Procedure for Surface Preparation and Coating

AARTI INDUSTRIES LIMETED-
JHAGADIA
Procedure for Surface Preparation and Coating

Document No.: AIL/JHAGADIA/PAINTING/PROJECT/01
Issue No.: 1, Rev. No.: 0, Date: 01/08/2019
1 0 VAKUL CHAUHAN MANOJ Harendra Pandya

KUMBHARE/
SAMIR DAVE
Issue Rev. Prepared By Reviewed Approved By

No.
This document is the property of AARTI INDUSTRIES LTD.

and must not be copied or lent without their permission in writing.
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AARTI SPECIFICATION
FOR SURFACE
Doc. No. AIL/JHAGADIA/PAINTING/01
INDUSTRIES PREPARATION &
COATING
Rev. 1 Date: 01/08/2019
LIMITED
CONTENTS
1.0 SCOPE
2.0 REFERENCES
2.1 Industry Codes and Standards
3.0 DEFINITION AND ACRONYMS
4.0 GENERAL
4.1 Safety Precautions
4.2 Brands & Products
4.3 Contractor Requirements
4.4 Coating Manufacturer’s Data Sheets
4.5 Coating Procedure Test (CPT)
4.6 Mixing of Coatings of Different Coating Manufacturers
4.7 Color
4.8 Pre-Construction Primers
4.9 Paint Free Surfaces
5.0 SURFACE PREPARATION

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5.1 General Preparation for Abrasive Blasting
5.2 Preparation for Abrasive Blasting
5.3 Hand or Power Tool or Water jet Cleaning
5.4 Abrasive Blasting
6.0 COATING APPLICATION
6.1 General Application Requirements
6.2 Weather Conditions
6.3 Materials
6.4 Mixing and Thinning
6.5 Shelf and Pot Life
6.6 Stripe Coat
6.7 Spray Application
6.8 Priming
6.9 Top Coating
6.10 Film Thickness
6.11 Defects
6.12 Touch-Up
6.13 Brush or Roller Application
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7.0 INSPECTION
7.1 General
7.2 Personnel
7.3 Inspection Equipment
7.4 Compressed Air Cleanliness
7.5 Abrasive Material
7.6 Environmental Conditions
7.7 Surface Preparation (Including Touch-Up Preparation)
7.8 Coating Application
7.9 Transportation, Handling and storage of coated components
7.10 Inspection by Company
7.11 Coating Manufacturer’s Representatives
8.0 GALVANIZING
8.1 Galvanizing Standard
8.2 Surface Preparation
8.3 Zinc Coating Weight
8.4 Surface Finish
8.5 Welding
8.6 Damaged Items

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8.7 Reinstatement of Damaged Surfaces
8.8 Painting Galvanized Surface
APPENDIX
Appendix A: Inspection & Testing Requirement
Appendix B: Finish Colour Schedule
Appendix C: Surface Preparation and Painting Inspection Record.
Appendix D: Generic Coating System
Appendix E: Approved Product List
Appendix F: Pipe Line color coding with IS shades
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1.0 SCOPE
This procedure covers the surface preparation, Paint application and paint materials
requirements for painting of Steel Bulk Piping items, Fabricated Piping, Supports and pipe
accessories.
2.0 REFERENCES
 The following documents are referenced herein and are considered part of this
Procedure.
 Use the edition of each referenced document in effort on the date of the publication of
this procedure.
 Any discrepancies or conflicts among these documents and the technical requirements
in this procedure shall be called to the attention of Company/Contractor for resolution.
2.21Industry Codes and Standards
American Society for Testing and Materials (ASTM)
D 610 Standard Test Method for evaluating degree of rusting on painted steel
surfaces
D1125 Standard Test methods for Electrical conductivity and Resistivity of water
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D4285 Standard Test Method for Indicating Oil or Water in Compressed Air
D4417 Standard Test Methods for Field Measurement of Surface Profile of Blast
Cleaned Steel
D4541 Standard test method for pull off strength of coatings using portable adhesion
testers
D4752 Standard Test Method for Measuring MEK Resistance of Ethyl Silicate
(Inorganic) Zinc-Rich Primers by Solvent Rub
D4940 Standard Test Method for Conductimetric Analysis of Water Soluble Ionic
Contamination of Blasting Abrasives
D 5064 Standard practice for conducting a patch test to assess coating compatibility
E337 Standard Test Method for Measuring Humidity with Psychrometer
(The Measurement of Wet-and Dry-Bulb Temperatures)
Society for Protective Coatings (SSPC)
PA1 Shop, Field, and Maintenance Painting of Steel
PA2 Measurement of Dry Coating Thickness with Magnetic Gages
PA3 A Guide to Safety in Paint Application
SP1 Solvent Cleaning
SP2 Hand Tool Cleaning

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SP3 Power Tool Cleaning
SP5 White Metal Blast Cleaning (NACE No.1)
SP7 Brush-off blast cleaning
SP10 Near White Metal Blast Cleaning (NACE No. 2)
SP11 Power Tool Cleaning to Bare Metal
Vol-1 Good Painting Practice
Vol-2 Systems & Specifications
SP COM Surface Preparation Commentary
VIS-1 Guide and Reference Photographs for Steel Surfaces Prepared by Dry
Abrasive Blast Cleaning
International organization for standardization (ISO)
ISO 9001 Quality management systems
ISO 2409 Paints & Varnishes – Cross Cut Test
ISO 2808 Paints & Varnishes – Determination of Film Thickness
ISO 3549 Zinc dust pigments for paints – specifications and test methods
ISO 4624 Paints & Varnishes – Pull Off Test
ISO 4628-2 Evaluation of degradation of coatings. Designation of quantity and size of

defects, and of intensity of uniform changes in appearance
Part 2: Assessment of degree of blistering
ISO 4628-4 Part 4: Assessment of degree of cracking
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ISO 8501 Preparation of Steel Substrate Before Application of Paints & Related
Products – Visual Assessment of Surface Cleanliness
ISO 8502 Preparation of Steel Substrates Before Application of Paints and Related
Products – Tests for the Assessment of Surface Cleanliness
ISO 8503 Preparation of Steel Substrates Before Application of Paints and Related
Products- Surface Roughness Characteristics of Blast Cleaned Steel Substrates
ISO 8504 Preparation of steel substrates before application of paints and related products
ISO 11124 Specification for metallic blast clean abrasives
ISO 11125 Test methods for metallic blast cleaning abrasives
ISO 11126 Specification for non-metallic blast clean abrasive
ISO 11127 Test methods for non-metallic blast cleaning abrasives
ISO 12944 Paints and Varnishes – Corrosion Protection of Steel Structures by Protective
Paint Systems
ISO 14877 Protective clothing for abrasive blasting operations using granular abrasives
ISO 19840 Paints & Varnishes – Coating Protection of Steel Structures by Protective
Paint Systems – Measurement of & Acceptance Criteria for the Thickness of
Dry Films on Rough Surfaces
ISO 20340 Paints & Varnishes – performance requirements for protective paint systems
for offshore and related structures
NACE International (NACE)
SP0188 Discontinuity (Holiday) Testing of New Protective Coatings
3.0 DEFINITION AND ACRONYMS

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AIL Aarti Industries Ltd. , Jhagadiya
Coating The Coating contractor is the party that is responsible for surface
Contractor preparation, priming and application of coating materials.
(AARTI-JHAGADIYA)
Abrasive The impingement of a high kinetic-energy stream of abrasive onto the
Blast surface to be prepared.
Chalking The appearance of a loosely adherent fine powder on the Surface of a paint
coating, arising from the degradation of one or more of its constituents,
typically caused by UV attack.
Cracking The splitting of a dry paint film.
CUI Corrosion Under Insulation.
Dew Point The temperature of a given air/water-vapour mixture at which, under

atmospheric pressure, condensation starts.
DFT Dry Film Thickness; the thickness of the dried or cured paint or coating film.
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Flaking The detachment of pieces of the paint film itself either from its substrate or
from paint previously applied. Cracking or blistering usually precedes
flaking.
HSE Health, Safety and Environment.
MSDS Material Safety Data Sheet.
NDFT Nominal (specified) Dry Film Thickness.
Pore Pinhole or very small size defect in a coating system, penetrating the entire
thickness of the coating.
Pot Life The time interval, after mixing of paint or coating materials, during which the
mixture can be applied without difficulty or loss of final coating quality.
Shop Primer Primers applied in a shop or manufacturing facility to provide temporary

