Professional Documents
Culture Documents
July 1994
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Prepared by :
Cheques, bank drafts or money orders must be payable to HONG KONG GOVERNMENT
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FOREWORD
July 1994
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CONTENTS
Page
No.
GENERAL
01 Abbreviations 13
SUBMISSIONS
02 Supply of information 15
03 Coding system 15
04 Storage life 15
05 Method of using paint components 15
06 Surface preparation of concrete 15
07 Dry film thickness and coverage 15
08 Overcoating 17
09 Physical properties 17
10 Durability 17
11 Health and safety 17
12 Maintenance 19
Page
No.
APPENDICES
APPENDIX 1 45
Page
No.
APPENDIX 2 49
APPENDIX 3 55
APPENDIX 4 57
Page
No.
APPENDIX 5 61
APPENDIX 6 65
APPENDIX 7 71
Page
No.
APPENDIX 8 77
APPENDIX 9 83
APPENDIX 10 87
Page
No.
APPENDIX 11 91
APPENDIX 12 97
APPENDIX 13 101
Page
No.
APPENDIX 14 103
APPENDIX 15 105
GENERAL
Abbreviations 01 (1) Abbreviations used in this Specification shall have the following
meanings :
SUBMISSIONS
Supply of 02 Prior to the Engineer giving approval of a particular paint type, the
Information Contractor shall supply information which will satisfy Clauses 03 to
11, and independent test certificates from a HOKLAS or similar
accredited laboratory, traceable to the paints proposed, demonstrating
that they comply with the requirements of this Specification. The
Contractor shall also supply information on the surface finish, colours,
chemical properties, weathering resistance under exposure to sunlight,
previous and existing applications of the paint in Hong Kong. All such
information shall be independently verified; any tests or case histories
on structures shall have been witnessed by an independent,
accountable third-party such as a HOKLAS accredited laboratory.
Coding System 03 All primers, paints and solvents to be used in the works shall be
identified by a unique coding system, relating to the batch of raw
materials from which the product was manufactured and the date of
manufacture.
Storage Life 04 Storage life shall normally be a minimum of one year. If the storage
life is known to be shorter, the expiry date must be marked on the
container prior to dispatch from the manufacturer’s factory.
Method of 05 Preparation and application techniques for all components of the paint
Using Paint system shall be stated. This information shall include the methods of
Components mixing to be used and the maximum dilutions, if any, by solvents or
water.
Dry Film 07 The minimum and maximum DFT limits for each component of the
Thickness paint system shall be given for a temperature of 27 ¡ ηC. The
and Coverage corresponding coverage in L/m2 shall be quoted for prepared concrete
surfaces typical of low strength (Grade 20) and high strength
(Grade?40) concrete cured under site conditions, in order to achieve
recommended DFT values.
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Notes
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Overcoating 08 Drying and overcoating times of the pretreatments and coats of the
paint system shall be given for a temperature of 27 ¡ ηC and a relative
humidity of 80 ¡ 5 % . I nf or mati on s houl d al s o be gi ven on t he li m
it
of temperature and humidity at which painting work should cease.
Durability 10 (1) The suitability of the coating for application on damp, alkaline,
cement-based materials shall be stated.
(2) The decorative life of the paint shall be stated, in terms of the
colour-fastness of the finish coat and resistance to chalking, loss of
gloss and atmospheric dirtying.
(3) The life of a paint system prior to the need for recoating shall be
at least 10 years. Examples shall be cited of where the paint system
has achieved this life.
Health and 11 (1) The Contractor shall supply health and safety data relating to the
Safety storage and application of all components of the paint system. As a
minimum, the check list contained in Table?1 shall be completed.
Notes
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(4) The Contractor shall also supply information on the long term
effects of volatile or leachable components of the paint system upon
the environment, with particular reference to leachable heavy metal
contents such as mercury based algicides or lead driers.
PRODUCT NAME
USES
COMPOSITION
PHYSICAL AND CHEMICAL PROPERTIES
HEALTH HAZARDS
FIRE HAZARDS
STORAGE PRECAUTIONS
TRANSPORT PRECAUTIONS
HANDLING/USE PRECAUTIONS
(including advice on personal protective equipment)
DISPOSAL PRECAUTIONS
EMERGENCY ACTION
Fire, spillage, first aid
ADDITIONAL INFORMATION
Ecological hazards
Relevant regulations
Advice to Occupational Medical Officers
References
NAME, ADDRESS AND TELEPHONE NUMBER OF SUPPLIER
REFERENCE NUMBER, DATE OF ISSUE
(2) The Contractor shall state which types of paint, other than the
original product, are compatible with the finish coat for recoating
purposes.
(4) Shrinkage cracks of width less than 0.3 mm, blow holes or other
defects in the finished concrete surface shall be filled with a levelling
compound compatible with the paint system to be applied; the
compound shall be knifed into defects and tight-trowelled to remove
all surplus materials.
Surface 14 (1) The adhesion of existing paint layers to the concrete surface
Preparation shall be evaluated initially by a cross-cut test, in accordance with
for Painted Appendix?15.
Concrete
(2) Measurements of cross-cut adhesion shall be made in sufficient
numbers to represent one reading per 10?m2 of coated surface for the
first 100?m2 evaluated, then three readings per 100?m2 thereafter.
Notes
Clause 15
This Clause relates to applications on building structures and civil engineering structures exposed to the weather,
away from the influence of marine spray or other sources of regular wetting.
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Coating 15 (1) All concrete surfaces to receive paint shall be dry at the time of
Application application. Sufficient drying time shall be allowed either after
for Dry construction or after wet preparation methods, to satisfy either one of
Concrete the following requirements :
Surfaces
(a) Moisture meter readings is consistently less than 5%.
