IGS-M-TP-20-1(1) May 2010

APPROVED

IGS
Iranian Gas Standards

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Polyurethane (PUR) Coating for Pipeline Rehabilitation

Part(1)

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Fax:(9821)-8131-5679 http://igs.nigc.ir/igs igs@nigc.ir
NIGC May 2010 IGS-M-TP-020-1(1)

FORWARD
The purpose of this standard specification is to describe and
explain the uses and specification of polyurethane coating for
refurbishment of metallic gas pipeline .

This standard intended to be mainly used by all division of

(N.I.G.C.) and has prepared on interpretation of recognized
standards , technical documents , knowledge , backgrounds and
experiences in national gas industry at national and
international levels .

Iranian gas standards (IGS) are prepared, reviewed, and

amended by technical standards committee within NIGC
standardization division of research and technology
management and submitted to the standards council of NIGC
for approval .

Iranian GAS standards are subjected to revision, amendment or

withdrawal , if required , thus the latest edition of IGS shall be
checked/ inquired by NIGC users and EPC/ PC contractors .

Any comment from concerned parties or individuals on IGS are

welcome .
NIGC May 2010 IGS-M-TP-020-1(1)

CONTENT PAGE
1. SCOPE 1
2. REFERENCES 1
3. DEFINITIONS 2
4. COATING SYSTEM QUALIFICATION 2
5. COATING MATERIAL GENERAL CHARACTERISTIC 2
6. COATING SYSTEM PROPERTIES (Table 1) 3
7. THE UNMIXED PROPERTIES OF POLYURETHANE MATERIAL 5
(Table 2)
8. QUALITY ASSURANCE 6
9. INSPECTION AND TESTING 6
10. COATING REPAIR INSTRUCTION 6
11. DOCUMENTATION 6
12. PACKAGING 7
NIGC May 2010 IGS-M-TP-020-1(1)

1. SCOPE

This standard specification specifies the NIGC requirements for over the ditch coating of
pipeline with polyurethane (PUR) as an external anti-corrosion coating .
The coating performance , test method and inspection shall be all in accordance with Table 1
and manufacturer's recommendations.

2. REFERENCES

Throughout this standard specification the following standards and codes that are in effect at
the time of issue of this specification (2010) shall , to the extent specified herein, form part of
this specification .
The applicability of changes in standards and codes that occur after the date of standards that
referred shall be mutually agreed upon by the purchaser and supplier and/or manufacturer .

2.1 Normative References

BS EN 10290 (2002) "Steel tubes and fittings for onshore and offshore pipelines-external
liquid applied polyurethane and polyurethane modified coatings"

ASTM D 16 (2000) "Paint , related coatings , materials , and applications"

ASTM D 543 (2001) "Evaluating the resistance of plastics to chemical reagents"

ASTM D 570 (1998) "Water absorption of plastics"

ASTM D 2240 (2002) "Rubber property-durometer hardness"

ASTM D 4060 (2001) "Abrasion resistance of organic coatings by the Taber abraser"

ASTM D 4541 (2002) "Pull-off strength of coatings using portable adhesion testers"

ISO 527 (1996) "Plastics – determination of tensile properties"

NACE RP0394 (2002) "Application , performance , and quality control of plant-applied ,

fusion-bonded epoxy external pipe coating"

2.2 Informative References

ANSI/AWWA C222 (2008) "Polyurethane coating for the interior and exterior of steel water
pipe and fittings"

NACE TG 281 (2005) "Field applied rigid polyurethane coating for field repair , rehabilitation ,
and girth weld joints on pipeline : application , performance , and quality control"

NACE RP0184 (1984) "Repair of lining system"

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NIGC May 2010 IGS-M-TP-020-1(1)

IGS-M-TP-14 (1999) "Technical specification of polyurethane/polyurethane tar for coating of

field weld joints , valves , and fitting and repairs"

3. DEFINITIONS

Applicator
The organization responsible to the purchaser for the coating application .

Coating material
100% Solid rigid polyurethane coating chemistry .

Coating system
The coating system shall consist of an ASTM D16 type V thermoset , Aromatic , ployurethane
plastic polymer that is the reaction product of diphenylmethane disocyanate (MDI) resin and
polyol resin .

High build
A term referring to a paint film which can produce a thick film in a single coat .