protection to steel sheet or components during transport and/or fabrication.
Surface Contour of a blast-cleaned surface on a plane perpendicular to the surface.
Roughness
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TDFT Total Dry Film Thickness; the overall thickness of the total number of coats
in a paint system.
Thinner Volatile liquid added to lower the viscosity of the paint to ease application.
VOC Volatile Organic Compound.
WFT Wet Film Thickness; the thickness of the wet paint or coating.
Application Application instructions, recommendations, and guidelines described in
Data the published literature of the coating materials manufacturer, referenced
industry standards, and any specific requirements noted in specification
including drawings issued to the coater. In case of conflicting requirements

between the documents, coater shall submit all conflicting information to the
contractor for resolution. If the published literature of the manufacturer does
not contain required information, coater shall obtain additional information
from the manufacturer and forward the same information to the contractor.
Any deviations from or changes to Manufacturer’s published literature shall
be subject to contractor’s review, acceptance, or rejection without comment,
explanation and/ or justification.
Insulated Surfaces for which insulation requirements are specified or noted on the
drawings and
Surfaces related documentation and which will be insulated at a later time. Surfaces
requiring to be insulated for Personnel protection using open mesh guards
shall be painted as bare surfaces
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Operating The operating temperature which prevails inside piping during any intended
Temperature operation
Surface The temperature of the external surface of the metal exposed to weather
Temperature during normal operating conditions, generally the operating temperature shall
be considered as the surface temperature unless the item is internally

insulated or refractory lined. In the case of items with internal insulation or
refractory lining, the surface temperature is the temperature of external
surface exposed to weather. Higher temperatures required for piping steam
out, start up or other non-operating conditions shall not be considered as a
basis for paint systems selection unless specifically instructed in writing by
PMC/principal and acknowledged by the contractor.
Bulk Piping Pipe lengths, fittings, valves, supports and pipe accessories that are purchased
in bulk quantity and whose intended use in a specific piping system is
unknown at the time of purchase
Fabricated/ Fabricated or installed piping including fittings, pipe supports, and accessory
Installed items, whose operating temperature and insulation status are available on the
Piping drawings.
Coat One full layer of a coating material applied to its specified thickness. Multiple
passes including initial mist pass are necessary to form a coat. A mist pass is
not considered as a full coat.
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4.0 GENERAL
Protective coatings shall comply with AARTI JHAGADIYA IMS (Integrated management
system) and all applicable state, and local codes and regulations on surface preparation,
coating application, storage, handling, safety, and environmental requirements, including the
safety precautions in Section 4.0. The coating systems given in this procedure are suitable for
a C4 atmospheric environment as specified in ISO 12944-2 and also suitable for the
conditions during fabrication and construction.
4.1 Safety Precautions

a) All work shall be carried out in accordance with AIL health, Safety and Environment
(HSE) requirements and statutory regulations.
b) AIL shall ensure that all activities involved in the selection, application, inspection
and testing of protective coating systems are managed to ensure personnel safety,
minimal environmental impact and safe, operable facilities
c) AIL shall ensure implementation of safety measures for protecting workers in
accordance with all local and national regulations including provision of appropriate
personal protective equipment and training in its use, regular safety briefings/tool-box
talks, Job Safety Analysis.
d) AIL shall ensure implementation of appropriate training schemes to ensure necessary
competence to perform their allocated tasks
e) AIL shall ensure that the blasting and spraying equipment are in good condition and
well maintained, and blasting and painting equipment shall fully comply with the
local and / or regional regulations.
f) AIL shall ensure availability of fire-fighting equipment near to blasting & painting
locations
g) Abrasive blast cleaning equipment shall be of an intrinsically safe construction and
equipped with a remote shut off valve triggered by the release of a dead man’s handle
at the blasting nozzle.
h) The air fed personal protection equipment shall be of positive pressure fed by clean,
cool air supplied through a filter.
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i) Contractor shall ensure appropriate waste disposal and / or recycling systems to meet
all local, national requirements.
j) Contractor shall be aware of the many potential hazards involved in the preparation of
steel and the application of coatings.
k) Personnel involved at the job site shall review the hazard prior to beginning work.
l) All local, state, and health and safety regulations shall be complied with.
m) The coatings used shall be with minimum content for volatile organic compounds
(VOC).
n) Coating manufacturer’s recommended precautions regarding toxicity and safe
handling of all coating materials shall be followed.
o) Special care shall be observed when mixing (paints and thinner) to avoid fire hazards.
p) The abrasive blast nozzle and paint pumps shall be bonded (grounded) to the work
metal in order to prevent the buildup of electrostatic charges, which could cause a
spark discharge.
q) Nozzle blast operators shall wear a approved helmet or equivalent connected to a
source of clean air. All other persons exposed to the blast dust shall wear appropriate
respirator mask.
r) Adequate ventilation shall be provided during all work and for at least four hours after
the coating application, to keep solvent concentrations within safe, non-explosive
limits.
s) Provision of adequate access/scaffolding/working platforms shall be ensured to all
personals engaged for blasting and painting work
4.1.1 Hazardous Paint Material Components
a) AIL and Contractor shall ensure that all layers of a coating system and all abrasive
blasting materials comply with any local and/or regional standards or regulations on
banned materials such as lead, chromate, crystalline silica or coal tar.
b) All coating system shall fully comply with any local and/or regional air quality or
Volatile Organic Compounds (VOC) levels or emission standards or regulations.
c) Coatings shall contain a minimum monomeric isocyanate at the time of painting.
d) Handling and disposal of hazardous waste resulting from the AIL painting activities
shall be in accordance with local regulations.
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4.1.2 Access
a. Access for coating work shall be constructed so as to provide easy and sufficient
access for surface preparation, painting and inspection of all surfaces. Scaffolding
shall be constructed in accordance with local regulations and AIL HSE standared.
4.1.3 Weather protection
a) Contractor shall provide all the weather protection, scaffolding and other equipment
necessary to ensure that the work is carried out in accordance with this procedure and
the agreed programme.
4.2 Brands & Products
a) Contractor shall only use paint material complying with state, and local air pollution
regulations.
b) Coating systems shall be as per Appendix-D.
c) While selecting coating systems, environmental conditions of application site shall be
given due importance.
4.3 AIL Requirements

a) AIL and Manufacturer representative shall hold a pre-job conference to discuss all
aspects of the procedure. Particular emphasis shall be placed on job safety,
environmental regulations, plant rules, surface preparation, coating application, and
inspection.
b) As an option, AIL shall have a technical representative from Coating manufacturer
present to assist and witness the application of each coating system. AIL shall obtain
further technical assistance from Coating manufacturer when problem arise.
4.4 Coating Manufacturer’s Product Data Sheets

a) The latest version of Coating manufacturer’s product data sheets, application
instructions, and material safety data sheets shall be available at the painting site and
complied with during painting operations.
b) Contractor, Vendor, Company and manufacturer representatives shall have current
copies and shall be familiar with limitations and requirements of the coating
4.5 Coating Procedure Test ( CPT )

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a) A CPT shall be used to qualify all coating system.

b) A test panel (minimum 100mm x 100mm ) minimum 6 mm thick shall be selected on
which the CPT shall be carried out.
c) The coating procedures shall be qualified under realistic conditions likely to be
present during coating application
d) Inspection and testing requirements for the CPT, including acceptance criteria, shall
be as per Paint manufacturer recommendation.
4.6 Mixing of Coatings of Different Coating Manufacturers

a) Each multi-coat system shall use materials from a single Coating manufacturer unless
reviewed and accepted by Company in writing.
4.7 Color
a) The finish coat color of external coating systems shall be as specified by Company in
Appendix-B
b) Contrasting colors shall be used for each of the intermediate coats to allow inspection
for full coverage.
4.8 Pre-Construction Primers

a) Shop primers may be used as pre-construction primers and weld bevels shall be free
of all primer before welding.
b) No coating shall be applied within 50 mm of areas that are to be later welded.
c) To ensure that only correctly blasted surfaces are coated, a minimum of 100 mm
around the edges of abrasive blasted areas shall be left uncoated, unless adjoining a
coated surface.
d) Before application of coating system over pre-construction primer, secondary surface
preparation shall be done in accordance with paint manufacturer recommendation as
per appendix-D.
4.9 Paint Free Surfaces

