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Painting instruction
Plant : Dalmia DSP (Unit-II), (A unit of Dalmia Cement (Bharat) Ltd)
Plant at Biswali, Cuttack (Odisha)

Project No. : 1945704_800

Document No. : 50095410

Revision Summary of changes Author Date of issue

1 First issue DN 16-Apr-2019

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Table of contents

1. GENERAL REQUIREMENTS ..................................................................................................................................3

2 PAINTING....................................................................................................................................................................4
2.1 STEEL SURFACE PREPARATION AND REQUIREMENTS ...............................................................................................4
2.1.1 Visible surface (not insulated)........................................................................................................................4
2.1.2 Insulated and internal surfaces ......................................................................................................................5
2.2 PAINTING SYSTEMS .................................................................................................................................................5
2.2.1 Visible surfaces: .............................................................................................................................................5
2.2.2 Insulated and internal surfaces: .....................................................................................................................5
2.2.3 NonFLS equipments: Machines, standard components and electrical equipment: ........................................5
2.3 PERFORMANCE OF WORK ........................................................................................................................................5
2.4 REQUIREMENTS FOR FINISHED SURFACES ...............................................................................................................6
2.5 CHECKING...............................................................................................................................................................6
2.6 REPAIR OF FINISH PAINTED SURFACES.....................................................................................................................7
3. GALVANIZING...........................................................................................................................................................7
3.1 STEEL SURFACE REQUIREMENTS .............................................................................................................................7
3.2 PERFORMANCE OF WORK ........................................................................................................................................7
3.3 CHECKING...............................................................................................................................................................7

4. STAINLESS STEEL ....................................................................................................................................................7

4.1 STEEL SURFACE REQUIREMENTS .............................................................................................................................7
4.2 PERFORMANCE OF WORK ........................................................................................................................................7

5. ACCESS FACILITIES - RAILINGS .........................................................................................................................7

6. RUST PREVENTIVE OIL..........................................................................................................................................7
7. PAINTING FOR PIPING ...........................................................................................................................................8
8. ANNEX 1- CHECK LIST AND CONTROL SHEET (PAINT).............................................................................10
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1. GENERAL REQUIREMENTS

Corrosion Surface
Surface Color
category preparation Intermedi Finish/ Total
Item roughness Primer/ DFT
– ISO ISO 8501-1 / ate /DFT DFT DFT
12944 ISO 8501-2,3

Visible surface Zinc rich Epoxy Epoxy RAL

≤120°C N/A Sa 2 ½ & P2 50-75 µm Polyurethane 7037
60 µm 120 µm
60µm
Zinc Ethyl silicate Silicone
Visible surface Sa 2 ½ & P2 20-50 µm -- Aluminum
120 to 400°C 50 µm
30 µm 80 µm
Internal, Epoxy Zinc phosphate
Insulated surface N/A St2 / Sa 1 & --/ <40 µm Red
and Gas contact P1 - - brown
area 40 µm
40 µm
Guards, railing,
toe guard , N/A 50-75µm Epoxy Zinc Epoxy RAL
ladder, Monorail, Sa 2 ½ & P2 Phosphate Polyurethane 1003
material handling 120 µm
eqpt. 60µm 60µm
Air header, other Epoxy Zinc Epoxy
pressure vessels N/A Sa 2 ½ & P2 50-75µm Phosphate Polyurethane RAL
5012
60µm 60µm 120 µm
Geared/ Supplier standard Supplier
Motors standard
Oil resistant – N/A Sa 2 ½ &P2 50-85 µm Polyamine cured
,Pinion bearing Phenolic/ Novolac
housing&Girth epoxy Red
gear ( 120 µm brown
unmachined 120 µm
area), Gear
guard for kiln
F.K Pump and N/A St 2 N/A Red oxide primer Urethane alkyd Hammert
S.K Valves 40 µm 60 µm 100 µm one Grey

Piping Refer Clause 7.Painting for piping

Grating, steps N/A St 2 N/A Hot Dip Galvanized > 60 µm

Machined N/A N/A N/A Rust preventive oil N/A N/A
Surface, surface Refer.
requires no 30-50 Clause 6
primer µm
Note : Powder coating of Air header is also acceptable.

