SOP Painting of Civil & Steel Structures - Verson11 30.04.21

STANDARD OPERATING PROCEDURE
Form No: EHSMSM/446/4013 FORM REVISION NO : 01 EFFECTIVE DATE : 01-04-2009

SOP NO TSLPL/SOP/01 EFFECTIVE DATE 30.08.2023 REVISION NO 00
SOP DESCRIPTION PAINTING OF CIVIL & STEEL SECTION CIVIL
STRUCTURES
DEPARTMENT CIVIL PAGE
STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

NO (WHAT) REQUIREMENTS/ TY REFERANCES
HAZARDS/IMPACT (WHO)
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1 Obtaining SAFETY : Vendor  Work permit format EHS-MSM/446/4007 is applicable SS/GEN/

Work Permit Unawareness of supervis for inside works. 25/
before proximity or  For routine jobs, Shut down jobs and break down jobs (< 48 Hrs WORK
starting of hazards may jobs) permit will be renewed after one shift ( A shift ,B shift ,C PERMIT
Job. lead to an shift & General Shift). SYSTEM
accident  For MSD ( >48 Hrs jobs ) permit will be renewed after one shift
or after 24 Hrs.
ENVIRONMENT  Permit requested by: – Permit will be requested by the executing
: NA departmental agency under which job will be carried out in all cases
QUALITY -  Permit Issued by: - Permit will be issued by Owner of the area
Work permit / equipment in all cases
should be filled  Permit taken by: - Permit will be taken by the agency that
properly with will perform the job.
all relevant  Permit to work certificate for gas hazard jobs
information in shall be taken in Form # EHSMSM /
form EHS- WORKS
MSM/446/400 /446/4001 by the executing agency and to be issued
7 by the owner.
 Electrical Power cutting clearance will be given in Form# EHSMSM
/ WORKS / 446 /4005 and for Electrical job which requires
grounding / discharges, clearance will be given in Form # EHSMSM
/WORKS/446/4010. The Power cutting clearance will
be requested by executing agency.
 Fluid power energy source isolation clearance shall be taken in Form #
PREPARED BY:- APPREOVED BY:-
NAME & DESIGNATION :- NAME & DESIGNATION :-
SIGNATURE: SIGNATURE:
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EHSMSM / WORKS/ 446/4016

 Six direction hazards are to be filled up by the requester of the
permit.
 Permit to be obtained in work permit booklet issued by
department only.
 Work permit should be returned on each day after completion of
work.
ENVIRONMENT
QUALITY: 1)
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Only Calibrated pack, ELBA in case of emergency.

gas detector
should be used.
3 Working near SAFETY : Vendor  Obtain clearance in form EHSMSM/WORKS/446/4005. SS/GEN/

Electrical Electrocution supervis  Equipment electrically operated like cranes etc. should be completely 26
source. Hazard or isolated from electrical source. POSITIVE
ENVIRONMENT  For Areas like transformers, electrical panel’s job should be done after ISOLATIO
QUALITY proper masking and during Shut down only. N
 Power rails should be protected using masking tape or paper or both.
 Do not use mobile phones near high power lines.
 Work should not be carried out under suspended loads of cranes. If
a load is being carried away by an overhead crane above the working
area job should be stopped and the workmen should step away from
the suspended load.
4 Working At SAFETY : Vendor Steps to taken before working at height SS/ENGG

Height Falling from supervis  Check there is a safe method of getting to and from the work area. -3 Version
Height/ or  Decide what particular equipment will be suitable for the job and the 6
ENVIRONMENT conditions on site.
: Paint Spread  Make sure work platforms and any edges from which people are likely
to larger area. to fall have guard rails and toe boards or other barriers.
QUALITY :
NAME & DESIGNATION :- NAME &DESIGNATION :-
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 Due considerations to be given for scaffolding and ladder standards. For

this refer safety standard SS/ENGG-08 and SS/ENGG-09 for
scaffolding.
 Check that the equipment and Body Harness is in good condition and
make sure that whoever puts the equipment together is trained and
knows what they are doing.
 Make sure those who use the equipment are supervised so that they
use it properly. The more specialized the equipment (for example,
boatswain's chairs and rope access equipment or system), the greater
the degree of training and supervision required to ensure
Safety.
 Check any equipment provided by another company is safe on site before
using it.
 Make sure that tested equipment, systems etc. are used
Points to be followed while selecting means of access :
 When it is not practicable to provide a work platform with guard rails