The following specific items shall not be coated and shall be protected from blasting and
coating being applied to adjacent equipment:
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a) Bearings and seals

b) Gaskets surfaces, RF and RTJ
c) Nameplates
Field weld shall be minimized. Field weld shall be coated with the same kind of paint as
applied in the shop.
Sensitive leak testing according ASME B31.3 clause 345.8 applies for all piping system
classified as Fluid category M service. For this air soap test the weld must be left uncoated up
until completion of the test.
5.0 SURFACE PREPARATION
5.1 General
a) All edges shall be ground to a minimum radius of 2 mm. Flame cut areas and weld
spatter shall have been ground flush consistent with the requirements of ISO 8501-3,
preparation Grade P3.
b) Abrasive blast cleaning and coating operations shall be carried out during daylight
hours. However, abrasive blasting and coating may be carried out at night providing
the lighting and environmental conditions are acceptable. The surface roughness
profile for carbon steel and low alloy steels to be coated shall be in accordance with
the written recommendations of the paint Manufacturer. When not specified by the
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paint Manufacturer. In all cases, the surface roughness shall have a sharp angular
profile.
c) The shop and field weld margin area subject to field testing shall be masked off for a
distance of 50mm after blast cleaning. The protective tape shall be of sufficient
quality to protect the achieved profile from deterioration. Paper backed tape shall not
be used. It shall be the Coater’s responsibility to see that all masking material is
thoroughly removed Unless coated with a primer that is safe for welding, previously
painted surfaces that require further fabrication shall have all coatings completely
removed from an area of 50mm minimum wide either side of the line of burning or
welding. The remainder of the paint shall be chamfered back for approximately a
further 100mm to 150mm. “Before abrasive blast cleaning, all equipment and serrated
flange face which could be damaged by blast, dust or particulate matter shall be
suitably protected by wrapping, taping, or other means to prevent damage.
5.2 Preparation for Abrasive Blasting
a) Sharp edges those resulting from flame cutting, welding, etc., shall be removed by
any suitable method such as a soft grinding wheel before abrasive blasting and
application of any coating system ( SSPC-SP10, and SSPC-SP COM)
b) Surfaces to be coated shall be clean of all contaminants that would affect the integrity
of the coating system.
c) Prior to surface preparation, the surfaces shall be cleaned, as necessary, to remove oil,
grease, dirt, salts, or other foreign material.
d) Cleaning shall be with an appropriate biodegradable detergent and/or solvent.

e) Detergent or solvent cleaning shall be performed as outlined in SSPC-SP1.
f) The presence of oil shall be checked by rubbing a lime chalk / water drop on the steel
surface.
g) Surfaces shall be tested prior to abrasive blasting or surface preparation with the
Elcometer 130 SCM 400 or Bresle patch.
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h) Test sites shall be selected to be representative of the surface as a whole.

i) For non-immersion service, maximum acceptable levels for Chloride shall be
25mg/m² as per Paint manufacturer’s recommendation.
j) Chloride contaminated surfaces shall require high-pressure water washing.
k) Surface shall be tested and treated as required until test results are less than or equal
to the limits listed above.
l) Surface preparation grade and anchor profile shall be confirmed to the Coating
manufacturer’s product data sheet prior to use.
5.3 Hand Tool/ Power Tool and Water Jet cleaning

a) Hand tool cleaning or power tool cleaning shall be per SSPC-SP2, SSPC-SP3, and
SSPC-SP11.
b) AIL/Paint manufacturer acceptance shall be required on a case-by-case basis prior to
substituting power tool cleaning for abrasive blasting.
c) When hand or power tool cleaning is required on stainless steel, only stainless steel
wire brushes that have not been previously used on carbon steel surfaces shall be used.
d) Hand tool cleaning is performed with non spark producing copper strips while
cleaning in flammable area.
5.3.1 Water Jet Cleaning
Water jet cleaning is performed at High-Pressure Water Cleaning (HP WC) with
pressures of 34 to 70MPa (5,000 to 10,000 psig).Cleaning performed at pressures of
34 to 70 MPa (5,000 to 10,000 psig) until and unless it is exclusively mentioned by
AIL authorities.
Surface Cleanliness achieved by water jetting will meet NACE WJ-3/SSPC-SP WJ-3..
5.4 Abrasive Blasting

a) Abrasive Blaster shall be experienced in blasting and shall have relevant knowledge
of health and safety hazards, use of protection equipment, and shall be experienced in
works of the same nature.
b) Abrasive blaster shall be tested & qualified by AIL NACE certified Level-1/2 coating
inspector or Paint manufacturer representative.
c) All abrasive blasted surfaces shall be blasted in accordance with the SSPC or NACE
blast specified on the coating system data sheets.
d) The anchor profile shall be as specified on Coating manufacturer’s product data sheets.
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e) The anchor profile shall be verified in accordance with ASTM D4417 or equivalent.
5.4.1 Abrasives
a) Abrasive blast cleaning shall be performed with a clean, sharp grade of abrasive as
specified in ISO 11124 & ISO 11126.
b) Dry abrasives shall only be used. Grain size shall be suitable for producing the
specified anchor profile.
c) Abrasives shall be free of dust, dirt, and other foreign matter and shall be kept dry at
all times.
d) Abrasives shall be supplied with certification documentation traceable to batches of
material.
e) For carrying out blasting over non ferritic substrate like S.S and galvanized surface
Garnet shall be used for blasting.
Abrasive specification
Type Generic Name Characteristics Standard
Iron grit > 1.7 % carbon ISO 11124-2

Metallic
Steel grit 0.8 % to 1.2 % carbon ISO 11124-3
Natural mineral Garnet Calcium iron silicate ISO 11126-10
Copper slag Ferrous silicate ISO 11126-3

Synthetic mineral
Coal slag Aluminium silicate ISO 11126-4
5.4.2 Prior to Blasting
a) Prior to the start of blasting, AIL shall select an appropriate blast air pressure with
abrasive and mesh size to attain the specified anchor profile.
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b) AIL shall demonstrate that the selected nozzle pressures and abrasive shall provide
the specified anchor profile by blasting a representative piece of steel and measuring
the anchor profile as described in ASTM D4417.
c) The air discharge temperature shall not exceed 65°C
d) The presence of oil and water shall be determined in accordance with ASTM D 4285
at least two times per twelve hours and following every compressor start up.
e) Blast air pressure shall be a minimum of 95 psig unless the demonstration test proves
acceptable otherwise.
f) Weld areas shall be ground, chipped, or wire brushed as necessary prior to blasting to
remove rust, residual flux, and weld spatter.
g) When possible, name tags shall be installed after painting is complete.
h) If it is not possible to coat under tags, their edges shall be sealed with silicone to
prevent moisture accumulation.
5.4.3 Blasting
a) Blasting shall be performed in dry weather. Dry blast cleaning operations shall not be
conducted on surfaces exposed to rain, water spray, or any other moisture.
b) All abrasive blasting equipment shall have inline oil traps and air after coolers/driers.
c) Abrasive blast cleaning shall not be performed when the ambient or substrate
temperature is less than 5°F (3°C) above the dew point temperature.
d) Dew point temperature shall be determined by sling psychrometer in accordance with
ASTM E337 or equivalent electronic device, at the location where the work is being
performed.
e) Substrate temperature shall be determined with a surface thermometer
f) Blasting nozzles shall be replaced when the specified minimum blast pressure, surface
cleanliness and surface roughness can no longer be achieved.
g) Blasting shall be accomplished so that previously painted surfaces are not
contaminated by abrasive or blast wastes.
h) The rough edge of any existing coating shall be feather-edged before applying the
next coat. This shall be accomplished by abrasive blast, power, or hand sanding.
i) Subsequent blasting shall continue a minimum of one inch into the primed surfaces
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to ensure that no coating is applied over unblasted steel.
j) Steel surface slivers, lamination, laps, scabs shall be repaired prior to coating.
5.4.4 Post Blasting
a) After blasting and immediately before spraying, dust and loose residues shall be
removed by brushing, blowing off with clean dry air, or vacuum cleaning.
b) Blast cleaned surfaces that show evidence of rust bloom or that have been left
uncoated for more than four hours shall be re-cleaned to the specified degree of
cleanliness prior to coating.
c) All blast cleaned surfaces shall be blown down dust free, and then inspected for
proper cleaning prior to painting. SSPC-VIS1 shall be used as a visual standard for
confirming the degree of surface cleanliness.
6.0 COATING APPLICATION
6.1 General Application Requirements
a) Painter shall have a minimum of two year experience in painting and shall be tested &
qualified by AIL NACE certified Level-2 coating inspector and Paint manufacturer
representative.
b) Application shall be in accordance with SSPC-PA1, Coating manufacturer’s
published application instructions, material safety data sheet (MSDS), and the
requirements specified herein.
c) Application equipment shall be as recommended by Coating manufacturer, shall be
clean and in good condition, and shall be suitable for applying the coating as specified.
d) The number of coats to be applied shall never be fewer than the number of coats
required by coating system and shall have individual coat dry film thicknesses not less
than the minimum thickness specified.
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e) Wet film thicknesses are to be verified at the start of work (until the painter is familiar
with the paint and work) with a wet film thickness gauge.
f) Thickness requirements shall be met with each coat and total thickness shall not be
“made-up” in any one coat.
g) When coating over zinc silicate primers, a mist coat of paint shall be applied to avoid
bubbling and surface defects.
6.2 Weather Conditions

a) Blasting & Painting shall be continued if the specified metal and air temperatures and
relative humidity requirements are met at all times during preparation, painting, and
curing, and minimum light of 500 lux is available.
b) Coatings shall be applied within the environmental conditions shown in Coating
manufacturer’s data sheets.
c) No coating shall be applied when any of the following conditions are present:
 Ambient or surface temperatures are above or below Coating manufacturer’s
recommended temperature limits.
 Ambient or substrate temperature is less than 3°C above the dew point
temperature.
d) Dew point temperature shall be determined by sling psychrometer in accordance with
ASTM E377 or equivalent electronic device, at the precise location where the work is
being performed.
e) Substrate temperature shall be determined with a surface temperature guages.