The authorities' requirements for working environment etc. in connection with the work are to be fulfilled. It is the supplier´
responsibility that all aspects regarding Health and Safety are followed.

FLS do not accept use of paint with red lead or lead chromate or toxic elements on the steel constructions or packaging
or non-FLS equipments. The lead content must be below 200 ppm for paint and colour pigments.

Documentation of the used paints and colour such as Technical Data Sheets and Material Safety Data Sheets (MSDS) etc
must be available on request. Contact FLS if any doubt.

From the paint supplier’s home page all Product Datasheets as-well-as health and safety must be down loaded, if not
delivered with the paints.

It is a general principle for the supply that the surface treatment performed shall minimize corrosion to the greatest
possible extent.

The execution of the work shall be supervised at all stages. Supervision shall be undertaken by suitable qualified and
experienced people.
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Personnel trained in the relevant operations shall carry out the work.
The surfaces to be treated shall be safely accessible and well illuminated.

Surface treatment shall take place within the recommended climatic conditions .

Surface treatment of steel constructions or parts of constructions, which are inaccessible after assembly, shall be painted
before the assembly commences.

Weld-able shop primer can be used if it is compatible with the other relevant paint. Full documentation of "weld able" and
compatible must be part of the documentation forwarded to FLS.

It is important that signs, Name plates, motor, shafts, lubricating nipples, valve etc. are not painted over or splashed.

The surface treatment shall be sufficiently dry and hard before moving, stacking, packing and/or transporting the goods
such as the paint film will not be damaged.

The supplier shall free of charge repair damages arising before the delivery date. Discrepancies found after the delivery
date due to the fault of supplier will be repaired at the supplier´s account. Discrepancies can be caused because of
incorrect preparation of the surfaces, painting and packing.

Project Specific for OCL:-

• Shop Coating shall be continuous over all edges including area for field Joints.
• Approved Make of paints
o Jotun
o Hempel
o PPG/Asian Paint
o Akzo Nobel
o Berger
o Shalimar

2 PAINTING

2.1 Steel surface preparation and requirements

Structures must not have any corrosion traps such as:

- Steel with too high a degree of corrosion (never D according to ISO 8501-1, and C only to a limited extent, and
always subject to agreement with FLS).

- Severe undercuts, scratched surface due to torn off material, defects due to milling, laminations, weld deposits,
defects due to milling or deep pores in welds.

2.1.1 Visible surfaces

The preparation of surfaces, which are to be treated with multiple coats of paints or galvanization, must be done in the
following order:

a) The surface of the welds shall satisfy the requirements of ISO 5817 symbol C (identical with FLS general
workshop instruction 520530 class QB). Handrails: see also section 5

b) All sharp edges and corners shall be rounded off at a radius of min. 1 mm.

c) Oil and grease are to be removed by using suitable detergent/solvent.

d) Water soluble impurities and alkali remains, coming from welding with covered electrodes or spray against
weld spatter, or salts or other contamination, to be removed by using suitable method, grinding or washing
with water or steam.
Stainless steel must be pickled and/or glass-blasted and/or "Brushed" see PO.

e) Cleaning, Blasting and Roughness of the surfaces shall conform to the demand from the paint supplier, see
the Painting Specification mention on front page.
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f) Dust to be completely be removed before painting.

Blast cleaning of sheet steel less than 4 mm thick may result in its being deformed. That can be avoided or reduced by use
of:
. Low pressure, fine particles and abrasives with low apparent density

OR

..A small blast angel with sharp-edges particles and a short blasting period. In the case of firmly adhering mill
scale or extensive rusting, preliminary measures such as grinding or acid pickling may be required prior to
blasting.
If roughness is required, blasting must be done with plate in plan position i.e. before cutting,
welding

The compressor shall have an efficient Dryer, water and oil separator.
The abrasives shall be free of impurities such as oil, clay, chlorides and sulphates.