Rigid
Polyurethane coating material that exhibits less than 10% elongation .

4. COATING SYSTEM QUALIFICATION

The polyurethane coating system shall be qualified by NIGC prior to application . Testing
should be conducted on each applicable coating and shall meet the acceptance criteria of
Table 1 .
Qualification shall be based on tests carried out by an independent recognized certifying body
and the relevant documents shall be submitted by manufacturer .

4.1 Polyurethane material shall be a plural component, fast setting, short pot life.

4.2 Coating system that shall be applied using plural component equipment and techniques
according to the manufacturer / supplier instructions.

4.3 Material should be brush applied or manually/Automatically sprayed.

5. COATING MATERIAL GENERAL CHARACTERISTIC

A high build two-component 100% solid polyurethane coating , shall be an ASTM D16 type V
polyurethane material, formulated to have a minimum solid content of 98% and a volatile
organic compound (VOC) level of less than 14 g/l .
No primers shall be required by the polyurethane coating to achieve proper performance .
Coating material and applied coating system requirements shall be according to Tables 1 and
2 respectively .

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 NIGC May 2010 IGS-M-TP-020-1(1)

6. COATING SYSTEM PROPERTIES

Table 1
Item Element Unit Requirement Test Method
Class A Class B
1 Dry thickness of the coating system ?m 1000 ± 100 1500 ± 200 EN 10290
Annex A
2 Elongation % less than10 less than10 ISO 527
2
3 Specific electrical insulation resistance , min Dm EN 10290
0 7 8 Annex F
– after 100 days at 23 ± 2 C 10 10
0 4 5
– after 30 days at Tmax ± 2 C 10 10
4 Adhesion test – Resistance to removal , max --- EN 10290
0 Annex D
– at 23 ± 2 C rating 2 rating 2
0
– at Tmax ± 2 C rating 3 rating 3
5 Adhesion test – Pull off method , min psi 1500 1500 ASTM D 4541
6 Impact resistance , min J EN 10290
0 Annex C
– at 23 ± 2 C 5J*k*mm 5J*k*mm
0
– at -5 ± 3 C 3J*k*mm 3J*k*mm
7 Hardness , min shore D 70 70 ASTM D 2240
8 Cathodic disbondment , max mm EN 10290
0 Annex E
– at 23 ± 2 C for 28 days 8 8
0
– at Tmax ± 2 C for 2 days 10 12
9 Flexibility --- EN 10290
0 Annex K
– at 23 ± 2 C pass pass
0
– at 0 ± 2 C pass pass
10 Thermal ageing --- EN 10290
0 Annex J
– 100 days at 80 ± 2 C free from pin hole ---

– 100 days at 100 ± 2 C

0 --- free from pin hole
11 Water absorption , max % 2.0 2.0 ASTM D 570
12 Chemical resistance % 5 5 ASTM D 543
(10%H2SO4,10%HCl,30%NaOH,
3%NaCl,deionized water) ,change in mass ,
length or width after 90 days immersion ,
max
13 Indentation resistance , max EN 10290
0 Annex H
– at 23 ± 2 C mm 0.2 0.2
– at Tmax ± 2 0C % of initial 30 30
measured
thickness
14 Hot water soak test (adhesion) , --- rating 3 rating 3 NACE RP0394 : 02
0
at Tmax ± 2 C / 28 days Annex J
and
EN 10290
Annex D
(see note 2)
15 Abrasion resistance , CS-17 , 1 kg wheel , mg 100 100 ASTM D 4060
max loss/1000
revolutions
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NIGC May 2010 IGS-M-TP-020-1(1)

Note 1 : Tmax (maximum service temperature) : For class A : 60 ± 2 0C

For class B : 80 ± 2 0C

Note 2 : The hot water soak test shall be carried out in accordance with NACE RP0394 and the
adhesion test of the coating shall be performed according to EN 10290 .

