MUMBAI TRANS HARBOUR LINK PROJECT

PACKAGE II

PAINTING PROCEDURE

2 11.09.2020 Comment J.S.SEOK S.E.YUN C.K.PARK

1 29.04.2020 Comment J.S.SEOK S.E.YUN C.K.PARK

0 31.03.2020 First Issue J.S.SEOK S.E.YUN C.K.PARK

REV DATE DESCRIPTION WRITE CHECK APPROVAL

Document No: DWST-MTHL-QP-007

PAINTING PROCEDURE
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REVISION LOG

REV. NO. REV. DATE REVISED PAGE REVISION DESCRIPTION

0 31.Mar.2020 All First Issued

1 29.Apr.2020 6 Revised as comment

2 07.Sep.2020 6~29 Revised as commented

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CONTENTS
1.  SCOPE ........................................................................................................................... 4 
2.  REFERENCE DOCUMENTS .......................................................................................... 4 
3.  DEFINITIONS AND ABBREVIATIONS ........................................................................... 4 
4.  RESPONSIBILITIES ....................................................................................................... 4 
4.1  Painting Supervisor .......................................................................................................................... 4 
4.2  Painting Forman ............................................................................................................................... 5 

4.3  Application Personnel (Painters) .................................................................................................... 5 

4.4  QC Inspector ..................................................................................................................................... 5 

5.  STORAGE AND PRESERVATION OF PAINT MATERIAL. ............................................ 5 

6.  PAINT SYSTEMS ........................................................................................................... 6 
6.1  External Surface of Bolted Connection for Box Girder - F11 .................................................... 6 
6.2  Internal of Bolted Connection for Box Girder - F12 .................................................................... 10 
6.3  External Surface of Welded Connection for Box Girder -F13 .................................................... 13 

6.4  Internal Surface of Welded Connection for Box Girder and Deck (F14) ................................... 17 
6.5  External Surface of Welded Connection for Deck (KJ) ............................................................... 19 

7.  APPLICATION .............................................................................................................. 20 

7.1  Surface Treatment .......................................................................................................................... 20 
7.2  Painting ............................................................................................................................................ 21 
7.3  Repair of Damages ......................................................................................................................... 23 

8.  INSPECTION, TESTING AND ACCEPTANCE CRITERIA ........................................... 27 

8.1  Inspection Equipment .................................................................................................................... 27 
8.2  Surface Inspection.......................................................................................................................... 28 
8.3  Environmental Condition ............................................................................................................... 28 
8.4  Painting Inspection......................................................................................................................... 28 
8.5  Reporting and Final ........................................................................................................................ 28 

9.  APPENDICES ............................................................................................................... 29 

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1. SCOPE

This procedure describes the Surface Preparation, Corrosion Protective Treatment and Coating of the
MUMBAI TRANS HARBOUR LINK PROJECT PACKAGE II.

Bolt Connection Welding Connection

Location
External Internal Ext. Box girder Internal Ext. Deck

Paint system F11 F12 F13 F14 KJ

Number of
4 2 5 2 1
Coating
DFT(μm) 355(430) 300(375) 250 375 30

( ) : Including Shop Coating

2. REFERENCE DOCUMENTS
a) SPECIFICATIONS FOR HIGHWAY BRIDGES PART2 STEEL BRIDGES_2002
b) Coating and Anticorrosion Handbook for Steel Highway Bridges.
c) Steel Structure Painting Council (SSPC)
d) International Organization for Standardization (ISO)
e) Manufactures Instruction
f) Painting drawing

3. DEFINITIONS AND ABBREVIATIONS

a) DFT Dry Film Thickness. The thickness of the dried or cured paint or coating film
b) ISO International Organization for Standardization
c) NDFT Nominal Dry Film Thickness
d) RAL Color Matching System
e) TDFT Total Dry Film Thickness. The thickness of the total number of coatings specified
f) WFT Wet Film Thickness. The thickness of the uncured or wet paint or coating film

4. RESPONSIBILITIES
4.1 Painting Supervisor

Schedules, assigns, plans and supervises the work of painting. Plans and develops work schedules,
equipment usage schedules, priority of painting expenditures and procedures for equipment mainte-
nance. Estimates and monitors the acquisition and use of materials.

Trains or informs employees of new work methods or procedures, changes in safety regulations and
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work policies.

4.2 Painting Forman

Forman skilled painters in shop and outside work, assigns subordinate painters to work details, and
inspects work in progress and upon completion to ensure that it meets required standards.

