes,
eachr
eadi
ngshal
lbet
heav
erageoft
wo
det
ermi
nat
ionswi
tht
hepr
obesr
ever
sedposi
ti
on.
 Met
hodofTestf
orAdhesi
on:Usi
ngast
rai
ghtedgeandhar
denedst
eelscr
iberwhi
chhas
beengr
oundt
oashar
p30degr
eepoi
nt,
scr
ibet
wopar
all
ell
i
nesatadi
stanceapar
tequal
t
oappr
oxi
mat
ely10t
imest
heav
eragecoat
ingt
hickness.I
nscr
ibi
ngt
het
wol
i
nes,appl
y
enoughpr
essur
eoneachoccasi
ont
ocutt
hrought
hecoat
ingt
othebasemet
ali
na
si
ngl
est
roke

7. I
NSPECTI
ON:

Det
ermi
nat
ionofLocal ckness:
Thi 

Met
ali
zi
ng:
150µ

8. ADHESI
ON:

 The spr
ayed met
alcoat
ing shal
lbe subj
ect
ed t
o an adhesi
on t
estusi
ng t
he met
hod
descr
ibedabov
e.I
fanypar
toft
hecoat
ingbet
weent
hel
i
nesbr
eaksawayf
rom t
hebase
met
al,
itshal
lbedeemedt
ohav
efai
l
edt
het
estAr
ti
cles,
whi
chhav
ebeenr
eject
edshal
lhav
e
t
hedef
ect
ivesect
ionsbl
ast
edcl
eanofal
lspr
ayedmet
alpr
iort
ore-
spr
ayi
ng.Wher
ethe
r
eject
ionhasbeensol
elyduet
otoot
hinacoat
ing,
spr
ayedmet
aloft
hesamequal
i
tymaybe
addedpr
ovi
dedt
hatt
hesur
facehasbeenkeptdr
yandi
sfr
eef
rom v
isi
blecont
ami
nat
ion

9. SURFACEPREPARATI
ON&SHOPPAI NTING(Al
lPl
ainsurf
acesexceptHSFGBolt
edArea):
 Af t
ercompl
eti
onofalumi
num met
ali
zingatHSFG bol
tedarea,al
lthemetal
izedsurf
aces
shal
lbecov
eredbymaski
ngt
apes.
 Af
terpr
otect
ingt
hemet
ali
zedar
eabymaski
ngt
ape,Sur
facepr
epar
ati
onandShopPai
nti
ng
wi
l
lbeappl
i
ed f
oral
lpl
ainsur
faces(
expectbol
tedar
eaal
lot
hersur
facest
reat
edaspl
ain
sur
faces)
 Sur
facepr
epar
ati
onandShoppai
nti
ngmet
hodol
ogyandappl
i
cat
ionshal
lbef
oll
owedasper
cl
ause no 10 and i
nspect
ion t
est pl
an of appr
oved FMQAP (
vide y
our l
ett
er no:
L/
OCGC/
DFCC/
CMT/
CTP-
15B/
1803/
10758)andCAspeci
fi
cat
ionpar
t-3Cl
auseno10.
9.4.
 Ther
ewi
l
lbeNoov
ercoat
ing appl
i
edonmet
ali
zedar
ea(
HSFGbol
tedar
ea)asperI
RSB1-
2001Addendum andcor
rect
ionsl
i
pno-
6
 Af
terer
ect
ion f
inalcoatwi
l
lbe appl
i
ed al
lthe sur
faces oft
he t
russ i
ncl
udi
ng (
HSFG
Fast
ener
s)

Page6of6
METHODSTATEMENTOFMETALIZI
NGANDPAINTI
NG
FORUNDERSLUNGTYPESTEELSTRUCTURE

I
IS-
Larsen&Toubr
o DocumentNo:DOC/CTP-
15B/
QAQC/
QSUB/
174–RevA
Consor
ti
um DateofRev
.19.12.
18

10.SAFETYHEALTHANDENVI
RONMENT:

 Hazar
dident
if
icat
ion,
riskassessmentandr
iskcont
rol
measur
esf
oreachandev
eryact
ivi
ti
es
andsub-
act
ivi
ti
esi
nvol
vedi
ntheSt
orageofr
aw mat
eri
alandt
ranspor
tat
ionofst
ruct
ural
spanshal
lbei
dent
if
iedandnecessar
yoper
ati
oncont
rolmeasur
esshal
lbei
nit
iat
edpr
ior
commencementoff
abr
icat
ionwor
k
 I
ncaseofanyemer
gencysi
tuat
ionf
oll
owi
ngmeasur
eswi
l
lbet
akenasperemer
gency
pr
epar
ednessandr
esponsepl
ananddet
ail
edsi
tesaf
etymanagementsy
stem,
proj
ectsaf
ety
andheal
thpl
anDOC/
CTP/
15B/
EHS/
GEN/
0006t
ober
efer
redsubmi
tt
edv
ideourl
ett
erno
L/
II
SLT/
DFCC/
CTP-
15B/
EHS/
GEN/
1116/
0402dat
ed16.
11.
16r
ecei
vedNONOv
idey
ourl
ett
er
noL/
OCGC/
DFCC/
CMT/
CTP-
15B/
1611/
1716dat
ed17.
11.
16.
 Env
ironment
alaspect
sandi
mpact
sassoci
atedwi
thv
ari
ousact
ivi
ti
esandsub-
act
ivi
ti
esi
n
t
hepr
esentsegmentandt
hei
rmi
ti
gat
ion/
cont
rolmeasur
esshal
lbei
dent
if
iedandnecessar
y
measur
esshal
lbei
nit
iat
ed
 Ref
ert
hef
oll
owi
ngdocumentf
ordet
ail
saboutsi
teenv
ironment
almanagementpl
an
 Env
ironment
almanagementpl
an Doc.
No:DOC/
CTP/
-15B/
EHS/
GEN/
0005 t
o be r
efer
red
submi
tt
edv
ideourl
ett
ernoL/
II
SLT/
DFCC/
CTP-
15B/
EHS/
GEN/
0916/
0302dat
ed06.
09.
16
r
ecei
vedNONOv
idey
ourl
ett
ernoL/
OCGC/
DFCC/
CMT/
CTP-
15B/
1609/
1006dat
ed14.
09.
16.

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METHODSTATEMENTOFMETALIZI
NGANDPAINTI
NG
FORUNDERSLUNGTYPESTEELSTRUCTURE

I
IS-
Larsen&Toubr
o DocumentNo:DOC/CTP-
15B/
QAQC/
QSUB/
174–RevA
Consor
ti
um DateofRev
.19.12.
18

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