(2) Prior to applying the paint, a test area shall be prepared on the
structure to be painted, except where a compatibility test has already
been undertaken in accordance with Clause 14(4). The complete paint
system shall be applied in accordance with the manufacturer’s
instructions, including any primers and undercoats, to an area of not
less than 5?m2.
(3) The actual consumption in L/m2 of the various coats of the paint
system shall be recorded in the trial area, in order that due allowance
may be made for rough, irregular or exceptionally absorbent concrete.
(4) When the paint system has cured for 14 days, a test of surface
adhesion shall be made in accordance with Appendix?8. The average
bond of 3 dollies to the concrete, via the completed coating system,
shall be satisfactory. A core sample shall be taken from the test area
for measurement of the DFT. Should the minimum and mean DFT
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Notes
Clause 16
values of the core sample be less than those specified, the coverage
rates for the paint shall be proportionally increased for the duration of
the Contract.
(5) If the bond strength results are not satisfactory, the concrete
surface shall be cleaned using high pressure water jetting in accordance
with Clause?13(2), followed by re-application and re-testing of the
coating in accordance with Clauses?15(1) to 15(4).
(7) The dew point shall be at least 5ΗC lower than the temperature
of the concrete surface before painting commences.
(8) Painting using water based paints shall not commence whilst the
relative humidity is above 85% or where it may be expected to exceed
90% during the 12 hour curing period.
(10) Where brush or roller techniques are used, the brushes or roller
heads shall be used for the day only and then discarded. The
equipment shall not be cleaned for re-use.
Coating 16 (1) Paint for application onto damp concrete surfaces shall be
Application specifically formulated for tolerance to moisture during application,
for Damp cure and in service.
Concrete Surfaces
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Notes
Clause 17
Severe drying can be taken to be a wind velocity of 3 m/s at 27 ± 2ΗC and 60 ± 5% relative humidity for 6 hours.
Clause 18
The frequency of carrying out the quality control tests listed at Appendix 13 depends on the size of the protective
coating contract or when the quality of the coating materials are suspected to have been changed.
The frequency of carrying out wet film thickness test is not fixed and is performed as required by the contractor and/or
engineer to ensure adequate film thickness has been applied.
The frequency of testing of dry film thickness of the protective coating by an approved laboratory is normally 1 per 50
square metres of applied coating.
The tests outlined in Appendix 13 are used as quality control tests to compare the properties of the coatings samples
before and during coating works. The basic acceptance criteria is that the average of the results from an individual
test is equal to the properties measured before the coating work and is within the agreed standard deviation which
may be obtained from the coating suppliers.
Responsibilities for tests and test results representation need to be specified in the Contract, e.g. 3 pull-off tests to
form a sample set and one sample set per 50 m² of applied coating or per production of one continuous application
shift, whichever is less.
The bond strength measured from a site test is normally slightly lower than that obtained from a laboratory test.
However, the acceptance criterion of average bond strength being above 1.2MPa mentioned in Clause 8.5(7) at
Appendix 8 should not be relaxed as this should be achievable for coatings applied properly.
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Paint Finish 17 All paints shall be free from cracking, wrinkling or other defects when
exposed to severe drying conditions.
(2) During the execution of the painting works the Engineer shall
randomly select samples of paint for comparison with the initial
samples in accordance with the methods stated in Appendix?13.
(3) The Contractor shall store all empty paint tins which have been
used in the Works, along with site delivery tickets, for inspection by
the Engineer who shall then authorize disposal of the tins.
Notes
Clause 19
The general purpose of applying anti-carbonation coatings is to protect buildings and structures directly exposed to
the atmosphere and ingress of carbon dioxide, and to satisfy aesthetic considerations.
The coating generic types expected to have good performance are acrylic, vinyl and polyurethane. The generic types
not likely to perform well are polyethylene, epoxy, tar epoxy, chlorinated rubber, bituminous, cementitious, silicone
and silicate.
The recommended R-values of coating systems for different concrete grades for both new and older construction are :
15 150
20 100
25 50
35 25
45 25
The R-values quoted are designed to prevent the carbonation front reaching the steel reinforcement in a 60
year life cycle, assuming the cover is not less than 25 mm. Where the cover is less than 25 mm, the R-value
may need to be increased to achieve the 60 year life.
15 300
20 300
25 200
35 100
45 25
The R-values for old concrete have been calculated for a 5 year old structure, carbonating rapidly. The R-value
should limit further carbonation of the concrete from its present level (x mm) to (x + 5 mm) in a further 55
years.
In considering older construction, for structures of age > 5 years, use of the R-values in the above table will
limit carbonation to less than 5 mm over 60 years life. For younger structures (age < 5 years), the carbonation
may be more than 5 mm over the remaining years.
The above recommended R-values for older construction are only for guidance. For old structures with
sufficient carbonation data from a detailed survey, the Engineer should make reference to the notes on p.30
and p.32 in the calculation of the appropriate R-values for application of anti-carbonation coatings.
It is important that the coating achieves the R-value at the minimum expected DFT following application on site. The
target value for DFT (target mean DFT) is calculated from experience as the minimum DFT plus 33%.
The target mean DFT shall be the average DFT achieved by the contractor. If either the minimum DFT measured on site
is less than the specified minimum DFT or the average DFT on site is less than the specified target mean DFT, then a
thicker coating will need to be applied to meet the specifications.