Forman and participates in preparation of surface, mixing paints and matching colors, inspects surfaces
for cleanliness and readiness for painting, inspects equipment. He maintains records, reports of mate-
rial and labor.

Check on material requirements, calculation of necessary material amount and performance of related
works.

4.3 Application Personnel (Painters)

Prepare surfaces to be coated by using power wire brushing, blasting and solvent cleaning to remove
grease, dirt and rust. Monitor extractors, drying fans and heaters.

Application of coating onto manufactured products to provide finished surfaces. Move items to drying
areas and unload and stack them for further painting or packaging. Touch up defective areas of painted
items Clean nozzles, containers and hoses of machines.

4.4 QC Inspector

Organizes all parties for painting inspections. Provides assurance of the quality of painting application.
Verifies that all surfaces are in suitable conditions for painting.

Reports to QC manager of any anomalies or irregularities during the application.

For Surface acceptance and substrate testing for painting reviews all areas in scope of work prior to
surface preparations and paint application, verifies reference areas during application.

Performs dry film thickness measurement and issues paint inspection reports.

5. STORAGE AND PRESERVATION OF PAINT MATERIAL.

1) Coating material and thinners has a risk of catching fire, and the gases generated from them are
harmful to human body when they reach or exceed a certain level of concentration, so it is neces-
sary to use a warning sign about storage and handling of coating materials and thinners

2) In the storage facility, there must be an area clearly defined where the material where the Material
Safety Date Sheet(MSDS) are available for the stored products
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The MSDS shall provide paint handling procedures what protective equipment should be used or -
in case of an accident – for doctors to determine the appropriate treatment method.

3) All paints have a finite shelf life after which they are considered expired and are no longer recom-
mended for use. The storage must be kept considering product rotation by age(FIFO management:
the first product stored is the first product used). This prevents forgetting products in the warehouse,
where they expire and can cause quality issues.

6. PAINT SYSTEMS
6.1 External Surface of Bolted Connection for Box Girder - F11

Painting Thinner Target Coating

Paint Name Final Color
Process Dilution ratio Thick.(μm) Interval
Surface
Power Tool(ISO St3) Max. 4 hr
Preparation
Modified Epoxy Resin Undercoat TECT EP Thinner
Mist Coating 1~10days
Paint ESCO NB 30~50%
Ultra Thic Film Epoxy Resin Paint TECT EP Thinner
Under coating 300 1~10days
EPOMARINE SHB 3~5%
Intermediate Intermediate Paint for Fluoro Resin TECT EP Thinner
30 1~10days
Coating Paint CELATECT F UNDERCOAT 0~10%
Fluoro Resin Top Coat Paint TECT TOPCOAT RAL 7035 Light
Top Coating 25
CELATECT F TOPCOAT Thinner 10~20% Gray
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1) Mist coat – Modified epoxy resin undercoat paint.

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2) Undercoat – Ultra thick film epoxy resin paint
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3) Intermediate coat – Intermediate paint for fluoro resin paint
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4) Topcoat – Fluoro resin top coat paint

6.2 Internal of Bolted Connection for Box Girder - F12

Painting Thinner Target Coating

Paint Name Final Color
Process Dilution ratio Thick.(μm) Interval
Surface
Power Tool(ISO St3) Max. 4 hr
Preparation
Modified Epoxy Resin Undercoat TECT EP Thinner
Mist Coating 1~10 days
Paint ESCO NB 30~50%
UltraThic Film Epoxy Resin Paint TECT EP Thinner
Under coating 300 Light Gray(N8.5)
EPOMARINE SHB 3~5%
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1) Mist coat – Modified epoxy resin undercoat paint

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2) Undercoat – Ultra thick film epoxy resin paint
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6.3 External Surface of Welded Connection for Box Girder -F13

Surface preparation shell be inspected comparing with ISO photo

Painting Thinner Target Coating
Paint Name Final Color
Process Dilution ratio Thick.(μm) Interval
Surface
Blasting(Se 2 1/2) Max. 4 hr
Preparation
Anticorrosion Organic Zinc Rich Paint TECT EP Thinner
75 1~10 days
Base Coat SD ZINC 500 0~10%
Modified Epoxy Resin Undercoat TECT EP Thinner
Under coating 60 1~10 days
Paint ESCO NB 0~10%
Modified Epoxy Resin Undercoat TECT EP Thinner
Under Coating 60 1~10 days
Paint ESCO NB 0~10%
Intermediate Intermediate Paint for Fluoro Resin TECT EP Thinner
30 1~10 days
Coating Paint CELATECT F UNDERCOAT 0~10%
Fluoro Resin Top Coat Paint TECT EP Thinner RAL 7035 Light
Top Coating 25
CELATECT F TOPCOAT 10~20% Gray