f) During strong winds or gusty conditions, rain, snow, or fog, or on damp surfaces or
surfaces that may have frost ; spray application shall not be performed.
g) Newly painted surfaces damaged by rain shall be thoroughly inspected and repaired.
6.3 Materials
a) Coating materials shall be furnished in Coating manufacturer’s unopened containers,

clearly identifiable, and shall be kept covered, clean, and protected.
b) Each coating container shall be clearly labeled to show coating identification, date of
manufacture, batch number, and any other information to satisfy regulatory
requirements at the job site.
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c) Each coating material shall also be accompanied with its material safety data sheet
and product data sheet.
d) Coating container shall be kept in the factory sealed condition until use.
e) Materials older than the Coating manufacturer’s recommended shelf life shall not be
used.
f) Materials shall be used in order of the oldest first. / First In First Out ( FIFO )
g) Coating that has deteriorated during storage shall not be used.
h) Solvents used for thinning shall be as recommended by Coating manufacturer.
i) Materials shall be handled and stored in accordance with Coating manufacturer’s
latest published instructions.
6.4 Mixing and Thinning
a) Mixing of different brands or generic types of coating materials shall not be done.
b) Components shall be thoroughly mixed per recommendations noted in Coating
manufacturer’s data sheets.
c) Mixing shall be done in clean containers, free from traces of grease, other paints, or
Contaminants.
d) Coating container shall be kept covered to prevent contamination.

e) Paint shall be mechanically mixed in full batches and as per Paint manufacturer
recommendation, all mixing shall be done using factory proportioned containers only.
f) Multi-component coatings, such as inorganic zinc, epoxies and urethanes, shall have
the components accurately measured according to Coating manufacturer’s directions.
g) Mixing of partial kits shall be strictly monitored with periodic audits.
h) Thinning shall not exceed the allowable VOC level for the coating used.
i) Continuous agitation type spray pots shall be used when applying metal pigmented
coatings such as zinc or aluminium loaded coatings.
6.5 Shelf and Pot Life
a) Materials that have exceeded Coating manufacturer’s recommended shelf life shall
not be used.
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Rev. 1 Date: 01/08/2019
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b) Coating manufacturer’s recommended pot life shall not be exceeded. When this limit
is reached, the spray pot shall be emptied and cleaned, and new material mixed.
6.6 Stripe Coat

a) Irregular surfaces such as sharp edges, welds, small brackets, interstices etc. shall be
stripe coated, usually by brush, to ensure the specified film thickness is provided.
b) Time between abrasive blasting and priming, stripe coating of primer coats may be
carried out following spray application of the full primer coat.
6.7 Spray Application
a) Contractor’s applicators shall be skilled in the proper application technique for each
coating.
b) Proper equipment, per Coating manufacturer’s data sheets, shall be used.
c) Applicators or equipment failing to meet this requirement, to AIL or Coating
manufacturer’s satisfaction, shall be removed from coating application.
d) Spray guns, lines, and pressure pots shall be cleaned prior to adding new material.
e) The air caps, nozzles, and needles shall be those recommended by Coating
manufacturer for the material being sprayed.
f) Moisture traps, separators, and driers shall be installed between the air supply and the
pressure pot. The drain valve must be kept open slightly to permit continuous draining
of any condensate during operations.
g) Operating pressures shall comply with the recommendation of Coating manufacturer.
h) All pressure pots shall be equipped with pressure regulators and gauges.
i) Paint shall be applied in a uniform layer, with 50 percent overlapping of the previous
pass utilizing the cross hatch method. During application, the spray gun shall be held
perpendicular to the surface being painted.
6.8 Priming
a) The specified coating system primer shall be applied within 4 hours from the time that
surfaces are cleaned and before rusting, discoloration, or surface contamination occurs.
b) Surfaces to be coated shall be clean, dust-free, and dry before application of any
coating and shall meet applicable hand, power tool, or abrasive blasting surface
preparation requirements before priming.
c) Care shall be exercised to prevent overspray, spillage, or application of coatings to
surfaces for which they are not intended.
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d) Skips, sags, and drips shall be repaired.

e) For equipment that will be welded after application of primer coat, leave an unprimed
strip of at least 2 inches (50 mm) from the surfaces to be welded.
6.9 Top Coating

a) Each coat of paint shall be of contrasting color to indicate extent of coverage.
b) All coatings shall be allowed to dry for at least the minimum time recommended by
Coating manufacturer, considering temperature and humidity, before applying
succeeding coats.
c) Maximum overcoat time shall be limited to Coating manufacturer’s recommendation.
d) When the maximum overcoat time has been exceeded, Contractor shall perform
additional surface preparation as agreed by Coating manufacturer’s.
e) Additional surface preparation shall include, but not limited to, hand sanding, pressure
washing, mist coat application, degreasing, or reblasting.
f) When amine type epoxies are used in humid conditions, the primed surfaces shall be
checked for amine blush.
g) If amine blush is present, it shall be removed by a thorough washing of the surface
with a detergent recommended by Coating manufacturer.
6.10 Film Thickness

a) Wet film thickness shall be checked during the application of each coat to assure the
specified dry film thickness (DFT) will be met.
b) Wet film thickness measurements shall not suitable for some materials such as
inorganic zinc primers.
c) The DFT of each coat shall be checked in accordance with the procedures defined by
SSPC-PA2 using Electronic Type-2 gauge that has been properly calibrated.
d) Coating thickness measurements shall be taken after removal of dry spray and
overspray.
e) The DFT of final coating system shall meet 90/10 rule and only 10% of reading
allowed with 10% lower of what is specified and in only 10% of area.
f) All gauges shall be adjusted to compensate for the surface profile effect prior to
application of any coating.
6.11 Defects
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a) Coatings shall be free of defects such as runs, sags, pin holes, voids, blisters, wrinkles,
mud cracking, and bubbles.
b) Dry spray and overspray shall be removed.
c) The DFT of each coat shall not be outside the specified range by Paint manufacturer
or as per 7.10.1 of this procedure.
6.12 Repair of coating defects
a) Prior to application of any coat, all defects and damage to the previous coat(s) shall be
repaired.
b) Damage to finished work shall be thoroughly cleaned and re-coated.
c) Coating damage not exposing substrate surface and found contaminated shall be
cleaned by solvent cleaning and /or lightly brush blasted ensuring that the surface is
free of all contaminations prior to applying the following coats. After cleaning, any
residual contaminants shall be removed by dry compressed air and wiped by hand
with clean, dry rags. The coating around the damaged area shall be chamfered, and
coated to ensure continuity of the patch coating.
d) Coating damage exposing substrate surface shall be spot blast cleaned or power tool
or manual cleaned as necessary to restore any exposed steel to its original degree of
cleanliness. The re-cleaning shall carry over onto tightly adhering surrounding coating
for not less than 50 mm all around and the edges shall be chamfered
e) Damaged surfaces of fully cured epoxy coatings and/or painting of a fully cured and
aged epoxy coating, the coating work shall be carried out after the surface of the fully
cured epoxy to be coated has been suitably abraded to provide and adequate tooth for
the coating to be applied
f) All loose, cracked, and damaged coating shall be removed and the adjacent sound
coating feathered back approximately 2 inches (50 mm) to form a uniform and
smooth surface.
g) Feathering shall be done by hand or power sanding with a grit wheel or sandpaper.
h) The prepared surface shall be free of loose, burnt, or blistered coating.
i) Unless specified otherwise, the coating used for repair shall be the same as the
original and shall have the same DFT.
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6.13 Brush or Roller Application
a) Brush or roller application shall be as specified by Paint manufacturer.