The dry film thickness (DFT) shall be converted to wet film thickness (WFT), allowing for losses, to get a correct
coverage (L/m²). The target mean WFT shall be used by the contractor/supplier to calculate actual coverage rates and
not the minimum DFT or WFT which is commonly done.
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(3) The DFT used to calculate the R-value for the paint system shall
be the minimum DFT to be achieved in service. The target mean DFT
shall be greater than the minimum DFT by 33%.
(4) The paint shall be applied in two coats. The minimum DFT
shall be not less than 150?µm.
(5) The SD value of the paint system at the mean DFT shall not
exceed 4?m equivalent air layer resistance and shall be measured in
accordance with Appendix?1.
(7) The paint system shall not support algal growth, when measured
in accordance with Appendix?12.
(8) Water uptake by the paint system shall be zero when measured
in accordance with Appendix?10.
Notes
Selection of Anti-carbonation Coatings for Application to Old Construction with Sufficient Carbonation Data from a
Detailed Survey
The first step is to estimate the carbonation coefficient of the concrete, by measurement of the carbonation depth
around the structure. This is done by taking the maximum carbonation recorded or a value that more appropriately
represents the carbonation state of the structure (Xo), and substituting into equation (1) to obtain the carbonation
coefficient (D),
Xo²
D= (1)
2To
where
The second step is to select the parameters necessary for estimating the required R value of the coatings as follows :
(a) Maximum depth of carbonation before reinforcing bar becomes active (XM).
(b) Required design life of the structure (TM).
(1)
According to Engelfried , depth of carbonation for older construction with a coating applied at some point after
construction is given by :
½
X = (Sc² + K) - Sc (2)
where
Thus, in order to determine the necessary performance of a coating, the appropriate parameters are fed into equation
(2), as follows :
½
XM = (Sc² + K) - Sc (3)
and
K = 2ScXo + Xo² + 2D(TM - To)
R = Sc ηµc (5)
where
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Notes
Notes
Example
A 7-year old concrete structure was found to have a carbonation depth ranging from 15 mm to 23 mm. It was proposed
to select an anti-carbonation protective coating to reduce further carbonation to less than 5 mm in the next 25 years.
Solution
Xo²
D =
2To
23²
=
2 η7
2
= 38 mm /year.
= 163 mm
R = 163 η400 mm
= 65200 mm
= 65 m (say)
Hence the Engineer should select a coating which has the property of R 3 65m. Provided that the coating is applied
properly with sufficient film thickness and that degradation of the coating under natural weathering will not reduce the
R value of the coating to below 65 m, then the carbonation front will not advance more than 5 mm in the next 25 years.
If the coating is expected to degrade to R < 65 m within the design life, then recoating will be required. The Engineer
will thus need to consider the need to recoat the structure to ensure a continuous, high performance barrier is present.
REFERENCE :
(1) Engelfried, R., "Carbonation of Unprotected Concrete and its Control by Means of Coatings", Defazet, V31, n9,
1977, pp 353-359.
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Notes
Clause 20
Situations occur where concrete is saturated on one face, but is exposed to the air or sea spray on others. Structures
which are subject to these conditions include water towers, swimming pools and subways.
Where this occurs, coatings must not form a barrier to the passage of water vapour through the concrete, otherwise
blistering of the coating may occur. The thickest area of the coating will be at greatest risk from blistering, hence the
maximum thickness is specified for testing in accordance with Appendix 1 of this Model Specification.
Coatings which are suitable for application in these conditions include the higher performance acrylics and
cementitious coatings. Coatings which are unlikely to be suitable include barrier coatings based on epoxy and
polyurethane resins.
Clause 21
Paints which would be expected to comply with Clause 21 are moisture curing or two-component polyurethane based
systems, with the property to penetrate into the concrete surface. These types of paint may not necessarily be
compatible with all the requirements contained in Clauses 19 & 20.
Clause 22
The coatings applied to structures in the splash zone and atmospheric zone should have good resistance to U.V.,
abrasion, and be suitable for application under high humidity/moisture conditions. The aesthetic considerations are
normally of secondary importance.
Suitable coating systems include acrylic and polyurethane. Epoxy and coal tar epoxy may also be used if protected
from sunlight. Coating systems not appropriate for wet applications or not suitable for splash zones are water based
coatings and soft coatings such as bituminous coatings.
Water-repellent systems such as silanes are not suitable for lower grade concrete, as rapid carbonation would occur.
However, for new construction of Grade 45 and above or where carbonation is not a concern, the R-value requirement
may be waived, allowing the use of water-repellent systems. The non-film forming water repellent system should be
specified to comply with Clauses 22(2) and 22(3), at the manufacturer's minimum recommended coverage rate. Also,
the treated concrete should be resistant to water uptake when measured in accordance with Appendix 10 of this Model
Specification, both before and after artificial weathering to 4000 hours in accordance with Appendix 3 of this Model
Specification.
Clause 23
The coatings applied to structures in the tidal zone will be subject to abrasion from various floating objects and
possible contamination by oils and solvents.
Coating systems such as cross-linking high performance epoxy, coal tar epoxy and polyurethane are normally
effective for immersed conditions. Heavily modified cement based coatings may not be suitable for permanent
immersion and are not recommended.
For structural elements subject to flexural cracking under load, the paint system should be specified not to fail under
1000 cycles of flexure when tested in accordance with Appendix 6 of this Model Specification at a temperature of 27 ±
2ηC.
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Back Pressure 20 (1) The requirements for paints applied to new concrete or to old
Acting on concrete shall be in accordance with Clause 19, except as stated in
Coatings Clauses?20(2) and 20(3).
