ABU DHABI SEWERAGE SERVICES COMPANY

(ADSSC)

GENERAL SPECIFICATION FOR MECHANICAL

WORKS

DIVISION 15 MECHANICAL

SECTION 15004 CORROSION PROTECTION

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description / Purpose of Issue

01 April 2008 First Issue.

02 Jan. 2011 ADSSC new logo

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

TABLE OF CONTENTS

1. SURFACE PREPARATION ............................................................................. 4

1.1 GENERAL ............................................................................................ 4
1.2 SURFACE BLASTING.......................................................................... 5
1.3 REMOVAL OF SURFACE CONTAMINATIONS ................................... 5
2. PAINTING SYSTEMS ...................................................................................... 7
2.1 TABLES ............................................................................................... 7
2.2 GENERAL .......................................................................................... 12
3. QUALITY ASSURANCE AND WARRANTY .................................................. 13
3.1 QUALITY ASSURANCE FORMS ....................................................... 15

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

1. SURFACE PREPARATION

1.1 GENERAL

a) Account shall be taken of the specification and recommendation of the

paint manufacturer.

b) The type of protective coating system required for any particular material
will depend on the environment to which it is to be exposed.
Accordingly, there are four surface classes of environmental exposure
as follows:-

i. Non-immersed aggressive conditions to include:

• Wet wells (sewage and sludge) above maximum sump levels.
• Enclosed sewage treatment process units and sludge holding
tanks above maximum working levels.
• Open sewage treatment process units and sludge holding tanks
above working levels but susceptible to splashing, windblown
spray, etc.
• Chemical storage, batching and dosing equipment and rooms
not in direct contact with the chemical.

ii. Immersed (non-potable) conditions to include:

• Wet wells, reservoirs, sludge tanks, sewage treatment process
units below operating levels.
• Chemical storage batching and dosing (additional special
treatment may be necessary as recommended by the supplier)

iii. Immersed in potable water:

• Potable water storage tanks and associated pipework surfaces
in contact with the water.

iv. Non-immersed non-aggressive conditions:

• Areas that do not come into contact with process fluids, or their
related atmospheres, i.e. normal atmospheric conditions.
• Tables A to E below detail the minimum acceptable coating
systems to be applied generally to plant and fabrications in
each environment (Tables A to D), and also that specific to
station/plant pipework and associated fittings (Table E).

c) Plant fastenings and fixings that are to remain unpainted shall be

stainless steel grade 316L, galvanized or sheradised to BS EN 13811,
but in accordance with its location.

d) Electro-galvanising, nickel cadmium or any other plating processes will

not be acceptable.

e) Where zinc spray is specified it shall be to EN22063 or equivalent.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

f) Structural corrosion resistant aluminium alloy shall only be used in none

aggressive locations and shall not be painted unless specifically called
for by ADSSC except bolt holes and faces which shall be degreased and
given one coat of zinc epoxy.

g) Machined sliding and rotating surfaces, shall not be painted, but shall be
given one coat of a mixture of white lead and tallow or other similar
approved material before dispatch from Works.

1.2 SURFACE BLASTING

a) All welded areas shall be given special attention by applying a pre-

blasting to ensure all weld flux slag, splatter, heat oxides, slivers and
other defects likely to affect the application of the coating system are
removed prior to the commencement of blasting.

b) All areas shall be very thoroughly blast cleaned to SA2½ standard

before coating.

c) Site touch up preparation is acceptable for rusted areas and areas

where rust is breaking through or where rust blisters exist below existing
paint work and shall be prepared to St3 standard and spot primed with
the specified primer. The prepared and primed areas shall then be
coated with the remainder of the specified system.

1.3 REMOVAL OF SURFACE CONTAMINATIONS

a) The use of water jetting shall be permitted. Where electrical equipment

is present, before commencement, ADSSC approval shall be obtained
concerning the appropriate protection of the equipment.

b) When deposits of grease, oil, salts and other debris contaminate a

galvanised, painted or uncoated surface, an emulsifying agent of 2%
detergent solution shall be used. Data sheets on detergents shall be
submitted to ADSSC prior to use.

c) An emulsifying agent shall be used in conjunction with jetting only with

ADSSC approval.

d) The use of sand media for blasting is not permitted.

e) Unless otherwise stated, the surface profile after blasting shall have an
average peak to trough measurement not exceeding 50µm and
maximum height not exceeding 75µm.

f) The cleanliness and surface profile achieved shall be judged against the
pictorial standard ISO 8501-1.

g) Galvanised structures shall be sweep blasted prior to painting unless

otherwise specified.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

h) All surface defects, including cracks, surface laminations and deep

pitting, likely to be detrimental to the protective painting system shall be
dressed. Where extensive grinding has been necessary, the dressed
areas shall be re-blasted to removal all rust and to provide an adequate
paint key.