2.1.2 Insulated and internal surfaces

The preparation of the surfaces must be done in the following order:

Oil and grease to be removed prior to Power toll cleaning or blasting to St2 /Sa1 acc. to ISO 8501-01.

2.2 Painting systems

The following painting systems shall be applied.

If the supplier choose to use other systems or paints than specified, the system specification and the product specification
are to be forwarded to FLS for acceptance before the work commences.

2.2.1 Visible surfaces (not insulated):

Paint system for Primer to Finish paint shall be from Same manufacturer, Change of over coating material
manufacturer shall be approved by paint manufacturer in writing and agreed by FLSmidth .

The required colors will appear from the Purchase Order.

2.2.2 Insulated and internal surfaces:

Only approved manufactuers paint shall be used.

2.2.3 non-FLS equipments: Components, motors and electrical equipments….

As per manufacturer standard.

2.3 Performance of work

Product Datasheets and Specifications issued by the paint supplier shall be complied with, (temp., humidity, pot life,
recoating intervals…).

The substrate temperature shall be at least 3oC higher than the dew point of the surrounding air starting from blasting to
completion of all coats.

Blasting and painting must not be performed when relative humidity is higher than 85 %, and never outdoor when snow,
rain or wind with dust and other impurities can pollute the surfaces.

The supplier is obliged to record daily in the “log book” the description of climatic conditions, temperatures of the
surrounding air, relative humidity and dew point as well as the temperature of the steel surfaces – before start of painting
and during painting.
All gaps on visible surfaces, also intermittent welds, shall be pre-treated and surface treated, together with the necessary
jointing, using silicon-free and weather-resistant material.
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First coat shall be applied immediately (max 4 hours for 70% RH ) after blasting and cleaning. Roller may only be used for
application if recommended by the paint manufacturer. Roller application is not allowed for primers in full coat
systems (visible surfaces).

Before spraying of each coat, not easily accessible locations and all edges, corners, and weld seams must be stripe
coated.
Each coat of paint applied shall have varying shade.
Unfinished painted steel structures or components which have been stored outdoors shall be washed carefully in plenty of
fresh water and subsequently dried before applying the next coat of paint. Greasy surfaces shall be rinsed with emulsifying
agent prior to fresh water washing.

2.4 Requirements for finished surfaces

The finished surfaces are to be evenly smooth without orange peel appearance, wrinkles, blisters, runners, spray dust, pin-
holes, cracks, imperfections and impurities.

The thickness of the coat of paint must be even. This also applies to corners and edges.

The finished surfaces must have a uniform appearance in terms of colour and gloss. Unless standards colours are used,
all the paint required shall be mixed in one batch.

Touch up painting of areas which at a later state will be inaccessible, e.g. due to covering, must be performed when said
areas are still accessible.

Visible touch ups must be carried out so that they will not spoil the aesthetic appearance of the structure.

2.5 Checking

The supplier shall check the equipment daily in order to ensure the greatest possible degree of uniformity of work.

While the work is being carried out, the subcontractor shall regularly inspect whether it is being performed in accordance
with the specifications.
During execution of the work the supplier shall keep a record of all inspections and climatic observations. FLS and its client
shall at all times have access to this record.
After completion of the work the record shall be submitted to FLS.
FLS and its client shall at any time be entitled to check each operation to the extent deemed necessary.

If the results of the specified final tests are not approved, the supplier shall repaint the parts concerned at no expenses to
FLS.

The areas checked shall include plane surfaces as well as edges and weld seams. Minimum 5 measurements per 10m2.
Depending of the type of work performed, and if nothing else has been agreed upon with FLS, the following methods shall
be adopted for painting systems with more than one coat:

- Cleanness compared with ISO 8501-1 comparator.

- Surface roughness compared with Rugo-comparator, ISO 8503-2.

- Measurement of dry film thickness with electric film thickness measuring device. Min. 80 % of the specified
coating thickness must be obtained and max. 20 % of the measurements must be under the specified coating
thickness. In no case should any reading be less than 80 % of the specified coating thickness. The average of
the film thickness must as minimum be as the specified film thickness.