(2) The SD of the paint system shall not exceed 4?m equivalent air
layer resistance at the maximum DFT, measured in accordance with
Appendix?1. The maximum DFT shall not be greater than 1.5 times the
target mean DFT.
Concrete 23 (1) The paint system shall be formulated for application onto
Subject to surface dry but saturated concrete in the tidal range.
Cyclic
Immersion (2) The paint system shall cure rapidly between the tidal cycles,
in Seawater such that it may be immersed in seawater within 3 hours of
application.
Notes
Clause 24
Water repellent systems such as silanes are not suitable for lower grade concrete, as rapid carbonation would occur.
However, for new construction of Grade 45 and above or where carbonation is not a concern, the R-value requirement
may be waived, allowing the use of water repellent systems. The non-film forming water repellent system should be
specified to comply with Clauses 22(2) and 22(3), at the manufacturer's minimum recommended coverage rate. Also,
the treated concrete should be resistant to water uptake when measured in accordance with Appendix 10 of this Model
Specification, both before and after artificial weathering to 4000 hours in accordance with Appendix 3 of this Model
Specification.
Clause 26
Coatings will be immersed and subject to a variety of chemicals, including possible acid attack due to sulphur
oxidizing bacteria.
Coating systems such as cross-linking high performance epoxy, coal tar epoxy and polyurethane normally perform
well under exposure to sewage.
Where the concrete structure is expected to crack, perhaps due to shrinkage or flexural movement, the paint system
should be specified to be reinforced with glass-fibre fabric, of density 280-300 g/m² open weave lapped by 25 mm at its
edges. In such circumstances, the minimum DFT of the system would be expected to exceed 1 mm.
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(5) The paint shall be applied in two coats. The minimum DFT
shall be not less than 150?µm.
Concrete 24 (1) The paint system shall comply with Clauses 20 or 28, except as
Water stated in Clauses?24(2) and 24(3).
Retaining
Structures (2) The paint system shall be resistant to the ingress of salt spray,
Subject to Salt when measured in accordance with Appendix?4.
Spray
(3) The paint system shall be resistant to salt spray in accordance
with Clause 24(2) after 4000 hours artificial weathering to Appendix?3.
Concrete 25 (1) The paint system shall comply with Clause 20 or 28, except as
Subject to stated in Clauses?25(2) and 25(3).
Chloride
Back- (2) The paint system shall be resistant to the ingress of salt spray,
penetration when measured in accordance with Appendix?4.
from Soil
(3) The paint system shall be resistant to salt spray in accordance
with Clause?25(2) after 4000 hours artificial weathering to Appendix?3.
(2) The paint system complying with Clause 26(1) shall be tested in
accordance with Appendix?9, using 1% sulphuric acid test solution,
and shall not deteriorate over a 3 month test duration.
Notes
Clause 27
In this environment, coatings may be immersed in strong acids, alkalis and solvents.
Coating systems such as high performance solvent free epoxy and coal tar epoxy with at least 400 µm DFT are likely to
be suitable.
Where the concrete structure is expected to crack, perhaps due to shrinkage or flexural movement, the paint system
should be specified to be reinforced with glass-fibre fabric, of density 280-300 g/m² open weave lapped by 25 mm at its
edges. In such circumstances, the minimum DFT of the system would be expected to exceed 1 mm.
Clause 28
The ability of concrete to crack, opening to widths from hairline to 0.3 mm, places very high stresses on paint films. In
order to bridge cracks successfully the coating must have a substantial thickness, typically with a minimum DFT of at
least 300 µm, and be elastomeric or plastomeric in physical terms.
Elastomeric coatings for concrete are typically polyurethane based, whereas plastomeric are soft acrylic copolymer
formulations, which commonly have high rates of dirt pick-up and may need cosmetic top coats.
Alternative approaches are either to reinforce over the crack with glass-fibre fabric, or to chase out the crack, fill the
chase with sealant and then apply a conventional paint.
It is unlikely that crack-bridging paint systems will perform adequately when applied over existing brittle paint finishes.
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Resistance 27 (1) The paint system shall be applied in at least two coats. The
to Highly minimum DFT shall be not less than 275?µm and the target mean DFT
Aggressive shall be not less than 400?µm,
Chemicals
(2) The paint system complying with Clause 27(1) shall be tested in
accordance with Appendix?9. The coating shall not deteriorate over a
3 month test duration.
(a) The paint system shall not fail under 1000 cycles of
flexure, when tested in accordance with Appendix?6 at
temperatures of 5 ¡ C and 27 ¡ C at the minimum
DFT.
Notes
Clause 30
This Clause relates to applications on concrete in the splash or tidal zone that remains saturated beneath the concrete
surface.
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(4) The target mean DFT shall be at least 33% greater than the
minimum DFT.
(5) The paint shall be applied in two coats. The minimum DFT
shall be not less than 150?µm.
Wet Concrete 30 (1) Paint for application in the tidal and splash zone shall comply
Surfaces with Clauses 29(1) to 29(8).
(2) All concrete surfaces to receive paint shall be free from surface
water at the time of application.
Notes
Listed below are short lists of some types of coating system studied by Consultancy Agreement No. 47/88
Recommended
Coating system Supplier Generic Type DFT (microns)
Recommended
Coating system Supplier Generic Type DFT (microns)
Notes
Recommended
Coating system Supplier Generic Type DFT (microns)
Recommended
Coating system Supplier Generic Type DFT (microns)
Notes
Recommended
Coating system Supplier Generic Type DFT (microns)
Recommended
Coating system Supplier Generic Type DFT (microns)
Recommended
Coating system Supplier Generic Type DFT (microns)
APPENDIX 1
Scope 1.1 This method covers the determination of the water vapour diffusion
resistance of coatings for concrete by measuring the water vapour
transmission through a coated composite.