For the F13 system painting refer to next pages of Paint Manufacturer recommendation
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1) Surface preparation
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2) Undercoat – Modified epoxy resin undercoat paint
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3) Intermediate coat – Intermediate paint for fluoro-resin paint
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4) Topcoat – Fluoro resin top coat paint

6.4 Internal Surface of Welded Connection for Box Girder and Deck (F14)

Painting Thinner Target Coating

Paint Name Final Color
Process Dilution ratio Thick.(μm) Interval
Surface
Blasting(Se 2 1/2) Max. 4 hr
Preparation
Anticorrosion Organic Zinc Rich Paint TECT EP Thinner
75 1~10 days
Base Coat SD ZINC 500 0~10%
UltraThic Film Epoxy Resin Paint TECT EP Thinner
Under coating 300 Light Gray(N8.5)
EPOMARINE SHB 3~5%

For F14 system painting refer to next pages of paint manufacturer’s recommendation
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1) Anticorrosion base coat – Organic zinc rich paint

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2) Undercoat – Ultra thick film epoxy resin paint

6.5 External Surface of Welded Connection for Deck (KJ)

Painting Thinner Target Coating

Paint Name Final Color
Process Dilution ratio Thick.(μm) Interval
Surface
Blasting(Se 2 1/2) Max. 4 hr
Preparation
Anticorrosion Organic Zinc Rich Paint TECT EP Thinner
30 N/A
Base Coat SD ZINC 500 0~10%

For the KJ system painting refer to next page of Paint manufacturer’s recommendation
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1) Anticorrosion base coat – Organic zinc rich paint

7. APPLICATION
7.1 Surface Treatment
Steel surface shall be prepared with power tool.

7.1.1 Requirement of Steel Surface

a) Preparation grade shall be St 3 with power tool and Sa 2 1/2 with copper slag.
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b) All surface defects such as mill scales, cold laps and slivers to be removed.

7.1.2 Washing & Degreasing

a) Fresh water washing will be executed for the areas required by the Paint Manufacturer Repre-
sentative

b) Oil and grease will be removed from the surface

c) Degreasing with bush or rags impregnated with organic solvent restricted to small areas.

7.1.3 Surface Preparation Sequence:

Surface preparation and coating application shall be done after all welding, NDT, degreasing, removal
of sharp edges, weld spatter and treatment of welds is complete. It is important that all hot work is done
before coating application.

Surfaces will be treated by power tool for F11, F12 system and for the welded part of system, F13, F14
and KJ will be blasted with copper slag.

7.2 Painting

7.2.1 Weather Condition

Unless otherwise specified in the product data sheet, paint application shall not be performed on the
conditions as follows. Hence, painting shall be performed where weather control condition.

a) When the relative humidity higher than 85%.

b) When the metal surface is wet.
c) The steel temperature is less than 3 °C above the dew point.
d) Also artificial ventilation with temperature and humidity control will be provided in the paint booth

7.2.2 Mixing of Paint

Care for the mixing time of paint will be taken, and paint will be fully mixed before application in order to
keep the pigments in uniform suspension.

7.2.3 Coating Application

Each coat of paint system shall be colored such that each coat is distinguishable from the other. The color
of succeeding coats shall vary slightly from the color of the preceding coat to permit easy identification
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without affecting finish color. The color shade of each coat shall be checked with the ‘Sampled color Pan-
els’.

Before applying the subsequent coat, each coat shall be examined for dry film thickness and application
related defects such as runs, sags, drips, voids, bubbling, crater, overspray powder, dust ball at the weld
areas, etc. Defects that can be corrected during the application shall be brushed out while the paint is
applied. Defects that cannot be corrected during the application shall be corrected after the coating is dry.

The freshly applied coating material should be applied at pre-established wet film thickness provided by
the paint manufacturer. During application, wet film thickness shall be obtained as often as required to
maintain the dry film thickness within the specified limits.

Each coating shall be applied within the manufacturer's minimum and maximum recoat times. If the re-
coat time has been elapsed, then coated surface shall be sanded by using sand paper or method recom-
mended by the paint manufacturer.