b) Inaccessible and restricted areas that prevent spray application of paint at the
proper inclination angles shall be boxed in and seal welded prior to paint
application.
c) All welds that cannot be properly spray coated shall be brush or stripe coated with
an approved coating before applying successive spray coats over the primer
coating.
d) Brushes shall be of a style and quality that will enable proper application of the
coating.
e) Brushing shall be done so that a smooth coat with uniform thickness is obtained.
f) When applying coatings with a brush, multiple coats may be required to achieve
the specified thickness.
7.0 INSPECTION
7.1 General
a) AIL shall perform all inspection necessary to ensure that surface preparation and
coating application complies with the requirements of this procedure and paint
manufacturers recommendations.
b) The indicated records shall be kept daily and shall be submitted to Certifying
agency at least weekly.
c) An approved equivalent coating inspection record, shall be used to record this
information. (Refer to Appendix C)
d) Certifying agency representative shall be given daily notice prior to the start of
surface preparation and coating application so that they can witness the work.
e) Materials, equipment, and work shall be available to Certifying agency authorized
inspector(s) at all times.
f) Instruments used in inspection activities (e.g., thermometer, pyrometers,
hygrometers, thickness gauges, profile gauges, and holiday detectors) shall be
maintained by contractor in proper working order and calibrated prior to use.
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7.2 Personnel
a) The painting Inspector shall be certified under either one (1) of the following
certification institutes NACE International Certified or equivalent e.g. SSPC,
FROSIO, BGAS-CSWIP etc.
7.3 Inspection Equipment
a) The following instruments and equivalent brands shall be used for inspection and
shall be calibrated on a routine basis ( depending on frequency of use )
b) All instruments shall be maintained in good working condition at all times
TEST TEST INSTRUMENT TEST INSTRUMENT

( ELCOMETER , UK make) ( POSITEST /DEFELSKO, US
make) / Others
Elcometer 214L infrared digital Positector DPM

Surface thermometer
Temperature
Magnetic Surface Temperature

Gauge Elcometer 113
Elcometer 116 whirling and sling Positector DPM

Relative Humidity hygrometer
Whirling Hygrometer JRM

Thermometer
Surface Cleanliness SSPC-Vis-1
Surface Salt Elcometer 130 SCM 400

Contamination
Elcometer 123 surface profile Dial Profile Gauge Mitutoyo
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gauge
Surface Profile
Elcometer 124 thickness gauge PCWI make Digital thickness
and 122 testex replica tape gauge and replica tape
Elcometer 224
Wet Film Elcometer 112

Thickness
Dry Film Elcometer 456

Thickness
Holiday Detection Low Voltage Holiday Detector

Elcometer 269 / Elcometer 270
Adhesion Test Hydraulic Adhesion Testor

PosiTest AT
7.4 Compressed Air Cleanliness
a) The cleanliness of compressed air supply used for blast cleaning, pneumatic tools, and
spray equipment shall be checked for oil and water contamination in accordance with
ASTM D4285.
b) Compressed air lines shall be tested separately.
c) Testing shall be performed at the beginning and end of each work shift and at not less
than four-hour intervals.
d) In the event that contamination is discovered, all necessary corrective actions shall be
made and the air supply re-tested.
e) Surfaces that are determined to have been blasted with contaminated air shall be
cleaned with solvent and re-blasted with clean air and abrasive.
7.5 Abrasive Material
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a) Expandable abrasive like Copper slag & Garnet shall be used for abrasive cleaning in
open yards with barricading on sides
b) Tests for identifying contaminants in cleaning abrasive shall be made at the start of
blasting, at four-hour intervals thereafter, and at the end of blasting.
c) If oil or conductive contamination is evident, contaminated abrasive shall be replaced
with clean abrasive and re-tested before proceeding.
7.6 Environmental Conditions
a) The following shall be checked and recorded at the beginning of each day’s operation
and several times during the application process:
 Ambient temperature
 Relative humidity
 Dew point
 Moisture-free surface
 Temperature of the surface to be coated
b) If any of these criteria are not met, coating shall not be applied.
7.7 Surface Preparation (Including Touch-Up Preparation)
a) Immediately prior to priming, blasted surfaces shall be inspected by the following

methods to verify that the specified surface preparation has been achieved:
b) The anchor profile shall be verified as described in ASTM D 4417 or equivalent. The
measurements shall be recorded in the coating inspection record.
c) The degree of cleanliness shall be verified by comparison to SSPC-VIS1 or equivalent.
The cleanliness shall be recorded on the coating inspection record.
7.8 Coating Application
a) Dry film thicknesses shall be measured using a pull-off or electronic magnetic film
thickness gauge in accordance with SSPC-PA2.
b) The dry film thickness gauge shall be calibrated at the beginning of coating work and
thereafter, regularly.
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c) Calibration shall be made by comparison with the dry film thickness measured on
known standards such as a micrometer-measured paint film or National Bureau of
Standards Calibration
d) Coating Inspection Record for each coat as work proceeds as well as for the total
thickness of each finished coating system.
e) The 10% area of surface coatings shall be inspected for holidays using a Low voltage
type Holiday detector / or as recommended by paint manufacturer.
f) Areas containing holidays shall be locally blasted to bare metal, re-coated with the
same system, are re-tested for holidays. Detected holidays, correction, and final
holiday free inspection shall be recorded on the coating inspection record.Areas found
to contain runs, overspray, pinholes, sags, and/or other signs of improper application
shall be repaired in accordance with Coating manufacturer’s recommendations
7.9 Transportation, Handling and Storage of coated components

a) Contractor shall ensure that coatings are fully cured before handling
b) Coated items shall only be handled with soft belt slings to eliminate damages of
coated items, the belt shall be of sufficient width to prevent any damage being
sustained by the coating.
c) Coated components shall not be stored directly in contact with the ground or other
surfaces that could damage the coating
d) During stacking of bulk pipes, individual pipes shall be separated by appropriate soft
packing material
e) Air blowing shall be done from inside of pipe materials to remove blasting abrasive
debris and shall be closed from ends to prevent foreign material getting inside the pipe.
f) Adequate protection shall be provided to prevent mechanical damage to the applied
coating system and subsequent atmospheric corrosion in transit and at the jobsite.
g) Finished painted pipe and pipe spools shall be handled and /or stored in a manner to
protect the coating from damage.
h) Finished painted pipe shall not be dropped, rolled or impacted with or against solid
objects with a force capable of causing coating damage.
7.10 Stage Inspection
a) Work shall be subject to AIL & Paint manufacturer inspection.
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b) Work shall not proceed past each of the following inspection hold points without the
approval of AIL inspectors & Paint manufacturer representative
 Completion of surface preparation, prior to primer application.
 Completion of application of each coat (primer, intermediate, and top coat).
 Holiday detection and repair
 Final acceptance of completed coating work.
 AIL and Manufacturer’s inspectors shall ensure that all necessary inspections
are carried out at each hold point.
c) Necessary corrective actions shall be performed by contractor for any defects
observed during inspection
d) The completed coating shall be free from defects such as runs, sags, pinholes, voids,
bubbles, orange peel, grit, dust inclusions, etc and shall be of a good visual
appearance.
e) Top coat shall completely hide the colour of the underlying layers
f) Spot checks for wet film thickness shall be carried out during the painting operation to
ensure that the required film thickness is being maintained.
g) AIL shall provide safe access to all areas for personals engaged for Surface
preparation and coating process including inspection by Company/Contractor/
Certifying agency.
h) AIL shall maintain the area to prevent contamination of coatings
7.10.1 For the acceptance of an inspected area the following criteria shall be fulfilled:
a) The dry film thickness (DFT) of the completed coating system shall be equal to or
greater than the specified nominal dry film thickness (NDFT);
b) The dry film thickness (DFT) of any individual coating layer shall be equal to or
above 90 % of the specified nominal dry film thickness (NDFT) for that coat. Further,
the number of readings between 90 % of NDFT and NDFT shall be less than 10 % of
the total number of readings taken;
c) The DFT of the total coating system shall be maximum 1.5 x the NDFT, except for
areas such as corners where overlaps are difficult to avoid. For such areas a maximum
of 2.5 x the NDFT shall be accepted.
Sampling Plan
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Rev. 1 Date: 01/08/2019
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Area/length of inspection Minimum number of measurements

area (m² or m)
Up to 1 5
Above 1 to 3 10
Above 3 to 10 15
Above 10 to 30 20
Above 30 to 100 30
For additional ranges (m2 or m), the
Above 100 corresponding number of measurements shall be