Test 1.2 Unglazed ceramic tiles of 100 x 100 x 5 mm size shall be used as the
Substrate substrate. The tiles shall be of uniform quality and from a single batch,
free from contamination.
Procedure : 1.3 (1) The tiles and all materials shall be conditioned for 24 hours at
Preparation the application conditions of 27 ¡ C and 80 ¡ 5 %rel ati ve hu m
i dit y
of
Specimens (2) The coating system shall be applied in accordance with the
manufacturer’s instructions, using all necessary primers and
undercoats, and coverage rates shall be checked by weighing.
Procedure : 1.4 (1) The sample shall be set in a metal cell using silicone rubber,
Determination such that the uncoated face shall be sealed above a reservoir of distilled
of Water water.
Vapour
Transmission (2) The unit shall be placed in a desiccator at 27 ¡ C and 0%
Rate relative humidity. The change in weight of the unit with time shall be
measured periodically.
Calculation 1.5 (1) The water vapour transmission rate for the coated tile shall be
calculated in accordance with the equation :
dG
WVT = (g/m2 per 24 hr)
T.A
where :
(2) The water vapour diffusion coefficient shall be calculated for the
composite, from which the diffusion coefficient for a measured mean
thickness of coating shall be obtained. The water vapour diffusion
coefficient for the composite shall be calculated from the equation :
WVT . tT
dT = (cm2/s)
H2O
Pw
where :
tT tt tc
= +
dT dt dc
H2O H2O H2O
where :
(4) The equivalent air layer resistance of the coating to the diffusion
of water vapour shall be calculated from the equation :
da
H2O
SD = tc (m)
dc
H2O
where :
APPENDIX 2
Scope 2.1 This method covers the determination of the carbon dioxide diffusion
resistance of coatings for concrete by measuring the flow rate of a
mixture of oxygen and carbon dioxide gas through a coated composite.
Test 2.2 Unglazed ceramic tiles of 100?mm x 100?mm x 5?mm size shall be
substrate used as the substrate. The tiles shall be of uniform quality and
preferably from a single batch, free from contamination.
Procedure : 2.4 (1) The tiles and all materials shall be conditioned for 24 hours at
preparation the application conditions of 27 ¡ ♦C and 80 ¡ 5 %rel ati ve hu m
i dit y
of
specimens (2) The coating system shall be applied in accordance with the
manufacturer’s instructions, using all necessary primers and
undercoats, and coverage rates shall be checked by weighing.
Procedure : 2.5 (1) After conditioning, the coated sample shall be carefully placed
determination in the test chamber.
of gas flow
rate (2) The gas cylinders shall be turned on and the gas flow rates
monitored to obtain the same flow rate and pressure on both sides of
the coated tile.
(4) The carbon dioxide and oxygen diffusion rate through the coated
tile composite shall then be measured by gas chromatography.
Calculation 2.6 (1) The flux rate for carbon dioxide shall be calculated as the carbon
dioxide diffusion coefficient for the composite using Ficks first law of
diffusion :
QxL
d= (cm2/s)
AxC
where :
tT tt tc
= +
dT dt dc
CO2 CO2 CO2
where :
(3) The relative carbon dioxide diffusion coefficient for the coating
shall be expressed as a dimensionless ratio, as follows :
da
CO2
µ =
dc
CO2
where :
µ is the relative carbon dioxide diffusion coefficient of the
coating,
R = µ . t (m)
where :
R is the equivalent air layer thickness (R-value) (m),
R
Sc = (m)
µc
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where :
APPENDIX 3
Scope 3.1 This method covers the determination of the weathering resistance of
coatings for concrete, applied to various substrates, using a QUV
artificial weathering cabinet.
Method 3.4 (1) Coated specimens shall be located in the specimen tray of the
QUV weatherometer.
APPENDIX 4
Scope 4.1 This method covers the determination of the salt spray resistance of
coatings for concrete by using a salt spray cabinet.
Procedure : 4.3 (1) Concrete of Grade 20/20 shall be used to prepare the specimens.
preparation The approximate mix proportions shall be in accordance with Table
of 4.1 and trial mixes shall be used to finalize the concrete mix.
specimens
(4) After mixing, the concrete shall be placed and compacted within
30 minutes into cleaned, lightly oiled moulds. The concrete shall be
finished by trowelling with a wood float, and then covered with
polythene sheeting for 24 hours.
(5) After 24 hours, the mould shall be stripped and the panels shall
be wrapped in polythene sheeting and stored at 27 ¡ ∪C for at least 28
days, until ready for coating application.
(6) The test face shall be the moulded 500?mm x 500?mm side of
the panel.
(13) 2 coated core samples shall be cut in half and the maximum,
minimum and mean DFT measured using a travelling microscope; the
mean value shall be taken from at least 30 observations.
(14) The concrete surfaces of the core shall be encased on all sides
with a 5?mm layer of epoxy resin, except for the coated face.
(15) After the epoxy resin has hardened and fully cured, the
specimens shall be placed in a salt spray cabinet ready for testing.
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Procedure : 4.4 (1) The specimen shall be mounted in the salt spray cabinet and
determination shall be tested in accordance with the following weathering cycle :
of salt spray
resistance 4 hours salt water spray at 40∪C,
8 hours drying at 40∪C and 30% relative humidity
(4) The chloride content result for the coating shall be calculated as
the mean of two determinations.