STRIPE COATS
Stripe coats shall be applied prior to or after spraying application of 1st coat of internal and external sur-
faces and 2nd coat of external surfaces as per paint manufacturer’s recommendation. At the edge, stripe
coats shall be applied extending at two sides along approximately 25mm.

SPRAY APPLICATION
Spraying will be applied by airless paint sprayer to provide smooth and uniform spread so that no excess
paint will be collected at any point especially for structured details. The wet film thickness shall be con-
trolled during spraying.

BRUSH APPLICATION
Unless otherwise specified from paint manufacturer, brush application will be used only for;
a) Areas cannot be properly coated by spray for any reason.
b) For touch-up and stripe coats.
ROLLER APPLICATION
The parts that cannot be sprayed should be painted with roller or brush (nylons).

7.2.4 Ventilation
When coating products containing solvent is applied the solvent will evaporate and produce an explosive
atmosphere unless the solvent concentration immediately is reduced to a not-explosive level. Hence, ar-
tificial ventilation will be provided.
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This ventilation will be maintained during the paint application and drying time as given in the coating
products Technical Data Sheet. The ventilation shall ensure that the solvent concentration in the painting
hall at no time exceeds the maximum permitted.

7.3 Repair of Damages

Protective coating damages shall be carried out in accordance with the recommendations of the paint
manufacturer and relevant standards, specifications referred in this procedure.

All the receiving of shop fabricated block shall be inspected when it discharged from the ship.

Once it noticed the damage of painting, inspector shall report the specific condition, viz the location,
damaged area depth of the most damage spot. (refer to attached damage report)

1) Sufficiently investigate the damaged parts of the coating film that occurred during transportation and
installation. Identify the damaged area with masking tape.
2) Wipe off dust and dirt from the damaged part of the coating film with a waste cloth
3) Use sandpaper to remove the step around the damaged part of the coating film.
4) Keep the repair painting area to a minimum

7.3.1 Repair of painting

Surface preparation shall be done as manufacture’s instruction as shown on. Also painting system shall be
the instruction.
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Repair methods based on depth of damage – C5
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Repair methods based on depth of damage – D5
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8. INSPECTION, TESTING AND ACCEPTANCE CRITERIA

8.1 Inspection Equipment

All inspection equipment shall be calibrated and have an identification tag showing date of calibration and
due date.
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8.2 Surface Inspection
Visual examination shall be performed for the steel substrate prior to painting application and care shall be
taken for degreased surfaces if any.

8.3 Environmental Condition

Environmental condition of paint workshop such as temperature, humidity and dew point shall be controlled
and recorded during application.

8.4 Painting Inspection

Dry Film Thickness Inspection

The nominal dry film thickness (NDFT) of each layer shall be measured according to ISO 19840 “Measure-
ment of, and acceptance criteria for, the thickness of dry films on rough surfaces”.

Electromagnetic gauge for dry film thickness shall be used according to EN ISO 2808. The minimum num-
ber of reading is to be taken for the evaluation of dry film thickness is based on the lot definition. As per JRA
paint manual, one measurement point per 10 sq.m area, if selected lot is less than 200 sq.m area.

Measurement shall be taken 5 times at each point, and the average value is taken as the measurement
value at each point

The control reference values for coating film thicknesses need to satisfy the following conditions.

a) The average coating film thickness of a lot shall be 90% or more of the target total coating film thickness.

b) Th minimum measurement shall be 70% or more of the target total coating film thickness.

c) The standard deviation if the distribution of the measured values shall not exceed 20% of the target total
coating film thickness. However, it shall be considered satisfactory if the standard deviation exceeds 20%
but the average of the measured values is greater than the target total coating film thickness.

d) Treatment of Rejected Lots,

For rejected lots, the same number of measurements shall be taken again, and if the result calculated
together with the initial measurements meets the control reference values, they are regarded as accepta-
ble. For rejected lots, additional coating of the uppermost layer must be applied, and measurements must
be taken again.

8.5 Reporting and Final

Coating Progress Inspection Report shall be fulfilled for each inspection. Coating Progress Inspection Re-
port is given as Appendix 1.
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In addition to inspection report, schematic paint sketch showing the lot and selected points shall be at-
tached.

Final painting inspection of each segment shall be carried out and an inspection report shall be signed off
by Contractor regarding to completion of all painting.

9. APPENDICES

Appendix-1 Coating Progress Inspection Report

Appendix-2 Painting damage report

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Appendix-1 Coating Progress Inspection Report
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Appendix-2 Painting Damage Report