added.
NOTE: Areas above 1000 m² shall be divided into smaller inspection areas
7.10.2 Detection of pinholes
For coating thickness < 500 μm DFT, the low voltage wet sponge technique shall be used.
Defects found shall be marked, repaired in accordance with the Manufacturer’s
recommendations and retested to the requirements of this Procedure.
7.10.3 Adhesion
The quality of adhesion between the coating system and the steel substrate, shall be measured
using either:a) A portable, self-aligning, hydraulic controlled adhesion tester in accordance
with ISO 4624. The minimum pull-off strength for coating systems with a TDFT greater than
150 μm shall be:
- - 5 MPa for non-zinc primed coatings systems;
b) A crosscut test in accordance with ISO 2409, Class 0 for coating systems with
a maximum TDFT of 150 μm.
Testing shall be done on fully cured systems only. Adhesion testing shall be
carried out at least once per 500 m² on test plate/job.
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7.10.4 Manufacturer’s documentation
The Manufacturer’s test reports and project/track reports shall be submitted for the
Principal’s review and approval as part of the testing required. The reports shall contain test
results and proven suitability of the proposed coatings for the intended services.
7.11 Coating Manufacturer’s Representatives
Coating manufacturer’s representatives shall have access to the work site during the progress
of the work to perform any inspection and testing deemed necessary to ensure that the
coatings are properly applied as per the Paint manufacturers recommendation and Product
Data Sheet.
8. GALVANIZING
8.1 Galvanizing Standard
All steel grating, stair treads and other items specified as being galvanized shall be hot dipped
after fabrication in accordance with ASTM A123. Iron and steel hardware materials shall be
hot-dip galvanized in accordance with ASTM A153.
8.2 Surface Preparation
All welding slag and burrs shall be removed. Surface contaminants and coatings, which
cannot be removed by the normal chemical cleaning process in the galvanizing operation,
shall be removed by abrasive blast cleaning. Steelwork shall be prepared in accordance with
the requirements of ASTM A123 and/or ASTM A153.
8.3 Zinc Coating Weight
The weight of zinc coating on structural items shall be minimum 0.705 kg/sqm surface area.
The composition of the zinc used in the galvanizing bath shall not be less than 98% zinc.
8.4 Surface Finish
The galvanized coating shall be continuous, adherent, as smooth and as evenly distributed as
possible and free from any defect that is detrimental to the end use of the coated component.
On ‘silicon killed’ steels, the coating may be dully gray, provided the coating is sound and
continuous.
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8.5 Welding
Galvanized members, that are to be permanently fixed by welding, shall be attached after the
supporting members are primed, but before topcoats are applied. The heat affected area of the
supporting structure shall be cleaned of all welding flux, the surface prepared and the coating
reinstated. Grinding of edges prior to welding shall be permitted to reduce zinc oxide fumes
formed during welding and eliminate the potential for weld porosity to occur. Adequate
ventilation shall be provided and in confined spaces a respirator shall be used.
8.6 Damaged Items
All damage to galvanized items caused by fabrication, welding, handling and loading out of
installation shall be reinstated.
8.7 Reinstatement of Damaged Surfaces
Repaired surfaces shall present the same appearance as adjacent galvanized areas and have
approximately the same weathering characteristics as the galvanized surface.
8.8 Painting Galvanized Surfaces
All galvanized structural members except gratings shall be painted with coating system 1. All
galvanized surfaces shall be degreased, fresh water washed and treated as per SSPC SP1. It
will then be sweep blasted and coated with surface tolerant epoxy – primer or compatible
Epoxy primer followed by respective coating systems.
Appendix A: Inspection & Testing Requirement
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Extent / Frequency of Inspection and

Inspection / Parameter / Acceptance Testing
Test Method Criterion
Batch Process Individual Process
Rust, ISO 8501-1 Grade B or better
Visual Surface defects None

examination prior 100% of all surfaces 100% of all surfaces
to blasting Oil, grease, liquids None
Radius of curvature >=2 mm
Ambient temperature Minimum 5°C
Environmental T>DP+3° C At start, middle, and At start, middle, and end of

Steel Temperature
conditions minimum end of each shift each shift
Relative Humidity <85 %
Before start of each blast

Cleanliness of Before start of each
No oil or condensed cleaning shift or change in air
compressed air ASTM D 4285 blast cleaning shift or
moisture system, at least two times per
for blast cleaning change in air system
twelve hours
Area<100m²: Once
Once on 10% of total
Dust Particle
ISO 8502-3 Rating 2 or better no. of components per
quantity and size Area>100m²: Three checks
batch
per Day
Cleanliness ISO 8501-1 SSPC SP 10 100% of all surfaces 100% for all surfaces
Area<100m²: Once
Once on each
Roughness ISO 8503 As per clause 5.2.2
component per batch Area>100m²: Three times per
Day
SSPC Guide 15 / < 50 milligram / m²

Chloride test Once on each
ISO 8502-6 / for blasted l surfaces Once for every 300 m2.
conductivity component per batch
ISO 8502-9 and < 100 milligram /
m² in maintenance
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painting
Curing and solvent

Full cure, no solvent
Visual retention
examination of 100% of all surfaces 100% of all surfaces
coating Pinholes, blisters,
No defects
cracks, etc
10% of total batch area

ASTM D5162 or including welds if size 10% of coated area including
Holiday detection No holidays
NACE SP0188 of the components welds for linings only.
permits
ISO 4624 /
ASTM D4541 / 3 determinations per
Adhesion As per clause 7.10.3
ASTMD 3359/ paint batch on test plate
ISO 2409
Once on 10% of total

Curing test
ASTM D 4752 Rating 4 to 5 no. of components per Once per 100 m²
( for zinc silicate )
batch
Film Thickness SSPC PA 2 As per clause 7.10 10% of total batch area 5 spots for every 10 m² area
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APPENDIX B : Colour Coding
Pipe line color code is attached with the procedure.
Colour coding for Vessels/Tanks
1) Chemicals Smog Grey( IS 692)
2) AIr Sky Blue (IS 101)
3) Water Sea Green( IS 217)
4) Hydrogen Buffer RED (IS 536)
Colour coding for MS Structure
1) All structured shall be painted in Oxford Blue (IS 105) excluding chequred
plate (chequered surface only) which are top coated in smog grey (IS 692) colour
from top
2) For Handrails, Monkey ladders shall be top coated with golden yellow (IS 356)
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APPENDIX C
In case, painting activities are out source, vendors and contractors are free to use their own
report format as per their QMS with prior approval of AIL.
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APPENDIX D
All coating system are applicable with power tool cleaning (St3), manual tool cleaning (St2) ,
water jet cleaning (Nace WJ-3) until and unless exclusively mentioned with blasting
(SA 2 1/2).
COATING SYSTEMS
Coating System 1:
For less corrosive Plant structures , Pipelines , Supports , etc.
STAGE PAINT PROFILE/DFT REMARKS

REQUIRED (MICRONS)
Surface Preparation 60-70 Sa 2 1/2 for blasted

surface,
Primer Self-priming surface 100

tolerant High build
Epoxy (A1)
1st coat HB Epoxy Mastic 100

Intermediate MIO
(A2)
Top Coat Acrylic Aliphatic PU 60

finish (A3)
Total 260
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Coating System 2:
For CUI / insulated pipelines and structures up to 205 degree C and for immersion services (PH near
7).

REQUIRED (MICRONS)

surface,.
Primer Phenolic Epoxy 100

(A4)
Top Coat Phenolic Epoxy 100

(A4)
Total 200
* Coating shall be approved as External coating for the protection of insulated

(CUI)
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Rev. 1 Date: 01/08/2019
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Coating System 3*:

For High corrosive Plant structures , Pipelines , Supports etc.

REQUIRED (MICRONS)

surface,.
Primer HB Epoxy Mastic 150

Primer (A5)
1st coat Epoxy Blended 150

Glass flake (A6)
finish (A3)
Total 350
* In case 150 microns (required DFT) is not achieved by single coat during
brush application then multiple passes shall be applied to built up the required
DFT.
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Coating System 4:
For non-insulated Tanks /Equipment

REQUIRED (MICRONS)

surface.
Primer Phenolic Epoxy 110

(A4)
1st coat Phenolic Epoxy 110

(A4)

finish (A3)
Total 280
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Rev. 1 Date: 01/08/2019
LIMITED
Coating System 5:
For Galvanized surface Handrails , Structures , Pipelines etc

REQUIRED (MICRONS)
SSPC SP 7/Sa1
Surface Preparation 30-45
Primer Low VS epoxy 80

primer suitable for
aluminium &
Galvanized Surface
(A7)
1st coat HB Epoxy Mastic 120

Primer (A1)
Top Coat Glossy Aliphatic 60

Acrylic Polyurethane
Topcoat (A3)
Total 260
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Rev. 1 Date: 01/08/2019
LIMITED
Coating System 6:
For CUI / insulated pipelines and structures up to 650 degree C.