(g) The results for the salt spray resistance of the coating,
expressing the coating as resistant at the mean DFT, if the
chloride content in the 5-10?mm increment range and
deeper is ∪0.04%, or not resistant at the mean DFT, if the
chloride content is >0.04%, both before and after
weathering.
APPENDIX 5
Scope 5.1 This method covers the determination of the salt water immersion
resistance of coatings for concrete by immersing in artificial seawater.
Procedure : 5.3 (1) Concrete of Grade 20/20 shall be used to prepare the specimens.
preparation of The approximate mix proportions shall be in accordance with Table
specimens 1.5.1 and trial mixes shall be used to finalize the concrete mix.
(4) After mixing, the concrete shall be placed and compacted within
30 minutes into cleaned, lightly oiled moulds. The concrete shall be
finished by trowelling with a wood float, and then covered with
polythene sheeting for 24 hours.
(5) After 24 hours, the mould shall be stripped and the panels shall
be wrapped in polythene sheeting and stored at 27 ¡ ∪C for at least 28
days, until ready for coating application.
(6) The test face shall be the moulded 500?mm x 500?mm side of
the panel.
(13) 2 coated core samples shall be cut in half and the maximum,
minimum and mean DFT measured using a travelling microscope; the
mean value shall be taken from at least 30 observations.
(14) The concrete surfaces of the core shall be encased on all sides
with a 5?mm layer of epoxy resin, except for the coated face.
(15) After the epoxy resin has hardened and fully cured, the
specimens shall be placed in a container above a tank of artificial
seawater, ready for testing.
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Procedure : 5.4 (1) The specimens shall be immersed in artificial seawater and shall
determination be tested in accordance with the following weathering cycle?:
of salt water
immersion 6 hours immersion in artificial seawater at 1 metre depth at 27 i
resistance 2∪C,
(4) The chloride content result for the coating shall be calculated as
the mean of two determinations.
(g) The results for the salt water immersion resistance of the
coating, expressing the coating as resistant at the mean
DFT, if the chloride content in the 5-10?mm increment
range and deeper is ∪0.04%, or not resistant at the mean
DFT, if the chloride content is >0.04%, both before and
after weathering.
APPENDIX 6
Scope 6.1 This method covers the determination of the dynamic crack bridging
resistance of coatings for concrete based on German BAM
ZVT-BEL-OS recommendations.
Procedure : 6.4 (1) Sand-cement mortar shall be used to prepare the specimens in
preparation the proportions stated in Table 6.1; trial mixes shall be used to finalize
of the mortar mix.
specimens
(2) The PVC sleeve shall be fitted onto the central region of the
prestressing strand.
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(5) The surface shall be struck off and finished with a wood float.
(7) After 3 days curing, the mould shall be stripped and the prism
shall be wrapped in polythene sheeting and stored at 27 ¡ Ó ∪C for 28
days.
(8) The floated surface of the prism shall be the test surface to
receive the coating, as shown in Figure 6.2.
Procedure : 6.5 (1) The coated test specimen shall be fixed into the testing
determination equipment.
of crack-
bridging (2) The specimen shall be set to produce an initial crack width of
resistance 0.05?mm (Wu) with a manual or electronic movement gauges fixed to
the side of the specimen over the crack.
(3) The maximum crack width for the test shall be set to 0.3?mm
(Wo).
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(4) The frequency of the test for the opening of the crack shall be set
to 1?Hz.
(5) The equipment and the coated test specimen shall be maintained
in the test cabinet at 27 ¡ ∪C and 80 ¡ 5 %rel ati ve hu m
i dit y
(6) The test shall be started by cycling the test specimen with the
crack opening between Wu and Wo in a sine wave form for 1000
cycles.
(7) After 1000 cycles, the coated surface shall be examined with a
magnifying glass to check for cracks.
(8) The test shall be repeated with a new specimen of the same
coating system but shall be tested in the test cabinet at 5 ¡ ∪C and 70
¡ Ó5 %rel ati ve hu m
i dit y
APPENDIX 7
Scope 7.1 This method covers the determination of the water permeability
resistance of coatings for concrete by laboratory based and portable
in-situ permeability cells.
Equipment 7.3 (1) The laboratory based permeability cell may be of various
designs, and shall comprise the following :
(c) A perspex window to fit into the centre of the top ring.
(g) Stainless steel bolts to hold the top ring and bottom plate
together.
Procedure : 7.4 (1) Concrete of Grade 20/20 shall be used to prepare the specimens
preparation and the approximate proportions shall be in accordance with Table?7.1;
of trial mixes shall be used to finalize the concrete mix.
specimens
Table 7.1 Mix proportions for concrete specimens
(4) After mixing, the concrete shall be placed and compacted within
30 minutes into cleaned, lightly oiled moulds. The concrete shall be
finished by trowelling with a wood float, and then covered with
polythene sheeting for 24 hours.
(5) After 24 hours, the mould shall be stripped and the panels
wrapped in polythene sheeting and stored at 27 ¡ C for at least 28
days, until ready for coating application.
(6) The test face shall be the moulded 500?mm x 500?mm side of
the panel.
(13) 2 coated core samples shall be cut in half and the maximum,
minimum and mean DFT measured using a travelling microscope; the
mean value shall be taken from at least 30 observations.
(14) The top coated surface and the bottom concrete surface of the
core shall be masked with drafting tape and the specimen placed in a
lightly greased tapered brass sleeve without O-ring seals.
(15) The void between the concrete and the sleeve shall be filled with
epoxy resin.
(16) After the epoxy resin has hardened and fully cured, the
specimens shall be removed from the sleeve and the drafting tape shall
be removed from both surfaces.