(Scaffoldings) should other safe means of access e.g. boatswain's
chairs or rope access techniques) be used.
 When no other method is practicable, or risk assessment shows other
methods are safer when work platforms cannot comply with all
requirements for safe work (e.g. a guard rail has to be removed to
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land materials), should a way of arresting falls (for example, harness

and lines or nets) be relied upon;
 If no other means of providing a safe place of work at height is
available, then appropriately anchored harness should be worn.
However, whenever harnesses are used a method must be available
to enable people to be rescued from fall and be left suspended in
their harness.
 Nets may also be needed to protect those working to put guard rails
or other protection in place.
 Ladders should always be secured if possible both laterally &
longitudinally at the ends. They should be primarily used for access
and only be used as workplaces to do light work of short duration,
and only if it is safe to do so. It is generally safer to use a stable tower
Scaffold or MEWP, Man lifter even for short-term work.
When using a ladder ensure that the ladder is as per standard drawings
and the person on the ladder always has three points of contact, i.e. two
legs and a hand. People should never have to lean sideways when up a
ladder.
 When selecting a safe system of work at heights, all the risks have to
be considered before one method is selected. For example, if nets are
selected, is there adequate clearance under the nets to prevent injury
to those who may fall into them? If harnesses are used, is there
Sufficient clearance from the ground to allow the shock absorbing
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lanyard or inertia reel to fully extend?

 Before any work at height, check that there is adequate clearance for
equipment. For example, overhead power lines can be a risk when
erecting scaffolds or using MEWPs;
there can be a risk of crushing against nearby structures when mobile
access platforms are maneuvered.
 Work permit for working at height shall be issued in Form No.
EHSMSM/WORKS/446/4007 or its revision, before start of the job by
the authorized person of the department in duplicate. The original shall
be issued to working agency while the copy shall be kept by the issuing
authority. Following checks shall be carried out before taking permit to
working at height
(1) Personnel skill
(i) Whether the Person is a certified rigger.
(ii) Whether Person is fit for working at height (ask for certificate from
Doctor whether the person has vertigo-height phobia, for working at height
more than 2 meter).
(iii) Person is trained on working at height. Height Pass issued by TSL
(2) Suitability of approach.
(i) Physical condition and suitability of steps, rung ladders.
ii) Scaffolding ,ramps, stairs with respect to load
(3) Suitability of platform
(i) Whether handrails provided at 1.0 meter height with top rail middle rail
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and toe guard.

(ii) Whether extended support roof/working platform fabricated or available.
(iii) Whether secondary support provided while working at fragile
or hazardous roof.
(4) Availability of PPE and tools.
(i) Helmet with chin strips, in working condition.
(ii) Safety belt with double lanyard with arrangement for life line support.
(iii) Fall arrester.
(iv) Manila rope used as lifeline or for any other purpose shall be
checked before each application, when it is in use. Diameter to be
ascertained before use and to be certified by a competent & qualified
Engineer of the department executing the job.
The test procedure for manila rope will be same as being followed for all
other construction tools & tackles.
(5) Communication.
(i) Tools, tackles, fixtures, fasteners, cages, rope ladders, plant &
machinery, cranes etc. to be used must be tested prior to use.
(ii) Appropriate anchorage points identified / connected.
(iii) Hazard of nearby work vicinity has been identified like, power line,
power mobile equipment, gas line, etc. and proper care has been taken and
same communicated to persons expected to work at height.
(iv) Operator of mobile equipment in the close vicinity informed about job
being done.
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(v) Area on ground beneath the height where job is being executed has
been properly barricaded/fenced indicating danger.
(vi) Concerned departmental personnel whose work may get affected by
the job have been identified and communicated.
(vii) Loose material not to be kept at heights
(viii) Damaged, torn, bend scrap sheets not to be used on platforms.
(ix) Material at heights is kept in arranged manner to avoid slip/trip/fall
hazards.
(x) Tools, tackles, consumables, holders etc. are kept tied to avoid their fall.
 Any work at height shall be carried out only in presence of skilled
supervisor.
 Only trained persons shall be allowed to work at height.
 Permit shall be issued only if the findings of the above checks satisfy
the issuing authority.
SAFETY Cleaning :
Surface
:Health Risk Vendor Hand tool cleaning is shall be used only for removing loosely adhering paint
preparation
5 Health risk can supervis or rust. The hand tools include scrappers, abrasive pads, chisels, knives
ferrous
arise from the or and chipping hammers. The common processes of hand tool cleaning are –
substrate following: Wire brushing: Wire brushing is a conventional method not suitable for the
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1) Inhalation removal of mill scale, but suitable for the preparation of weld seams.
of dust Chipping: Chipping is should done in combination with wire brushing. It is
2) Dust suitable for local repairs with conventional or some specific paint systems. It
particles is very useful in removing thick rust scale and economises in later blasting
may fall operations.
into eyes Power Tool Cleaning: Power tool cleaning involves pneumatic or
3) Cut on electrically operated tools for cleaning operations.
figures Power driven equipment, such as sanders, grinders, wire brushes, chipping
during hammers, scalars, and needle guns shall be used.
scrapping/s Water Jet Cleaning :
anding On Water jetting uses water of sufficient purity and quality at high or ultra-high
sharp edges pressure to prepare a surface for recoating. It can be used to clean steel, non-
ferrous metals and other hard surfaces. It generally removes loose paint,
chemical contaminants, loose rust and scale, grease and other material not
tightly bonded to the surface.
Four types of surface preparations using water are given below
ENVIRONMENT • Low pressure water cleaning: Cleaning performed at pressures less than
: 34 MPa (5000 p.s.i)
 Land • High pressure water cleaning: Cleaning performed at pressures from 34
degradatio to 70 MPa (5,000 to 10,000 p.s.i)
n • High pressure water jetting: Cleaning performed at pressures from 70
 Dust to 170 MPa (10,000 to 25,000 p.s.i)
pollution • Ultra high pressure water jetting: Cleaning performed at pressures above
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170 MPa (25,000 p.s.i)
Water jet cleaning can be destructive to non-metallic surfaces. Soft wood,