REQUIRED (MICRONS)

surface,.
Primer Inorganic 100

copolymer.(A10)
Top Coat Inorganic 100

co-polymer A(10)
Total 200
* Coating shall be approved as External coating for the protection of insulated

(CUI)
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Coating System 7:
For Buried structure, equipment and piping

REQUIRED (MICRONS)

surface,.
Primer Coal Tar Epoxy 100
(A12)
Top Coat Coal Tar Epoxy 100
(A12)
Coal Tar Epoxy 100
(A12)
Total 300
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Rev. 1 Date: 01/08/2019
LIMITED
Coating System 8:
For Un insulated Plant structures , Pipelines , Supports , Tanks etc.(for Chimney etc. temperature up
to 400 degree Celsius with blasting only)

REQUIRED (MICRONS)
Sa 2 1/2 for blasted
surface
Surface Preparation 60-70
Primer Inorganic zinc 70-80

silicate coating SSPC
SP-20, Level-II,
containing minimum
80% zinc in dry film
by weight & zinc as
per ASTM D520
Type-II (A8)
1st coat Heat resistant 20-25

Aluminum paint
based on Silicone
Binder (A9)
Top Coat Heat resistant 20-25

Aluminum paint
based on Silicone
Binder (A9)
Total 110-130
49
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
Additional Coating System for special Cases
Coating System 9:
For Plant structures , Pipelines , Supports , Tanks etc.( for medium corrosive areas with high
chemical resistance.)

REQUIRED (MICRONS)

surface,.
Primer HB Epoxy Mastic 110

Primer(A1)
1st coat Phenolic Epoxy 110

(A4)

finish (A3)
Total 290
50
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
Coating System 10:
For Plant structures , Pipelines , Supports , Tanks etc.( for very severe/high corrosive areas,strictly
applied to blasted surface only with C5 atmosphere (near to sea with high relative humidity))

REQUIRED (MICRONS)

surface,.
Primer Organic zinc silicate 70-80

coating SSPC SP-20,
Level-II, containing
minimum 80% zinc
in dry film by weight
& zinc as per ASTM
D520 Type-II (A11)
Ist Intermediate HB Epoxy MIO/ 100-125

Mastic (A2)
2nd Intermediate HB Epoxy MIO/ 100-125

Mastic (A2)
Top Coat Acrylic Aliphatic PU 60-70

finish (A3)
Total 330-400
51
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
Coating System 11:
For Plant structures , Pipelines , Supports , Tanks etc.( for very severe/high corrosive areas,strictly
applied to blasted surface only with C5 atmosphere (near to sea with high relative humidity))

REQUIRED (MICRONS)
Sa 2 1/2 for blasted
surface,.
Surface Preparation - 60-70
.
InOrganic zinc
silicate coating SSPC
SP-20, Level-II,
Primer containing minimum
80% zinc in dry film 70-80
by weight & zinc as
per ASTM D520
Type-II (A8)
Ist Intermediate HB Epoxy MIO/ 100-125

Mastic .(A2)
2nd Intermediate HB Epoxy MIO/ 100-125

Mastic (A2)
Top Coat Acrylic Aliphatic PU 60-70

finish (A3)
Total 330-400
52
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
APPENDIX E
Approve Product List
Coating Hempel, Jotun International Carboline, Asian PPG

System Coatings,
No.1 Denmark Brand USA
Norway / (AKZO (CDC)
Jotun India
Pvt Ltd NOBEL), Carboline,
UK
India
A1 HEMPADUR JOTAMASTI Carbomasti amerlock

MASTIC C c 400
45880/1/4755 80/JOTAPRI INTERSEAL
0 ME MASTIC 547/670 615 / 400C
80
A2 HEMPADUR PENGUARD INTERGARD Carboguard Amercote

MASTIC MIO 475 HS
45880/1/4755 INTERMEDI 893 MIO 383 HS /
0 ATE 410
(MIO)
A3 HEMPATHA HARDTOP INTERTHAN Carbothane Amercoat

NE XP/AP E 990 HS
TOPCOAT 133 450 Series
55910
A4 HEMPADUR EPOXY HR INTERTHER Phenoline Amercoat

85671 M 228 90
187 VOC
HS
53
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
A5 HEMPADUR Jotamastic - - -
MASTIC 87,AL
45880 AL
A6 Hempadur Jotamastic - - -
multistrength 87,GF
GF 35870
A7 Hempadur Penguard Intergard 214 - Amercoat

059910
primer 182 ZP
A8 Galvosil Resist 78 Interzinc 22 - dimetcote 9

15780
A9 Silicon Solvalitt Intertherm 50 - Amercoat

aluminium
56914 878 HS
A10 Versiline CUI Jotatemp 1000 - - -

ceramic
56990
A11 Avantguard Barrier 80 Interzinc 52 - Amercoat

68
HS
A12 Grand poly Asian Nerolac Berger

coats
APPENDIX F
54
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
FINISH COLOUR SCHEDULE – PIPING JHAGADIA
Category First Second

S.No. Name (Chemical/ Ground Color Colour Colour
Utility) Band Band
1 p-Chloroaniline Dark Admirality Light

Chemical Grey Orange -
2 o-Chloroaniline Dark Admirality Light

3 m-Chloroaniline Dark Admirality Light

4 2.3 Dichloroaniline Dark Admirality Light

5 2,4-Dichloroaniline Dark Admirality Light





10 2,4,5 Trichloroaniline Dark Admirality Light

11 p-ChloroNitrobenzene Dark Admirality Canary

Chemical Grey Yellow -
55
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
12 o-ChloroNitrobenzene Dark Admirality Canary

13 m-ChloroNitrobenzene Dark Admirality Canary

14 2,3-Dichloronitrobenzene Dark Admirality Canary

15 2,4-DichlorNitrobenzene Dark Admirality Canary

16 2,5-DichloroNitrobenzene Dark Admirality Canary




20 2,4,5 Trichoro Dark Admirality Canary

Nitrobenzene Chemical Grey Yellow -
22 ODCB Dark Admirality Brown

Chemical Grey -
23 M-Dinitrobenzene Dark Admirality

Chemical Grey Fire Red -
24 NItrobenzene Dark Admirality

25 OrthoPhenylenediamine Dark Admirality

Chemical Grey Sky Blue -
26 Paraphenylene Diamine Dark Admirality

27 Metaphenylene Diamine Dark Admirality

28 Aniline Dark Admirality Dark Violet

Chemical Grey -
56
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
29 Orthofluoroaniline Dark Admirality Sea Green

Chemical Grey -
30 Parafluoroaniline Dark Admirality Sea Green

Chemical Grey -
31 2,4-Difluoroaniline Dark Admirality Sea Green

Chemical Grey -
32 4-Fluoro Isopropyl Aniline Dark Admirality White

Chemical Grey -
33 o-fluoroNitrobenzene Dark Admirality Canary

34 p-fluoroNitrobenzne Dark Admirality Canary

35 2,4-DifluoroNitrobenzne Dark Admirality Canary

36 Ammonia Chemical/ Canary yellow Dark Violet

Utility -
37 Chilling water Utility Sea Green Black Canary

Yellow
38 Hydrogenation Catalyst Black White

1% Pt Chemical -
39 Hydrogenation Catalyst Black Magenta

5% Pd Chemical -
40 Caustic Solution Chemical Smoke Grey Light

Orange -
41 Hydrogen Gas Chemical Canary yellow French

Signal Red Blue
42 Nitrogen Liquid (Tank) Utility Canary yellow Black -
43 Nitrogen Gas Utility Canary yellow Black -
44 Methanol Dark Admirality Deep Buff

Chemical Grey -
45 Benzene Dark Admirality Canary

57
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
46 Toluene Dark Admirality Gulf Red

Chemical Grey -
47 o-Nitrotoluene Dark Admirality Light

48 p-Nitrotoluene Dark Admirality Light

49 m-Nitrotoluene Dark Admirality Light

50 Process Water Chemical Sea Green Oxide Red -
51 Sulfuric Acid (98%) Dark Violet Brilliant Light

Chemical Green Orange
52 Nitric Acid (98%) Dark Violet French Light

Chemical Blue Orange
53 Spent Acid Dark Violet Brilliant Light

Chemical Green Orange
54 Raw Water Utility Sea Green White -
55 DM Water Utility Sea Green Gulf Red -
56 Sea Green French