Procedure : 7.5 (1) The short term water permeability resistance of the coating
determination system shall be determined as follows :
of water
permeability (a) The specimen shall be placed in the permeability rig with
by laboratory all the bolts tightened.
test rig
(b) The water, at 2 bar pressure (20?m head), shall be applied
through the rig to the bottom (uncoated) face of the
specimen.
(c) The time for water to appear through the coated face shall
be recorded over a 24 hour period.
Procedure : 7.6 The procedure from the operation manual of the CLAM In-situ
determination Permeability Tester shall be followed.
of water
permeability
by CLAM
Tester
APPENDIX 8
Scope 8.1 This method covers the determination of the bond strength of coatings
for concrete by the direct pull-off test.
Equipment 8.3 The LIMPET tester developed by Queen’s University, Belfast, shall be
used.
Procedure : 8.4 (1) Concrete of Grade 20/20 shall be used to prepare the specimens
preparation of and the approximate proportions shall be in accordance with Table?8.1;
specimen trial mixes shall be used to finalize the concrete mix.
(4) After mixing, the concrete shall be placed and compacted within
30 minutes into cleaned, lightly oiled moulds. The concrete shall be
finished by trowelling with a wood float, and then covered with
polythene sheeting for 24 hours.
(5) After 24 hours, the mould shall be stripped and the panels shall
be wrapped in polythene sheeting and stored at 27 ¡ C for at least 28
days, until ready for coating application.
(6) The test face shall be the moulded 500 x 500?mm side of the
panel.
(13) 2 coated core samples shall be cut in half and the maximum,
minimum and mean DFT measured using a travelling microscope; the
mean value shall be taken from at least 30 observations.
Procedure : 8.5 (1) The coated surface of each partial core shall be degreased with
determination alcohol and a steel dolly shall be bonded onto the coating using fast set
of bond epoxy adhesive.
strength
(2) After the epoxy has cured and hardened, the Limpet tester shall
be set over the dolly and the pull rod shall be screwed into the thread
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of the dolly.
(3) The test procedure outlined in the operation manual of the tester
shall be followed.
(8) Failure of the dolly adhesive to bond to the coating (Type 3c),
indicates poor dolly preparation and a repeat test shall be carried out.
(f) The results for the bond strength of the coating, being
satisfactory or otherwise, and comments on the modes of
failure, where applicable.
APPENDIX 9
Scope 9.1 This method covers the determination of the resistance of coatings for
concrete to aggressive liquids.
Procedure : 9.3 (1) Concrete of Grade 20/20 shall be used to prepare the specimens
preparation of and the approximate proportions shall be in accordance with Table?9.1;
specimen trial mixes shall be used to finalize the concrete mix.
(5) After 24 hours, the mould shall be stripped and the panels shall
be wrapped in polythene sheeting and stored at 27 ¡ C for at least 28
days, until ready for coating application.
(6) The test face shall be the moulded 500?mm x 500?mm side of
the panel.
(13) 2 coated core samples shall be cut in half and the maximum,
minimum and mean DFT measured using a travelling microscope; the
mean value shall be taken from at least 30 observations.
Procedure : 9.4 (1) A perspex cylinder of 80?mm internal diameter shall be bonded
determination onto the coated surface of the 100?mm core using epoxy resin
of resistance adhesive.
to aggressive
liquids (2) The specimen and chemicals to be used shall be conditioned at
40 ¡ C for 24 hours prior to commencing the test.
(3) The chemicals shall be poured into the cylinder to pond onto the
coated concrete surface to a depth of 10?mm and the arrangement
maintained at 40 ¡ C throughout the test.
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(5) After testing for three months, the coating shall be considered
resistant to chemicals if no noticeable deterioration has been found in
either of the two specimens tested.
APPENDIX 10
Scope 10.1 This method covers the determination of the water uptake of coatings
for concrete by the method of BS?1881:Part?5, Initial Surface
Absorption Test (ISAT).
Procedure : 10.3 (1) Concrete of Grade 20/20 shall be used to prepare the specimens
preparation and the approximate proportions shall be in accordance with
of Table?10.1; trial mixes shall be used to finalize the concrete mix.
specimens
Table 10.1 Mix proportions for concrete specimens
(4) After mixing, the concrete shall be placed and compacted within
30 minutes into cleaned, lightly oiled moulds. The concrete shall be
finished by trowelling with a wood float, and then covered with
polythene sheeting for 24 hours.
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(5) After 24 hours, the mould shall be stripped and the panels shall
be wrapped in polythene sheeting and stored at 27 ¡ C for at least 28
days, until ready for coating application.
(6) The test face shall be the moulded 500 x 500?mm side of the
panel.
(13) 2 coated core samples shall be cut in half and the maximum,
minimum and mean DFT measured using a travelling microscope; the
mean value shall be taken from at least 30 observations.
Procedure : 10.4 (1) After calibrating the ISAT equipment, the circular cap shall be
determination sealed onto the coated concrete panel with oil-based modelling clay.
of water
uptake (2) The test shall be performed in accordance with BS?1881:Part?5.
(3) The rate of water uptake into the coated panel shall be
determined after 10 minutes, 30 minutes, 1 hour and 2 hours, and shall
be calculated to the nearest 0.005?mL/m2s.
(5) The test shall be repeated at a second location and the mean
result obtained.
APPENDIX?11
Scope 11.1 This method covers the determination of the impact resistance of
coatings for concrete, by falling weight indenter.
Equipment 11.3 (1) The standard equipment to BS?3900:Part E3, fitted with a
14?mm diameter indentor and 4.75?kg weight.