insulation, electric installation and instrumentation must be protected from
QUALITY: Poor direct and indirect water jet. Water used in water jetting must be clean and
adhesion of free of erosive silts or other contaminants that damage pump valves or leave
coating if deposits on the surface being cleaned.
surface Abrasive Blast Cleaning
preparation is Involves the impingement of a high kinetic energy stream of abrasive (such
inadequate. as sand, grit or shot) onto the surface to be prepared. It may either be hand
operated by jet or automatically by impeller and is the most effective method
for removal of mill scale, rust and old coatings, but not oil or grease. Four
common grades of blast cleaning are:
White metal blast cleaning: (Swedish standard - Sa 3)
A white metal blast cleaned surface when viewed without magnification,
shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating,
oxides, corrosion products and other foreign matter.
Near - white metal blast cleaning: (Swedish standard - Sa 2½)
A near-white metal blast cleaned surface when viewed without
magnification, shall be free of all visible oil, grease, dust, dirt, mill scale,
rust, coating, oxides, corrosion products and other foreign matter. Generally
evenly dispersed very light shadows, streaks and discolouration caused by
stains of rust, mill scale or previously applied paint/coating may remain on
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no more than 5% of the surface.

Commercial blast cleaning: (Swedish standard - Sa 2)
A commercial blast cleaned surface when viewed without magnification,
shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating,
oxides, corrosion products and other foreign matter. Generally evenly
dispersed very light shadows, streaks and discolouration caused by stains
of rust, mill scale or previously applied paint/coating may remain on not
more than 33% of the surface. Slight residues of rust, paint/coating may
also be left in the crater of pits, if the original surface is pitted.
Brush off blast cleaning: (Swedish standard - Sa 1)
Brush-off blast cleaned surface when viewed without magnification, shall be
free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides,
corrosion products and other foreign matter. Tightly adherent mill scale,
rust and old paint/coating may remain on the surface.
6 Surface SAFETY: Vendor New concrete or masonry:

preparation Splashing of supervis Must be allowed to cure at least 30 days before coating. The moisture
Non-ferrous Acid /Alkali, or content of the concrete/masonry should be less than 6%. In case of large
substrate Hydrocarbon areas and for severe exposure conditions, the surface has to be prepared by
(concrete solvents into light blasting. In less critical areas where blasting is not practical, wire
surfaces) eyes or hand. brushing has to be adopted to remove laitance,
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ENVIRONMENT Old concrete surface:

: Land Remove the surface contaminants like grease, oil, etc., by solvent wiping or
degradation by 10% caustic solution. Preferably the surface has to be prepared by light
QUALITY blasting. In case, blasting is not practical, etch the surface to get a good
profile by treating white dilute hydrochloric acid (10%).
Remove acid and contaminants by liberal wash with water. Ensure that acid
solution does not retain on the surface and joints. Allow the surface to dry
thoroughly before applying primer. Any cracks should be cut out and filled
with suitable filler prior to painting.
SAFETY: Vendor While brushing is a somewhat slow procedure many small jobs do not
 Falling of supervis warrant the use of any other application method. Brushing is especially
paint or useful for touch up work, spot priming, work in confined areas or where
over eyes spraying is impossible. Less paint is wasted when applied by brush than by
 Allergic any other method.
Paint reactions  For solvent based coatings natural bristle or Synthetic bristle brushes
application ( on skin can be
7 ENVIRONMENT  For Water based coatings synthetic bristle brushes are to be used
Brush
Application) : • Use of high quality, clean brushes of the proper shape and size shall be
 Spillage used for each application
of paint • Assure that all holidays or voids are eliminated, but avoid excessive
 Land brushing which may reduce film thickness and decrease protection.
degradat • Avoid filling the heel of the brush with material. Approximately half of the
ion bristle length of the brush should be wet.
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 Water • Stroke the brush at 45° angle. Light strokes at this angle ensure even flow.
pollution • The brush application shall be by up and down strokes, then crosswise
and finally with up and down strokes lightly. This is called cross lapping
QUALITY and helps eliminate brush and lap marks. Fast drying materials often do
not permit cross lapping which may cause paint to pile up. If it is necessary
to brush apply fast dry material, it should be flowed on rapidly and
generously and then left undisturbed. To go back over such a surface
usually results in excessive brush drag, leaving ridges and brush marks.
SAFETY: Application - Roller
• Falling of Rollers are efficient tools for applying industrial coatings and are suited for
paint over eyes broad flat surfaces. The general rule for selecting a roller cover is 'the
• Allergic smoother the surface the shorter the nap'. Solvent thinned coatings should
reactions on be applied with either lamb's wool or synthetic covers and water reduced
skin coatings should be applied with synthetic covers. When using rollers to
ENVIRONMENT apply coating systems such as epoxies and polyurethanes which contain
: strong solvents, be sure that the roller cover selected is constructed with
• Spillage glues which are resistant to these strong solvents.
of paint Method for effective roller application:
Paint • Land • On large areas, material should be applied approximately on 0.75 sq.m.
application degradation at a time.
8 (Roller • Water • Saturate the roller cover thoroughly with the coating. Paint should be
Application) pollution loaded onto the cover until just before it drips.
QUALITY: • The first strokes with the loaded roller should be done in a "W" pattern
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within approximately 0.75 sq.m. area. The "W" pattern should then be fixed
in with successive strokes.
• Work from dry areas back into wet areas. In this way a more uniform film
thickness is maintained.
• When a material is applied to warm surfaces in direct sunlight or when
fast drying coatings are used, work in smaller areas to maintain a wet edge.
• Most coatings will dry to a slight orange peel appearance when applied by
rollers.
SAFETY Vendor The easiest and most rapid method for the application of protective coatings
ENVIRONMENT supervis to large areas is spraying. Spray application is preferred where a smooth
• Spillage or uniform finish is desired and speed of production is important.
of paint Conventional air atomization is used when quality of finish is of utmost
• Land importance or where great versatility is desired. Airless spray is best for
9 Paint degradation large scale operations not requiring very fine finish.
application • Water Both conventional and airless spray may be modified for increased
(Spray pollution performance or for specialized applications. One such modification includes
Application) adding heaters to fluid lines. The use of heated paint permits atomization at
lower pressures, decreases or eliminates the need for thinning, cuts down
an overspray rebound and provides a heavier film build with minimum
waste of paint and solvents. The only drawback associated with hot
spraying is that the pot life of catalysed products sprayed by heated method
is generally reduced.
Air Spray Application
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A conventional air spray gun is a precision tool which uses compressed air
to atomize spray able materials. Air and paint enter the gun through
separate passages and are mixed and ejected at the air nozzle to provide a
controlled spray pattern. The amount of paint leaving the gun is controlled
by the pressure on the fluid container, the viscosity of the paint, the size of
the fluid orifice, and by the fluid needle adjustment.
Suggestions for effective air spray painting:
• Use the lowest possible air and fluid pressure when operating a spray gun.
• Use the proper fan width for the job.
• Spray from the proper distance (6-10 inches).
Vendor • Hold the gun perpendicular to the work throughout the spray stroke.
supervis • Move the spray gun parallel to the work surface throughout the spray
or stroke.
• Move the spray gun at a speed which assures that a full wet coat is
applied to the surface.
• Overlap strokes at least 50%.
Airless Spray Application
Airless spray is a method of application which does not directly use
compressed air to atomize the coating sprayed. Hydraulic pressure is used
to atomize the fluid by pumping it at high pressures (500-3500 p.s.i.)
through a small precision orifice in a spray nozzle. As the fluid is released at
these high pressures, it is separated into small droplets resulting in a finely
atomized spray.

