ISO 8501-Pictorial Clasiification Standard For Surface Cleanliness

MAZAGON DOCK LIMITED
SHIPBUILDING DIVISION
INDEX
S. No.
Description
SURFACE PREPARATION
Page Nos.
3 - 11
Abrasive Blasting
Vacuum Blasting
Power Tooling
Dust removal
Removal of Oil and Grease
Surface Cleaning by Water
Preservation/Treatment of new steel plates
Blast Cleaning of Steel after fabrication
Internal Underwater Areas and Tanks
10
External Underwater Areas
10
11
Vertical Above Water Areas and Super Structure
10
12
Blast Cleaning of Minor Structural fittings
10
PAINTING
11 - 16
Spraying Method
11
Manual Method
12
Stripe Coats
12
Feathering
13
Paint Application
13
Maintenance Painting
15
SAFETY
16 - 18
Material Safety
16
Equipment Safety
17
Personal Safety
17
Job site safety
18
Fire Hazards
18
Blasting and Painting
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S. No.
Description
Page Nos.
QUALITY ASSURANCE
19 - 19
MDL SCOPE OF SUPPLY
20 - 20
CONTRACTORS SCOPE OF SUPPLY
21 26
Man
21
Machine
23
Material
24
Contractor Project Management
25
Services
25
SUPPLIER INFORMATION
27 - 27
APPENDIX
28 - 29
Appendix A
28
Appendix B
29
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TECHNICAL SCOPE OF WORK FOR BLASTING, SURFACE PREPARATION AND

APPLICATION OF PAINTS
SCOPE OF REQUIREMENT
1. Following are the minimum requirements, but not limited to, for Blasting and
Painting of the ships being built at MDL.
2. The intention of this Scope of Work is that all labour, material, equipment,
and other items necessary for the proper execution and completion of the
Work are included in the scope of contractor, except for any items expressly
identified as MDL Supply.
3. All work and services required for the administration of the Project shall be in
the scope of the Contractor.
4. Scope of Requirement is not intended to enumerate each and every item of
Work required. Words which have well-known technical or trade meanings
are used in the Contract in accordance with such recognized meanings.
Surface Preparation
1. Abrasive Blasting(Chilled Iron/Steel grit/Copper Slag)
i.
Open nozzle abrasive blast cleaning as applicable to para 7-12 is required

to be done as a primary step for paint application.
ii. The abrasives must be of good quality, should be hard and dry, free of
foreign matters and non-contaminated. There should be no soft sand, soft
particles and the like.
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iii. Iron/steel grits conforming to DS Cat No 5350-000139 & 5350-000140 shall