i) The abrasive used shall be such that it will produce an anchor pattern on
the steel, in accordance with the specification and the paint
manufacturers’ instructions.

j) Blasting shall not be carried out in the proximity to painting operations or

near any other surface susceptible to dust and particle contamination.
All steel not primed the same day shall be re-blasted prior to applying
the protective coating.

k) Painting shall not be permitted where the metal surface temperature is

less than 3°C above the dew point or when that relative humidity is
greater than that recommended by the paint manufacturer.

l) The dew point and metal surface temperature shall be determined prior
to commencement of work and at maximum intervals of four hours
thereafter.

m) All statutory blasting regulations shall be enforced.

n) Before application of the protective coating, all contaminants shall be

removed by vacuum, airline or soft brush. In the event of any
contaminants being found embedded under or in the paint film, the
affected area shall be cleaned as described previously and the complete
paint system reapplied.

o) Where items, numbers, signs or labels are removed or obliterated due to

the blast cleaning or paint application, they shall be replaced using the
original fixing methods.

p) All surfaces that have been inspected and accepted shall be coated
before any deterioration or contamination occurs. No coat of paint shall
be applied until the previous coat has fully hardened, unless otherwise
specifically directed by the manufacturer. It is imperative that all
subsequent coats are applied before the previous surface is
contaminated.

q) At marine locations, previously coated surfaces shall be checked for salt

contamination prior to applications of subsequent coats.

r) Coated surfaces that have become contaminated with salt, oil or grease
shall be washed with 2% detergent solution and thoroughly rinsed with
clean potable water before being allowed to dry.

s) No paint shall be applied during adverse weather conditions where it will

affect the application and/or drying of the coating.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

t) Unless otherwise specified all surface preparation and coating shall be

carried out in accordance with the General Principles laid down in ISO
12944 or equivalent.

2. PAINTING SYSTEMS

2.1 TABLES

The painting system used shall correspond to the substrate and appropriate
environment detailed in the following tables as required by the contract:

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

Table 2.1.1 Non-Immersed Aggressive Conditions

Site Total
Substrate Surface Shop Shop Shop Shop
Applied DFT

General
High Build High Build
(1) Degrease Purpose
Polyamide Polyamide
Steel and Abrade Epoxy N/A 250µm 325µm
Epoxy Epoxy
Galvanised Sweep blast Primer
150µm 75µm
100µm

(2) �MIO High Build High Build

As per paint
Steel Pigmented Polyamide Polyamide
manufacturer N/A 200µm 350µm
#HZS two pack Epoxy Epoxy
data sheet
(100µm) 50µm 150µm 150µm

(3) General
High Build High Build
Aluminium Purpose
Degrease & Polyamide Polyamide 200µm
& other Epoxy N/A 125µm
Abrade Epoxy Epoxy 200µm
non-ferrous Primer
75µm 75µm
metal 50µm

Zinc Rich �MIO High Build High Build

(4)
Blast Epoxy Pigmented Polyamide Polyamide
Ductile & 325µm 475µm
SA2½ Primer two pack Epoxy Epoxy
Cast Iron‡
100µm 75µm 150µm 150µm

Zinc Rich �MIO High Build High Build

(5)
Blast Epoxy Pigmented Polyamide Polyamide
Mild Steel 325µm 475µm
SA2½ Primer two pack Epoxy Epoxy
‡
100µm 75µm 150µm 150µm

Where extra abrasion resistance is called for, and for temperatures in

excess of 60°C, the priming coat shall be amine cured phenolic epoxy of
100µm thickness. For temperatures above 60°C, the finishing coat shall be
100µm first finishing coat applied at works and 100µm site applied final coat.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

Table 2.1.2 Immersed (Non-Potable) Conditions

# HZS - Hot Zinc Spray  MIO - Micaceous Iron Oxide

HAS - Hot aluminium spray DFT - Dry Film Thickness

‡ All steel, ductile and cast iron station/plant pipework shall be externally
painted to this specification

Shop Shop
Shop Site
Surface Applied Applied Total
Substrate Applied Applied
Preparation Second Third DFT
First Coat Final Coat
Coat Coat
General
High Build High Build
(1) Degrease Purpose
Polyamide Polyamide
Steel and Abrade Epoxy N/A 375µm
Epoxy Epoxy
Galvanised Sweep blast Primer
150µm 150µm
75µm

(2)
MIO High Build High Build
As per paint
Pigmented Polyamide Polyamide
#HZS manufacturer N/A 250µm
two pack Epoxy Epoxy
100µm data sheet
50µm 100µm 100µm