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Since air is not used to form the spray pattern, the term "airless" is used to
describe this method.
Airless spray painting is cleaner and faster than conventional spraying
methods. One advantage of airless spraying is that the overspray fog or
rebound associated with conventional spray is greatly reduced. This makes
use of equipment possible in places and applications where material
formerly had to be brushed.
Another significant advantage of airless spray is the ability to apply heavy
coating thickness more quickly than by any other method. Most coating
materials may be sprayed in their un thinned state which also helps
contribute towards the formation of heavy films and greatly reduces thinner
use.
Vendor Method for effective airless spray painting:
supervis The technique employed for airless spraying is similar to the technique
or practiced in air spraying.
• The ideal spraying pressure for any given tip is achieved by gradually
increasing the pressure until the spray pattern appears uniform across its
fan width and the atomized coating particles are of acceptable size.
• If the coating is coarsely atomized, the pressure may be increased slightly,
a smaller orifice tip used, or the coating thinned.
• Avoid using excessively high airless spray pressures, which may cause
effervescence or other finish defects.
• Hold the gun perpendicular and move it parallel to the surface at all times
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in order to obtain a uniform coating of material.

• Arcing, heeling and toeing should be avoided at all times.
• The proper working distance with airless spray is approximately 10-15
inches.
• When using wide angle spray tips, the gun must be moved closer
(approximately 10-12 inches) to the work. Excessive spray distances
increase paint fog and paint consumption.
Paint SAFETY: Vendor Hand gloved must be used while opening the paint drum to avoid cut
Application 1)Cut injury supervis injury. Air drying epoxy and polyurethane coatings are normally two
Technique while opening or component systems, consisting of a base and a hardener. The two
of paint drum components have to be mixed in the ratio as recommended by paint
with sharp edge supplier to ensure proper and complete curing of the coatings. Improper
tools. ratio leads to problems like soft/non-dried film, poor performance, etc.
The base and hardener are to be separately mixed first to obtain a
10 2)ENVIRONMEN
T homogenous mixture. The hardener is to be added to the base slowly, with
QUALITY continuous mixing/agitation and not the reverse. After complete addition,
mixing/agitation is to be continued to achieve a homogenous mixture.
Power agitation in preferred over hand mixing. Any addition of thinner to
achieve the application viscosity should be made only after the components
are thoroughly mixed and not to the base/hardener or while mixing the two
components. After thorough mixing of the product, the maturation time as
indicated in
PREPARED BY:-
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the product data sheet is to be allowed before applying the product. The
mixture thickens as the time progresses, and at the end of the pot life period
the mixture becomes highly viscous and unusable. It is best to consume
mixed paint at least one hour before the end of the pot life.
Avoid using excess thinner than the recommended volumes, since this can
lead to lower dft build up, sagging, longer curing time, etc.
11 Special coating SAFETY Vendor Surface Preparation

application ENVIRONMENT supervis • Remove oil, grease and other contamination with a suitable detergent,
QUALITY or followed by high pressure water washing. Aromatic solvents can also be
used to remove the contaminants.
• Ensure that all welds/weld seams are complete and continuous without
any cracks and pinholes. Remove all weld spatters & round off all the sharp
edges prior to further surface preparation. In case you find any traces of
soap/alkali deposits on weld joints which are used for pressure testing,
please remove the same by fresh water washing and scrubbing with stiff
nylon brushes.
• After above operation, grit blast to Sa 2 ½ to Sa 3 of Swedish
specification. For severe exposure conditions, grit blasting to Sa 3 is
recommended for optimum results. The surface profile after blast cleaning
shall be 50 - 75 microns.
• Substrate temperature should be at least 3°C above dew point but not
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above 50°C.
• Relative humidity should be less than 85%
Vendor • Use steel grits, copper slag, aluminium oxide grits or similar sharp edged
supervis abrasives, free of foreign matters and soluble salts.
or • Steel grit/copper slag with particle size of 0.2 - 1.0 mm or aluminium
oxide of 0.4 - 1.8 mm should generally help to achieve the surface profile of
50 - 75 microns with 100 p.s.i. air pressure.
Paint coating: Coatings should be applied by spray application only. Brush
application can be used only for touch-up areas.
• Air Spray :
Nozzle pressure - 43 - 57 p.s.i.
Nozzle orifice - 1.8 - 2.2 mm
Volume of thinner - 10 - 25 %
• Airless Spray :
Nozzle pressure - 1700 - 2100 p.s.i.
Nozzle orifice - 0.48 - 0.64 mm
Volume of thinner - 10 - 25 %
Note:
• Pressure pot must be fitted with an air driven agitator to maintain
continuous mixing while application.
• The fluid hose should not be more than 15 meters long.
• Use specified thinner as given in the data sheet for thinning and cleaning.
• Apart from correct spray technique, the amount of thinner should be
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adjusted in such a way that the coating applied is wet and smooth just after
application.
Vendor • The amount of thinner will depend upon site conditions such as
supervis temperature, humidity, wind flow, ventilation etc.
or • Select small nozzles for spray application of complicated and non-regular
structures.
Mixing of Paint
• Stir/shake the hydrolysate part thoroughly before mixing. The powder
portion (zinc dust) (in case of zinc silicates)should be added to the
hydrolysate component slowly with constant mechanical stirring. Continue
stirring until the mixed paint is free from lumps.
• Filter the mixture through a wire screen of 30-60 mesh. Keep the mixture
continuously stirred during application and ensure that it is used within 4
hours.
• Avoid part mixing of the paint.
Drying and Curing