- The film thickness shall be measured for both primer, intermediate coat and top coat and recorded in the
report.

- To check that the painted surfaces are sufficiently dry and hard before handling and packing, press the thump
hard on the painted surface and turn 90º. If the painted surface has mark or has been destroyed the surfaces are
not sufficiently hard.

The suppliers can use their own surface treatment reports , only if it contains all the requirements and information
mentioned in the FLS report annex 1 and it is in English.
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2.6 Repair of finish painted surfaces

In case of repair of the finish painted surfaces, the substrate must be cleaned as mentioned in 2.1.1 and in order to have a
smooth transition to the existing paint, it is necessary to grind the area of the existing paint with sandpaper. Regarding
extend of painting see also 2.4 last part.

3. GALVANIZING

Only hot dip galvanizing according to ISO 1461 and the herein mentioned standards shall be accepted.

3.1 Steel surface requirements, see section 2.1

3.2 Performance of work, see ISO 1461
3.3 Checking, see ISO 1461

If the supplier choose to use other standard than specified, the proposed standard or specification are to be forwarded to
FLS for acceptance before the work commences.

FLS and its client shall at any time be entitled to check each operation to the extent deemed necessary.

Before the steel constructions are galvanized, it must be assured that all weld spatter and other impurities are removed
from the surfaces.

After galvanizing the constructions must be visual tested for missing and incorrect galvanizing. Before delivery the
constructions must be cleaned for burrs, scratches and impurities.

Any weld repair after galvanizing to be painted with Zn-rich paint, see also ISO 1461 section 6.3.

4. STAINLESS STEEL
4.1 Steel surface requirements; see section 2.1.

4.2 Performance of work

Mild steel and stainless must be clearly separated/isolated and only tools free from mild steel can be used.

All welds must be carefully pickled. Ground surfaces to be passivated. Both processes require carefully cleaning with water
to stop the process.

In case the contaminated surfaces, all surfaces must be cleaned by passivating and/or glass blasting.

For protection of the surfaces after manufacturing and cleaning procedures, the surfaces must be carefully protected all
over, for example by use of plastic.

5. ACCESS FACILITIES - HANDRAILS

The weld class QB is required for railings of mild steel, i.e. Fully penetrated welds, Undercut max 0,5 mm,

6. Rust preventive Oil(RPO) application

After machining and deburring, the surface shall be cleaned thoroughly by solvent cleaner to remove dirt, rust, scale and
other contaminations. RPO to be applied when the surface is clean and dry.
Dilution of RPO is generally not required, if thickens during cold storage add aliphatic mineral sprit.

Applying over heat may result fire or explosion, applying by spray, dip or brush at temperature between 10-35degC is
recommended.

RPOs cures by solvent evaporation, Keep away from heat, parks and open flame. Adequate ventilation is necessary when
applying RPO.
RPO can be removed with mineral sprits or any similar petroleum solvents.Clorinated or high aromatic solvents to be
avoided as they will affect the paint.

Recommended RPO
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Tectyl 506WD / Black Japan / Rusnil 1141

7. Painting for piping

Intermediate Finish coat Total

Primer with coats with with thickness DFT
Pre
thickness thickness (indoor/ RAL
SN Eqpt. Name treat- Color
(indoor/ (indoor/ No
ment
outdoor)
outdoor) outdoor)

Piping

1 coat Epoxy 2 coats of Epoxy finish

Piping for Sa primer of coat of 30 μm/Coat Brilliant
1 100 μm Blue 5007
pressurized air 2.5
40 μm 60 μm

1 coat Epoxy 2 coats of Epoxy finish

100 μm
Control Air Sa primer of coat of 30 μm/Coat Past el
2. 5024
Pipelines 2.5 Blue
40 μm 60 μm

1 coat Epoxy 2 coats of Epoxy finish

Fresh Water Sa primer of coat of 30 μm/Coat 100 μm Light
3. 6027
Pipeline 2.5 Green
40 μm 60 μm