Polyamide High Build High Build

(3)
Blast Epoxy Polyamide Polyamide
Ductile & N/A 450µm
SA2½ Primer Epoxy Epoxy
Cast Iron
150µm 150µm 150µm
(4)
Polyamide High Build High Build
Mild Steel
Blast Epoxy Polyamide Polyamide
& Non- N/A 450µm
SA2½ Primer Epoxy Epoxy
ferrous
150µm 150µm 150µm
‡

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

Table 2.1.3 Immersed in Potable Water

Surface Shop Applied Shop Applied Site Applied Total

Substrate
Preparation First Coat Second coat Final Coat DFT

☼High Build ☼High Build

General
(1) Degrease Polyamide Polyamide
Purpose
Steel and Abrade Epoxy (free Epoxy (free 325µm
Epoxy Primer
galvanised Sweep blast from coal tar) from coal tar)
25µm
150µm 150µm

☼High Build ☼High Build

MIO
(2) As per paint Polyamide Polyamide
Pigmented
Steel #HZS manufacturer Epoxy (free Epoxy (free 325µm
two pack
100µm data sheet from coal tar) from coal tar)
50µm
100µm 100µm

☼High Build ☼High Build

Polyamide
(3) Polyamide Polyamide
Blast Epoxy
Ductile & Epoxy (free Epoxy (free 375µm
SA2½ Primer
Cast Iron from coal tar) from coal tar)
75µm
150µm 150µm

☼ High Build ☼High Build

Polyamide
Polyamide Polyamide
(4) Blast Epoxy
Epoxy (free Epoxy (free 375µm
Mild Steel SA2½ Primer
from coal tar) from coal tar)
75µm
150µm 150µm

☼ Coatings shall be suitable for use with potable water

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

Table 2.1.4 Non-Immersed Non-Aggressive Conditions

Site
Shop
Surface Shop Site Applied Applied
Substrate Applied
Preparation Applied DFT Final Coat Total
Primer Coat
DFT

(1) Degrease
Steel and Abrade None None None None
galvanised Sweep blast

High Build
(2) General
Recoatable two pack
Ductile and Blast Purpose
epoxy Urethane 165µm
Cast Iron Mile SA2½ Epoxy Primer
75µm gloss
Steel 50µm
40µm

Table 2.1.5 Station Pipework

Internal Coating for Internal coating for

Transported Fluid
Ductile/Cast Iron Painted Steel Painted
Irrigation water and
Table C(3) Table C(4)
potable water *
Raw Sewage Table B(3) Table B(4)
Primary Sludge Table B(3) Table B(4)
Humus Sludge Table B(3) Table B(4)
Activated Sludge Table B(3) Table B(4)
Co-settled sludges Table B(3) Table B(4)
Digested sludge Table B(3) Table B(4)

* For irrigation and potable water applications pipework may be concrete

lined.

This Table details the acceptable coating systems to be applied to internal

linings of station/plant pipework and associated fittings.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

2.2 GENERAL

a) The Contractor shall use only one paint manufacturer for coating of an
item of equipment included in this Contract and shall submit the name
and address of each paint manufacturer used for approval by ADSSC.

b) All coating materials shall be supplied in their original unopened

containers bearing the paint manufacturer’s labels and instructions. For
materials having a limited shelf life, the date of manufacture and length
of life shall be shown.

c) All paints shall be stored in such a manner that it avoids extremes of

temperature. No paints shall be used once their shelf life has expired.

d) Coating materials which have livered, gelled or otherwise deteriorated

during storage shall not be used. Thixotropic materials that may be
stirred to obtain a normal consistency are exempt from this restriction.

e) If the coating material requires the addition of a catalyst, the pot life
under application shall be clearly stated on the paint manufacturer's data
sheets. If the pot life of a material is exceeded, the spray pot shall be
emptied and the remaining material discarded. The application
equipment shall then be cleaned and new material catalysed.

f) Mixing of multi-pack coatings is only to be done on a complete container

basis.

g) The application of coating materials shall be carried out in accordance

with the paint manufacturer's recommendations, each coat shall be of a
different colour of a uniform thickness, free from runs, dry over spray,
mud cracking and other imperfections.

h) Where the Specification has omitted relevant details and where such
details are included in the manufacturer's data sheets, the relevant
manufacturer’s instructions shall be observed as if included in the
specification.

i) All angles, welds, edges, bolts and nuts shall be stripe coated with the
first two coats of the stripe coat shall be brush applied after the primer
has been applied over the previously accepted substrate.

j) Any painted surface that is damaged by welding or by rain, sand or dust

shall be spot prepared and retouched so as to comply with the
Specification, in terms of both depth and quality, in such a way as to be
indistinguishable from the surrounding paintwork.

k) Damaged paint films adjacent to welding shall be power-brushed, until a

sound area of primer is reached. Areas of more extensive damage shall
be cleaned back to bare metal.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

l) Welds shall be power brushed, weld spatter and rough welding areas
removed by vacuum blasting, scraping, wire brushing or grinding.