Inorganic zinc rich primers are sensitive to environmental conditions for
drying and curing. This product requires minimum relative humidity of 50%
and minimum steel temperature should be 10ºC. In case skin temperature
of steel is more than 40ºC, spraying shall be done by extra thinning, to
avoid dry spray application.
The curing may be promoted at low humidity by spraying fresh water after

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4-6 hours of application of primer and keeping the surface constantly wet
until curing is complete. The complete curing can be checked by rubbing
the coating with a cotton cloth soaked in thinner. If the coating remains
unaffected, the curing is complete. The full hardness and curing will be
obtained after weathering.
Film Thickness
High deposition of film thickness (125 microns +) can result in mud-
cracking while lower dry film thickness can affect the performance of
coating. In case one needs to augment the dft, apply one more coat of over-
thinned primer within 24 hours.
Vendor Recoating
supervis The most frequent problem associated when top coating is bubbling/pin
or holing especially with non-weathered zinc silicate coatings. To a great
extent, this bubbling of finish paint can be eliminated by applying a mist
coat of intermediate/topcoat as the first pass of the product, allow the
bubbles to subside and then apply a full coat, as required.
Note:
In case recoating of zinc silicate with epoxy/chloro/polyurethane coatings is
expected to be delayed, it is advisable to use a suitable tie coat to avoid
formation of white rust.
The cleaning/secondary surface preparation of inorganic zinc rich primers
before top coating depends on the condition of the primed surface.
Condition 1
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Zinc silicate coating is intact with sporadic formation of white rust also
called as zinc corrosion products.
• Remove oil, detergent, etc., by detergent wash
• Remove white rust by high pressure water jet washing (2000-5000 p.s.i.).
If the surface is slightly contaminated, hosing down the surface with fresh
water and scrubbing with stiff nylon brushes may be sufficient.
• Ensure that the primed surface is thoroughly dry before over coating.
Condition 2
Damaged areas, burns, weld spatters etc.
• Remove oil, grease, dirt, etc. by detergent wash
• Remove weld spatter
Vendor • Spot blasting to minimum Sa 2½ followed by removal of abrasive and dust
supervis by vacuum cleaning.
or • Touch up with inorganic zinc silicate or suitable epoxy coating
Special Instructions
• Excessive film build up more than recommended DFT may lead to mud -
cracking. In such a case the coating has to be re blasted.
• Application of second coat over the first coat should be avoided.
• The product should not be applied on surfaces, unless, blast cleaned to
minimum Sa 2½ of Swedish specification.
• Painted structures should be kept at least 4 inches above ground.
Use suitable sealer/tie coat over the primer in case of project painting, where
the finish paint application is generally done after erecting the structures.
• Good ventilation is essential in confined areas.
• Painters should wear adequate personal protective equipment’s e.g. air fed
mask, safety glasses, etc.
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• Keep away the material from flame and sparks. Protect zinc dust against
moisture.
Storage of SAFETY: Vendor • Store paints/solvents in an appropriate container in well ventilated room
paint and Fire and supervis of fire resistance material of construction
thinner at explosion or • Prohibit smoking/ fire in the area where paints are stored, mixed or used
paint store or hazards • Provide adequate ventilation in working areas
at work place Fire & • In confined areas or closed space, maintain and monitor the vapour
Explosion risk concentration below explosive limits
can arise from • Use non-sparking tools and electrical fittings
the following: • Ensure that all equipment, meters and lights in the area are grounded and
• Fire risk consider using only explosion-proof lighting.
12
during storage • Install appropriate type of fire extinguisher at storage and working areas
or transport • Keep pails of sand or any other suitable absorbent material
• Explosion • Always clean up paint or solvent spills immediately and dispose it suitably
hazard during  Cordoning off area where paint is kept to prevent spreading any spillage.
application  For keeping paint at workplace, take necessary consent from customer department
and cover the paint container with a fire-retardant cloth/ fire blanket and ensure
fire free area. There should not be any container of paint at work place after the job
at the end of each day. In case of SD/MSD/urgency, residue paint quantity at work
place after 5.00 pm should not be more than requirement of two shift to carry out
job till night shift only.
Most paints and
solvents are
highly
STRUCTURES