Cooling Water Utility Blue -
57 Light Brown French

Hot Oil (thermic fluid) Utility Blue -
58 Sealing Systemt Oil Utility Light Brown Light Grey -
59 Sky Blue French

Instrument Air Utility Blue -
60 Sea Green Light

Soft Water Utility Brown Signal Red
61 Dark Violet Jasmine

Soda Solution Chemical Yellow -
Category First Second

Ground
S.No. Name (Chemical/ Colour Colour
Color
Utility) Band Band
58
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
1 m-Dinitrobenzene Dark
Admirality
2 o-Phenylenediamine Dark
Admirality
3 p-Phenylenediamine Dark
Admirality
4 m-Phenylenediamine Dark
Admirality
5 o-Nitrotoluene Dark
Admirality Light
6 p-Nitrotoluene Dark
Admirality Light
7 m-Nitrotoluene Dark
Admirality Light
9 o-Toluidine Dark
Admirality French
Chemical Grey Blue -
10 p-Toluidine Dark
Admirality French
11 m-Toluidine Dark
Admirality French
12 Hydrogen Gas Canary Signal Red

Chemical yellow French Blue
13 Natural Gas Canary Signal Red

Chemical yellow French Blue
59
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
14 HCl 30% Signal

Chemical Dark Violet Red Light Orange
15 Caustic Solution Smoke Grey Light

Chemical Orange -
16 Lime Smoke Grey Canary

Chemical White yellow
17 CO2 Canary
Chemical yellow Light Grey -
18 Brine 40 % Chemical Smoke Grey White -
19 Methanol Dark Deep Buff

Admirality
Chemical Grey -
20 Nitrogen Liquid (Tank) Canary Black

Utility yellow -
21 Nitrogen Gas Canary

Utility yellow Black -
22 Low Pressure Steam Aluminun to French

(<7kg/cm2) Utility IS 2341 Blue -
23 Medium Pressure Steam Aluminun to

(7-11 kg/cm2) Utility IS 2340 Gulf REd -
24 High Pressure Steam Aluminun to Canary

(>11kg/cm2) Utility IS 2339 Yellow -
25 Process Water Chemical Sea Green Oxide Red -
26 Raw Water Utility Sea Green White -
27 DM Water Utility Sea Green Gulf Red -
28 Sea Green French

Cooling Water Utility Blue -
29 Light Brown French

Hot Oil (thermic fluid) Utility Blue -
30 Sealing Systemt Oil Utility Light Brown Light Grey -
60
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
31 Sky Blue French

Instrument Air Utility Blue -
The Indian Standard Colour Numbers are given below
Sr. No. IS CODE SHADE NAME
1 101 Sky Blue
2 102 Turquoise Blue
3 103 Peacock Blue
4 104 Azure Blue
5 105 Oxford Blue
6 106 Navy Blue
7 108 Aircraft Blue
8 166 French Blue
9 169 Traffic Blue
10 174 Oriental Blue
11 176 Phirozi
12 177 Satin Blue
13 216 Eau-De-Nil
14 217 Sea Green
61
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
15 218 Grass Green
16 219 Sage Green
17 220 Olive Green
18 221 Brilliant Green
19 222 Light Bronze Green
20 223 Middle Bronze Green
21 224 Deep Bronze Green
22 225 Light Burnswick Green
23 226 Middle Burnswick Green
24 227 Deep Burnswick Green
25 267 Traffic Green
26 275 Opaline Green
27 276 Lincon Green
28 277 Cypress Green
29 278 Light Olive Green
30 279 Steel Furniture Grey
31 280 Verdigris Green
32 281 Apple Green
33 282 Forest Green
62
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
34 283 Aircraft Grey Green
35 284 Indian Green
36 294 Sacmic
37 298 Olive Drab
38 299 Bus Green
39 309 Canary Yellow
40 352 Pale Cream
41 353 Deep Cream
42 354 Prim Rose
43 355 Lemon
44 356 Golden Yellow
45 358 Light Buff
46 359 Middle Buff
47 360 Deep Buff
48 361 Light Stone
49 362 Middle Stone
50 363 Dark Stone
51 364 Portland Stone
52 365 Vellum
63
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
53 368 Traffic Yellow
54 384 Light Straw
55 385 Light Biscuit
56 386 Champagne
57 387 Sun Shaine
58 388 Beige
59 397 Jasmine Yellow
60 410 Light Brown
61 411 Middle Brown
62 412 Dark Brown
63 413 Nut Brown
64 414 Golden Brown
65 415 Indian Bown
66 439 Orange Brown
67 442 Light Salmon Pink
68 443 Salmon Pink
69 444 Terra Cotta
70 445 Venetian Red
71 446 Red Oxide
64
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
72 448 Deep Indian Red
73 449 Light Purple Brown
74 451 Chocolate
75 473 Gulf Red
76 489 Leaf Brown
77 490 Beech Brown
78 499 Service Brown
79 536 Fire Red
80 537 Signal Red
81 538 Post Office Red
82 540 Crimson
83 541 Maroon
84 557 Light Orange
85 570 Traffic Red
86 574 Indian Saffron
87 591 Deep Orange
88 592 International Orange
89 628 Silver grey
90 629 Quaker Grey
65
AARTI SPECIFICATION
FOR SURFACE
COATING
Rev. 1 Date: 01/08/2019
LIMITED
91 630 French Grey
92 631 Light Grey
93 632 Dark Admiral Grey
94 633 AF Blue Grey
95 634 Slate
96 635 Lead
97 671 Middle Graphite
98 692 Smoke Grey
99 693 Air Craft Grey
100 694 Dove Grey
101 695 Dark Blue Grey
102 697 Light Admiral Grey
103 698 Steel Grey
104 796 Dark Violet
66

Procedure for Surface Preparation and Coating

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AARTI INDUSTRIES LIMETED-

Procedure for Surface Preparation and Coating

1 0 VAKUL CHAUHAN MANOJ Harendra Pandya

Issue Rev. Prepared By Reviewed Approved By

This document is the property of AARTI INDUSTRIES LTD.

2.1 Industry Codes and Standards

3.0 DEFINITION AND ACRONYMS

4.1 Safety Precautions

4.2 Brands & Products

4.3 Contractor Requirements

4.4 Coating Manufacturer’s Data Sheets

4.5 Coating Procedure Test (CPT)

4.6 Mixing of Coatings of Different Coating Manufacturers

4.8 Pre-Construction Primers

4.9 Paint Free Surfaces

5.0 SURFACE PREPARATION

5.1 General Preparation for Abrasive Blasting

5.2 Preparation for Abrasive Blasting

5.3 Hand or Power Tool or Water jet Cleaning

5.4 Abrasive Blasting

6.0 COATING APPLICATION

6.1 General Application Requirements

6.2 Weather Conditions

6.4 Mixing and Thinning

6.5 Shelf and Pot Life

6.6 Stripe Coat

6.7 Spray Application

6.9 Top Coating

6.10 Film Thickness

6.13 Brush or Roller Application

7.3 Inspection Equipment

7.4 Compressed Air Cleanliness

7.5 Abrasive Material

7.6 Environmental Conditions

7.7 Surface Preparation (Including Touch-Up Preparation)

7.8 Coating Application

7.9 Transportation, Handling and storage of coated components

7.10 Inspection by Company

7.11 Coating Manufacturer’s Representatives

8.1 Galvanizing Standard

8.2 Surface Preparation

8.3 Zinc Coating Weight

8.4 Surface Finish

8.6 Damaged Items

8.7 Reinstatement of Damaged Surfaces

8.8 Painting Galvanized Surface

Appendix A: Inspection & Testing Requirement

Appendix B: Finish Colour Schedule

Appendix C: Surface Preparation and Painting Inspection Record.

Appendix D: Generic Coating System

Appendix E: Approved Product List

Appendix F: Pipe Line color coding with IS shades

2.21Industry Codes and Standards

American Society for Testing and Materials (ASTM)

(Inorganic) Zinc-Rich Primers by Solvent Rub

Contamination of Blasting Abrasives

E337 Standard Test Method for Measuring Humidity with Psychrometer

(The Measurement of Wet-and Dry-Bulb Temperatures)

Society for Protective Coatings (SSPC)

PA1 Shop, Field, and Maintenance Painting of Steel

PA2 Measurement of Dry Coating Thickness with Magnetic Gages

PA3 A Guide to Safety in Paint Application

SP1 Solvent Cleaning