1 coat Epoxy 2 coats of Epoxy finish 100 μm

Treated Water Emerald
4. Sa primer of coat of 30 μm/Coat 6001
Pipeline Green
2.5 40 μm 60 μm

Industrial Water 1 coat Epoxy 2 coats of Epoxy finish 100 μm

Sa Grass
5. Pumps, piping, primer of coat of 30 μm/Coat 6010
2.5 Green
armatures 40 μm 60 μm

1 coat Epoxy 2 coats of Epoxy finish 100 μm

Cooling Sa Grass
6. primer of coat of 30 μm/Coat 6010
Water 2.5 Green
40 μm 60 μm

1 coat Epoxy 2 coats of Epoxy finish 100 μm

Drinking Sa
7. primer of coat of 30 μm/Coat
Water 2.5
40 μm 60 μm

1 coat Epoxy 2 coats of Epoxy finish

Waste Bottle
8. Sa primer of coat of 30 μm/Coat 100 μm Green 6007
Water
2.5 40 μm 60 μm
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Intermediate Finish coat Total

Primer with coats with with thickness DFT
Pre
thickness thickness (indoor/ RAL
SN Eqpt. Name treat- Color
(indoor/ (indoor/ No
ment
outdoor)
outdoor) outdoor)

Fuel Oil (Diesel 1 coat Epoxy 2 coats of Epoxy finish

Sa 100 μm Brown.
9. Lines) Pumps , primer of coat of 30 μm/Coat 8001
2.5
piping, armature 40 μm 60 μm

Danger Zones Sa Black/ 9005/

10.
(Stripped) 2.5 Yellow 1003

1 coat Epoxy 2 coats of Epoxy finish

Lube Oil Sa
11. primer of coat of 30 μm/Coat 100 μm Brown 8001
Line 2.5
40 μm 60 μm

1 coat Epoxy 2 coats of Epoxy finish

Transformer Oil Sa
12. primer of coat of 30 μm/Coat 100 μm Brown 8001
Line 2.5
40 μm 60 μm
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8. ANNEX 1 CHECKLIST AND CONTROL SHEET (Paint)

As per
GTR ST-CP-01-
Corrosion Protection Report ISO 12944-
8 Ver.2
Supplier : Supplier Name Supplier location : Report No:
Project Name: Main Eqpt. Desc :
Project. No : PO.No : Date :

Surface Intermediate/ Total FLS Paint

R Primer / DFT Finish /DFT
Preparation DFT DFT/shade Spec.No
E
Q Inside
U
I Paint system
R Surface Intermediate/ Total as per
Primer / DFT Finish /DFT
E Preparation DFT DFT/shade 520530 / ISO
D 12944-5
Out side

Rust Grade ( ISO 8501-1) Mill imperfection found Surf. preparation (ISO
Surface profile(ISO 8503-1)
A B C D Sharp edges & burr 8501-1)
Oil, grease & other impurities removed Sa 1 St 2 Comparator G S
removed Weld residue, Spatter, slag Sa 2 St 3
R2 rounding done for finish not removed Sa 2.5 Fine Medium
painted items Sa 3 Coarse
Surface preparation grade Surface profile Brand Name / Type of blast cleaning abrasive ( ISO
achieved ( ISO 8501-1 & 2): achieved (ISO 8503-2): µm 11124/ISO 11126,.. etc) :

Details of surface Detail of Paint Application

preparation 1st Coat 2nd Coat 3rd Coat 4th Coat 5th Coat
Part list No &
Pos.Nos
Dust removed prior to coating?
Date & Time
Air temperature ,°C
Relative Humidity, %
Dew Point, °C
Surface temp, °C
Paint Manufacturer
Designation of paint & type of
coat, Product No
Batch No:
Colour
Comp.B- Product No / Batch No
Thinner No / Mixing ratio
Mixing method
Stripe coating
Field welding location (weld
able primer Make)
Method of application
Location of painting work
NDFT µm
DFT µm-Min.
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µm-Max
µm-mean
Instrument used / Calibration
detail
Complies with Spec. ? Yes/No
Sign, date & time of inspn.
Supplier Name