S
inflammable
and extremely
dangerous
when exposed
to open flames,
sparks or high
temperature
ENVIRONMENT
QUALITY
13 Personal SAFETY : Vendor Following are the PPE’s that are mandatory while working inside Works
protective  FETALIT supervis  Head : ISI marked Safety helmet
equipment(PP Y or  Eyes : Safety eye goggles
E)  INJURY  Body: 1)At steel melting shop : Fire retardant jacket and trousers
2) Near track line or on roads : fluorescent jacket
ENVIRONMENT  Foot: Safety shoes
QUALITY: All  Nose : Dust respirator, Nose mask
PPE must be as  Ears : Ear plug
per TSL quality  Ankle : Leg guard
standards  Hands: Hand gloves.

STRUCTURES

S
14 Working with SAFETY : Crush Vendor Area should be barricaded with red tape. ES/PA/S
Powered injury in swing supervis No person will enter inside barricading area OP/02.02
access vehicle area or A trained flagman should present at site to divert the traffic.
No flag man as pedestrian will be allowed to move on the road to
guide above Powered Access Vehicle.
In case it is essential to guide any such vehicle the guide should be
escorted in another vehicle (four wheeler).
Powered Access Vehicles (Genie, JLG etc.) having reach of 80 feet
and more and crawler equipment can move on road from one
department to another ONLY during night shift between 11 PM and
5 AM without any pedestrian flag man.
All other Powered Access vehicles (JLG and Genie M/C )can move on
the road in the following time slots only:-
9:30 am – 11:30 am
2:30 pm-3:30 pm,
11:00pm-5:00 am.
It is advisable to use low bed trailer for long distance movement of

above equipment to the extent possible.

STRUCTURES

S
ENVIRONMENT
QUALITY
15 Working Safety : Hit by Vendor  Area should be barricaded with red tape.
along road running supervis  Display board should be placed on site
sides and vehicle/ loco or  Trained Flagmen should be placed to divert the traffic.
track line Environment  Florescent jacket is mandatory
Quality : Red  Supervisor should observe the approaching train and intimate
tape should be the working persons though whistle.
visible .  Red flag to be placed on each side of the track line at least 50 Mts
away from the working location like overhead conveyor or pipe
line.
 Clearance from relevant rail logistics personals/control room
of track line section should be obtained prior to start of work.
16 Working near Safety: Burn Vendor  Beware of the crane movement
Hot metal Injuries Sup.  Safety watcher should continuously watch all hot metal operation,
handling Environment any mishap like, hot metal spillage, fire etc. should immediately be
areas Quality conveyed and all persons should move to safer positions without
panicking.
 Paint & thinner should be kept in areas with normal
ambient conditions away from sunlight and heated sources.
 All persons should wear Heat proof Jacket during movement or

STRUCTURES

S
working near hot areas.

 Wind up Paint hoses after work during each break like lunch etc.
17 Material Safety : Caught Vendor  Loading/unloading of paint drums should be done using
handling between objects supervis suitable platform.
(loading & or  Loading/unloading point should be a designated place, sufficiently
unloading) wide , free from any obstruction and without any Slip/trip/Fall
hazard
 Paint drums and other material should not be thrown on tyres etc.
 Do not stack more than 2 drums on truck.
 Use proper PPE like Safety shoes, gloves etc. during loading
& unloading
 Heavy equipment like, Airless machine etc. should be loaded
using immovable ramp or slope secured at ground and at the
truck position.
Environment
Quality
18 Mobile phone Safety: Vendor  Use of Mobile phones is strictly forbidden in the work place.
at work place Injury/fatality Supervi
Environment sor  If a person wishes to make/ take a call, it should be done at
designated place only.
Quality