Note 3 : The mixed coating shall not be black .

k : Correction Factor
Pipe Diameter , mm k

D >219.1 1.00
76.1 < D K 219.1 0.85
D K76.1 0.70

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 NIGC May 2010 IGS-M-TP-020-1(1)

7. THE UNMIXED PROPERTIES OF POLYURETHANE MATERIALS

Table 2
Item Element Unit Requirement
1 Shelf life , min --- 12 months after manufacturing date
0
2 Ambient temperature C +5 to +45
0
3 Application temperature C -40 to +70 or as per manufacturerMs recommendation
4 Service temperature
0
C For class A : -20 to +60
For class B : -20 to +80
0
5 Flash point , min C 100
6 Solids content , min % 98
7 Viscosity --- The viscosity of each material component as supplied ,
shall be specified by the manufacturer .
8 Relative density --- The relative density of each material component shall be
specified by the manufacturer .
9 Pot life --- The pot life shall be specified by the manufacturer .
0
10 Initial set time at 23 ± 2 C , max minute 15
11 Curing time before handling --- The curing time before handling shall be specified by the
manufacturer .
12 Holiday testing time --- The holiday testing time shall be specified by the
(Holiday detection with a voltage 6 manufacturer .
V/?m of nominal thickness with a
maximum of 20kV , EN 10290 –
Annex B)
13 Curing time before backfilling --- The curing time before backfilling shall be specified by
the manufacturer .
14 Recoat time --- The recoat time shall be specified by the manufacturer.
Note 1 : The test methods shall be specified by polyurethane manufacturer .
Note 2 : Base and hardener should have different colours allowing the verification of the correct mixing and checking the
uniformity of the colour of mixed product .
15 Packaging Each part of polyurethane coating materials shall be packed in
hermetically sealed metallic containers and suitably marked giving ,
as a minimum , the following details :
- Product manufacturerMs name
- ManufacturerMs designation
- Application method
- Batch number
- Date of manufacture
- Expiry date
- Recommended storage conditions
- Health and safety warnings
- Colour of the materials (base , hardener and mixed)
16 The coating applicator shall provide the following items that shall be certified by polyurethane
manufacturer:
- Application instruction
- Repair procedure
- Product data sheet
- MSDS
- Instruction for handling and storing the coating material
- Curing temperature profile (temperature vs time)
Note : ApplicatorMs team shall be trained and certified by polyurethane manufacturer .

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NIGC May 2010 IGS-M-TP-020-1(1)

8. QUALITY ASSURANCE

The product manufacturer shall carry out quality inspection so that he guarantees the
consistent quality of the products and maintains the properties listed in Table 1 .
The product manufacturer has a quality control service (plan) approved by the coater , shall
provide a test certificate , on the understanding that the record of the results of his inspection
is made available to the coater for checking where necessary . The inspection shall be carried
out on every batch of material .
For specific requirements the purchaser can ask for additional information at the time of
enquiry and order .

9. INSPECTION AND TESTING

The NIGC authorized inspector shall have free access to the workshops storage yards and
laboratory of the coating applicator , who shall provide the inspector all the necessary facilities
for the proper execution of inspection activities .
Prior to start of coating application , the applicator shall submit all relevant documents
submitted by coating manufacturer/supplier as specified in this standard specification to NIGC
for review and approval .

The coating material inspection certificate shall include the results of all tests and inspections
as set forth in this standard specification and shall be signed by the appointed inspector .
The Inspection certificate shall certify that , all test and inspection have been performed by
coating applicator and has been witnessed by the appointed inspector .
The coating applicator shall provide all necessary tools , instruments , and equipments
requires for all specified tests and inspections .

10. COATING REPAIR INSTRUCTION

The coating applicator shall submit detailed procedures for coating repairs to the company for
review and approval.
This procedures shall contain :

- Repair of surface damage ;

- Repair of holidays and small damages ;
- Repair of damages due to site quality check ;
- Testing to prove the efficiency of the repairs .

11. DOCUMENTATION

The coating applicator shall keep accurate record of all relevant data of the coating process,
material and coating performance .

This documentation shall include :

11.1 Copies of the coating materials data including manufacturer's name , material
designation , date of manufacture and batch numbers ;

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NIGC May 2010 IGS-M-TP-020-1(1)

11.2 The results of all quality control testing ;

11.3 Repair procedures ;

11.4 Repair records ;

11.5 Calibration certificates of the testing and inspection instruments ;

11.6 Raw material details and relevant certificate ;

11.7 These documents shall be submitted to the company after completion of the each
rehabilitation project ;

12. PACKAGING

All materials supplied for coating shall be marked as a minimum, the following details :
Manufacturer's name
Name of material
Batch number
Date of manufacture and use by date
Recommended storage conditions
Colour of the material
Application method