m) All touching up of damaged surfaces shall be recorded on Coating

Application Forms PC1 to PC3, together with the Environmental
Conditions form PC4.

n) All final coats shall be applied following any remedial works necessary
after delivery/erection (see clauses above) over the entire structure
including damage repair areas, bolts and joints.

o) The final coats shall be applied on site in accordance with Tables A to E

unless otherwise agreed with ADSSC and will be of the colour specified
in the General Workmanship Section C03 of this specification.

p) The total DFT stated in the tables shall be the minimum accepted
standard following application of final coats.

q) The epoxy resin content together with its curing agent shall be less than
40% by weight of the solid binder, and the ratio of pigment to binder
shall not exceed 80% by weight.

r) Steel that is to be totally embedded in concrete shall be cleaned to

Swedish Standard Sa21/2 and shall not be primed.

3. QUALITY ASSURANCE AND WARRANTY

a) Quality assurance forms PC1 to PC4 inclusive, shall be completed and

submitted to the ADSSC for the preparation and application of corrosion
protection systems.

b) Coating storage and application areas shall be available for inspection

by ADSSC at all times.

c) Polymeric coatings shall comply with the following performance

requirements, as detailed in Section 5.0 of part 1.0 of Water Industry
Specification (WIS) 4-52-01 (Specification for Polymeric Anti Corrosion
(Barrier) Coatings).

d) Coatings shall be holiday free when tested on a holiday detector output

voltage equivalent to 5V per micrometre of coating thickness.

e) Coatings shall be free of any defects that are likely to be detrimental to

performance (eg blisters/ sagging and runs etc).

f) Coatings shall exhibit no adhesive disbondment during V-cut testing.

g) Coatings based on thermosetting resins shall exhibit consistent curing

behaviour, as demonstrated by differential scanning calorimerty (DSC)
techniques.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

h) Coatings shall exhibit satisfactory resistance to accelerated weathering.

i) The Contractor shall agree with ADSSC which of the above performance
requirements are relevant to the coating’s intended application and
which therefore must be satisfied.

j) If coatings have not been tested in accordance with WIS 4-52-01,

compliance with alternative performance specifications is acceptable
provided the Contractor can demonstrate equivalent or superior levels of
coating performance.

k) All painted surfaces shall be guaranteed for a period of five years

(commencing date of acceptance of the completed Contract) against
peeling, flaking and rusting. If this standard is not achieved, the
Contractor is to make good such defective areas at his expense, to the
standards of this Specification. The anniversary date shall be from the
date of completion of the full scope of works within the Contract.

l) The guarantee applies to areas of breakdown that are subject to normal

wear and tear. Mechanical damage, product spillage or fire shall not
constitute a breakdown under the guarantee.

m) The Contractor may, if he so desires or feels that it is necessary,

increase any of the quoted minimum dry film thickness to ensure that the
specified system performs to the minimum requirements of the
guarantee periods.

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

3.1 QUALITY ASSURANCE FORMS

FORM PC1 Coating manufacturer and raw material records for Quality
Assurance

Client
Surface Preparation and Coating Application Record for QA
Project Code
Project Title
Contract No
Main Contractor
Sub-contractor/applicator
Coating manufacturer

Coat System Spec Substrate Coating Type Data

Table Sheet No
Primer
Second Coat
Third coat
Final Coat

Primer
Second Coat
Third Coat
Final Coat

Primer
Second Coat
Third coat
Final Coat

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

FORM PC2 Surface Preparation Records for Quality Assurance

Client
Surface Preparation Record for QA

Project Code
Project Title
Contract No
Equipment description
(itemised)

Item Equipment Surface Prep Date of Time of Name &

No Description & Standard Inspection inspection Signature
of
Inspector

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

FORM PC2A

Client

FAO
Date

Four days notification for Stage Completion of Surface Coating

Project Code
Project Title
Contract No

Equipment Description
Stage of Surface Coating

Date available for inspection

Address for inspection

Contact name

Telephone
Facsimile

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

FORM PC3

Client
Coating Application Record for QA
Project Code
Project Title
Contract No
Equipment description
(itemised)

Item Equipment Coat Date Time Batch WFT DFT Approve

No Description No µm µm d Initials

Final approval

Date

Inspectors signature

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 General Specification for Mechanical Works
Abu Dhabi Sewerage Services Company
(ADSSC)

FORM PC4

Client
Environmental Conditions Record for QA
Project Code
Project Title
Contract No
Equipment description
(itemised)

Item Date Air Air Substrate Substrate Dew Dew

No Temp Temp min max Point Point
min max min max

Final approval
Date
Inspectors signature

END OF SECTION

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