Procedure : 11.4 (1) Concrete of Grade 20/20 shall be used to prepare the specimens
preparation and the approximate proportions shall be in accordance with
of Table?11.1; trial mixes shall be used to finalize the concrete mix.
specimens
(4) After mixing, the concrete shall be placed and compacted within
30 minutes into cleaned, lightly oiled moulds. The concrete shall be
finished by trowelling with a wood float, and then covered with
polythene sheeting for 24 hours.
(5) After 24 hours, the mould shall be stripped and the panels shall
be wrapped in polythene sheeting and stored at 27 ¡ C for at least 28
days, until ready for coating application.
(6) The test face shall be the moulded 200?mm x 200?mm side of
the panel.
(13) 2 coated core samples shall be cut in half and the maximum,
minimum and mean DFT measured using a travelling microscope; the
mean value shall be taken from at least 30 observations.
Procedure : 11.5 (1) Two test specimens shall be used for each determination,
determination conditioned at 5 ¡ C and 70 ¡ 5 %rel ati ve hu m i dit y, and at 27 ¡ C
of impact and 80 ¡ 5 %rel ati ve hu m
i dit y respecti vel y f or 24 hours bef ore t esti ng
resistance
(2) In order to prevent flexural failure under impact load, each
specimen shall be located in a bed of sand which will absorb the
impact stress wave.
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(6) The continuity of the coating after the test shall be measured
using an ISAT type of tester as stated in Appendix?10 at a water
column head of 225?mm.
(g) The results for water uptake of the impact area, being
classed as either satisfactory or not satisfactory after
impact at the mean DFT.
APPENDIX 12
Scope 12.1 This method covers the determination of the algae resistance of
coatings for concrete based on SISIR test method.
Procedure : 12.4 (1) A special primer or pretreatment (e.g. hydrofluoric acid etch) for
preparation the glass shall be applied to the inner surfaces and edges of the glass
of petri dishes for bonding purposes, according to the manufacturer’s
specimens instructions.
(4) The coating system shall be applied to the inner surfaces and
edges of two sterilized, petri dishes in accordance with the
manufacturer’s instructions.
Procedure : 12.5 (1) The two coated petri dish specimens shall be artificially
determination weathered to 4000 hours in accordance with Appendix 3.
of algae
resistance (2) After weathering, the specimens shall be inoculated with the
algal species by adding 2?mL of algae culture onto two coated and two
uncoated petri dishes. The culture shall be spread on the surface as
evenly as possible, so that it covers approximately 10% of the bottom
of the surface of the petri dish.
(3) After inoculation with the algae culture, the petri dishes shall be
covered with dish covers and subjected to exposure under fluorescent
lighting at a temperature of 27 ¡ C using a lighting cycle of 12 hours
on followed by 12 hours off.
(6) At the end of the test, the growth intensity of algae on the
coating samples shall be compared with those of the blank controls.
(7) The coating shall be considered to have passed the test if the
algae culture is killed, as evidenced by the bleaching of the green
colour. Any growth shall be compared with the increase in algal
growth in the blank petri dishes.
(f) The results for the algal resistance of the coating system,
being classed as either resistant or non-resistant to algal
growth at the estimated DFT.
- 100 -
- 101 -
APPENDIX 13
Scope 13.1 This appendix covers the test methods for site quality control of
coatings for concrete.
Method : 13.2 (1) A 200 mL coating sample shall be poured into a pre-weighed
determination disposable metal container and the sample shall be weighed.
of volatile
content (2) The sample shall be dried in a ventilated oven at 105 ¡ 5C for 3
hours.
Wo - Wd
Wv = x 100%
Wo
where :
Method : 13.3 The fineness of grind of the coating shall be determined in accordance
determination with the method stated in ASTM D?1210, using a grindometer at a
of fineness of temperature of 27 ¡ C.
grind
Method : 13.4 The viscosity of the coating shall be measured in accordance with the
determination flow cup method stated in BS?3900:Part A6, 1986 at a temperature of
of viscosity 27 ¡ C.
Method : 13.5 The specific gravity of the coating shall be determined in accordance
determination with the density bottle method stated in BS?3900:Part A12, 1975 at a
of specific temperature of 27 ¡ C.
gravity
Additional 13.6 If instructed by the Engineer, coating samples shall be sent for
Testing labelling using infra-red spectography and pyrolysis gas
chromatography, and the results shall be compared with master data
supplied by the manufacturer.
- 102 -
- 103 -
APPENDIX 14
Scope 14.1 This appendix covers the test methods for checking the film thickness
and continuity of coatings for concrete.
Method : 14.2 (1) For rough concrete surfaces, the measurement of film thickness
determination shall be obtained from a microscopic examination of the coated surface
of thickness of core samples, that have been either purpose-cut or taken from other
tests.
(2) Spot checks shall be made by drilling a tapered hole into the
film using an Erichsen Paint Borer and measuring the thickness and
number of coats.
Method : 14.3 (1) The continuity of the coating shall be measured using a concrete
determination resistivity meter. One lead of the meter shall be connected to the
of continuity reinforcing cage in the concrete, in contact with the bar beneath the
area of coating under test. The circuit shall be completed by using a
sponge contact unit soaked in a suitable electrolyte, which is pressed
onto the coated concrete surface.
APPENDIX 15
Method : 15.2 The adhesion test shall be carried out in accordance with the cross-cut
cross-cut test stated in ASTM?D?3359-83, except as modified below?:
test
(a) The coated surface shall be scribed with 11 parallel cuts,
made using a sharp cutting tool to BS?3900:Part?E6
against a steel straight edge. The cuts shall be spaced at
3?mm centres and each shall be at least 50?mm in length.