SOP NO ES/PA/SOP/751/01 EFFECTIVE DATE 30.04.21 REVISION NO 11
SOP DESCRIPTION PAINTING OF CIVIL & STEEL SECTION PAINT APPLICATION
STRUCTURES
DEPARTMENT ENGINEERING SERVICES PAGE
19 Empty drum Safety : Injury Vendor  Empty Paint drums are to be disposed of by vendor as per EHS norms of
disposal during handling supervis Tata Steel. Detail report shall submit by vendor in every month at PA
(loading & of empty drum or Section. Vendor not withstanding mentioned clause is liable for action
unloading) as per consequence management policy of Tata Steel.
 Loading/unloading of paint drums should be done using suitable
place.
 Loading/unloading point should be free from any obstruction and
without any Slip/trip/Fall hazard.
 Use proper PPE like Safety shoes, gloves etc. during loading
& unloading.
Environment  Vendor shall thoroughly clean as per standard procedure of waste

management of Tata Steel before disposing. The residual waste (cotton
waste /jute etc. ) generated in cleaning process shall dispose as per
environmental norms. Vendor shall dispose empty paint container
through Government registered vendor only and the same must be
intimated to Engineering Services (Paint Application). All legal
documents for transportation, handling, storage of hazardous waste
must be submitted to Engineering services.
Quality  Empty container of paint or chemical must be thoroughly cleaned.

SOP NO ES/PA/SOP/751/01 EFFECTIVE DATE 30.04.21 REVISION NO 11
SOP DESCRIPTION PAINTING OF CIVIL & STEEL SECTION PAINT APPLICATION
STRUCTURES
DEPARTMENT ENGINEERING SERVICES PAGE
20 Painting Job in Safety: Risk of Vendor 1. Work permit for confined space job should be provided by competent person to SS/PRO-01
confined space life due to lack of supervis the competent supervisor.
Oxygen. or 2. Before starting the job, department should confirm the oxygen level inside the
confined space. O2 level should be 19.5% to 21.5%.
3. Multi gas detector is must at site.
4. Electric bulb not more than 24watt is allowed inside confined space.
5. There should be a safety watcher for every shift to note all the timing for entry
and exit of workmen at confined space.
6. Oxy pack and ELBA should be present at site.
7. Rescue plan should be available at site with supervisor and training record for
the same should also be available.
8. No hot work, like welding or gas cutting to be done when painting job is in progress.
9. No mixing of paint to be done in confined space.
10. After completion of painting job, all rags, containers and equipment should
be removed from site.
11. There should be provision of ventilation or air circulation during work inside
confined space.
12. Must ensure all positive isolation has been done before start of work.
Environment Before & after the job cleaning & disposing.
Quality As per standard only permit to be taken from department.


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STANDARD OPERATING PROCEDURE

Form No: EHSMSM/446/4013 FORM REVISION NO : 01 EFFECTIVE DATE : 01-04-2009

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

1 Obtaining SAFETY : Vendor  Work permit format EHS-MSM/446/4007 is applicable SS/GEN/

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

EHSMSM / WORKS/ 446/4016

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

Only Calibrated pack, ELBA in case of emergency.

3 Working near SAFETY : Vendor  Obtain clearance in form EHSMSM/WORKS/446/4005. SS/GEN/

4 Working At SAFETY : Vendor Steps to taken before working at height SS/ENGG

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

 Due considerations to be given for scaffolding and ladder standards. For

Points to be followed while selecting means of access :

 When it is not practicable to provide a work platform with guard rails

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

land materials), should a way of arresting falls (for example, harness

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

lanyard or inertia reel to fully extend?

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

and toe guard.

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

170 MPa (25,000 p.s.i)

Water jet cleaning can be destructive to non-metallic surfaces. Soft wood,

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

no more than 5% of the surface.

6 Surface SAFETY: Vendor New concrete or masonry:

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

ENVIRONMENT Old concrete surface:

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

PREPARED BY:- APPREOVED BY:-

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

in order to obtain a uniform coating of material.

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

11 Special coating SAFETY Vendor Surface Preparation

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

Drying and Curing

PREPARED BY:- APPREOVED BY:-

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

PREPARED BY:- APPREOVED BY:-

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

It is advisable to use low bed trailer for long distance movement of

PREPARED BY:- APPREOVED BY:-

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

PREPARED BY:- APPREOVED BY:-

STEP. ACTIVITY ASSOCIATED RESPONSIBILI PROCESS/TOOLS/PPE’S (HOW) REMARKS

working near hot areas.

PREPARED BY:- APPREOVED BY:-

Environment  Vendor shall thoroughly clean as per standard procedure of waste

PREPARED BY:- APPREOVED BY:-

PREPARED BY:- APPREOVED BY:-

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