be used; a certificate of conformity to specifications to the kind, quality,
performance and values of material needs to be produced. The evidence
shall include, but not be limited to:
(a) An affidavit on the letterhead of the manufacturer, signed by a
responsible officer of the manufacturer, certifying that the Product and
its batch number is in conformance with the requirements of the
specified regulatory agency above, the reference standard and/or the
performance value, as applicable. Each such Affidavit shall be
identified by the name of the Product and the Specification section,
page and paragraph for which the Product is proposed; and
(b) A Testing Laboratory Certificate from a laboratory, bureau or agency
acceptable to MDL, signed by a responsible officer of that facility,
certifying that the designated Product has been tested within one year
of the date of submittal of the sample
(c) Customary standards on other projects shall not apply to determine
whether materials and workmanship are acceptable under the
Contract Documents for this Project.
iv. Recycled grit obtained from above fresh grits, must be dry, and should be
shown to be free from contamination by dirt, dust, oil, grease, and salt
contents. Approval is to be obtained from MDL/OEM representative
before usage.
v. Abrasive size distribution must be 0.2-1.1 mm for general work unless
specified otherwise.
vi. Nozzle size shall be 10-12 mm and should not be in a worn out condition.
vii. The distance of the nozzle from the substrate should be 30 cm and the
media should be directed at an angle of 60 to 85 to the surface.
viii. The desired surface profile of 50-75 microns should be created when the
air pressure measured at the nozzle is 6-7 bar/ 85-100 psi.
ix. Copper slag, if used as an abrasive, should render a surface profile
confirming to Sa2, which is to be duly inspected and approved by the
inspector.
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2. Vacuum Blasting
i. Vacuum blasting is less dusty and less likely to contaminate adjacent areas
than open nozzle abrasive blasting. Hence where ever machineries and
equipments have already been installed prior to painting, Vacuum Blasting
may be necessarily required to be done. Similarly weather decks where
openings to lower & upper decks, drain holes, vents etc. are present may
be required to be vaccum blasted to Sa2 standard.
ii. Abrasive quality should be hard and non-contaminated. There should be
no soft sand.
iii. Abrasive size distribution must be 0.2-1.1 mm for general work unless
specified otherwise.
3. Power Tooling
i.
Power tool cleaning to bare metal shall include removal of all rust, loose
mill scale, and paint to bare metal by chipping, scraping, sanding or wire
brushing. A minimum of a onemil profile is required.
ii. Chipping hammers, deck crawlers, needle guns, and wire brushes must be
used to remove tight corrosion, mill scale, and old paint from large
metallic areas.
iii. Wire brushes (cup or radial) are to be used to remove loose mill scale, old
paint, weld flux, slag, and dirt deposits.
iv. Grinders and sanders are to be used to smooth excessively rough surfaces.
v. Pneumatic power tools are to be used preferably (Grinders, Disc Sander
and Wire Brush)
vi. Electrical power tools, if must be used, should work at 110 V only.
vii. Compressed air must be free from oil and water.
viii. Wire brush must not polish the surface, hence worn out ones must not be
used.
ix. Care shall be exercised with power impact and grinding tools so they do
not cut too deeply into the surface, resulting in burrs that are difficult to
cover and protect satisfactorily.
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4. Dust Removal
i.
Dust causes poor adhesion and hence it must be removed;
ii. Dust may spoil the machines and equipments in its surroundings, hence
covering of machines must be ensured by the contractor to prevent
damages by dust during cleaning, blasting and painting.
iii. Removal of dust must be undertaken by
(a) Industrial Vacuum cleaners fitted with brushes.
(b) Clean bristle brush.
(c) Blowing with dry, clean compressed air.
iv. To establish whether dust has been sufficiently removed, transparent
adhesive tape must be used in which very small amount of dust should
remain.
v. No separate rate for removal of dust shall be given. Dust removal is to be
undertaken as a standard practice in each of the above dust generating
surface preparation methods and especially before painting.
5. Removal of Oil and Grease
i.
Oil and grease must be removed from the surface with Labolene solution,
method of preparation of which is given in Appendix A.
ii. Use only solvent cleaning on small areas and never on painted surface.
(a) Prior to solvent cleaning, remove any heavy deposits of oil, grease,
etc., with a scraper.
(b) Remove remaining oil, grease, etc., by wiping/scrubbing the surface
with rags or brushes wetted with solvent.
(c) It is important that the final wash/rinse be made with clean
rags/brushes and solvent so that a film of oil/grease, etc., wont be left
on the surface when the solvent evaporates.
iii. Rags must be changed regularly so that only clean rags are used.
iv. If water forms droplets, there is still oil/grease on the surface and hence
repeat the cleaning procedure.
v. The water must run-off in puddles.
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6. Surface Cleaning by Water

Surface Cleaning by Water Pressure as defined in Joint Surface Preparation
Standard NACE No. 5/SSPC-SP 12, 1995 shall be followed wherein :
i.
Low pressure water cleaning(LP WC):
upto 340 bar/5,000 psi.
ii. High pressure water cleaning(HP WC):
340-680 bar/5,000-10,000psi.
iii. High pressure water jetting(HP WJ):
680-1,700 bar/10,000-25,000 psi.
iv. Ultrahigh pressurewater jetting(UHP WJ): above 1,700 bar/25,000 psi.

v. Washing in general shall be carried out from top to bottom.
vi. The topsides must be washed close-enough, to remove contamination,
and far -enough, so as not to damage the coating.
vii. Underwater Washing and Cleaning :
(a) The underwater washing must always be carried out before the slime
dries.
(b) Remaining fouling must be removed.
(c) Repair areas must be marked for quick identification.
viii. Ship Exteriors, Ship Decks if required to be washed shall be cleaned for
coating contaminants especially oil and grease. MDL/OEM representative
shall decide which evaluation/test method to be used and its frequency if
the surface cleanliness is in doubt. Methods which can be used are visual
check, Chalk Test, Water on goose test, Acetone test.
ix. Tanks if required to be washed and cleaned may be measured for salt
contamination prior to coating.
x. Removal of water from tanks and other areas after water cleaning shall be
in contractors scope.
xi. Contractor shall be paid once, if the result of test (if conducted) is okay. If
the test fails, the contractor needs to redo the area at his own cost and
expense.
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7. Preservation / treatment of new steel plates

The following procedure is to be followed:
i. Clean thoroughly by washing with labolen solution (proprietary to Glaxo
India - preparation method given in Appendix A).
ii. Rinse with clean fresh water and dry.
iii. Abrasive blast to Sa2 confirming to Swedish Standards. Plates of
thickness less than 5 mm are to be abrasive blasted with sand/copper slag.
iv. Remove grit and dust from the surface by wire brushing.
v. The Blasted Surface is then to be subjected to Copper Sulphate Test for
presence of Mill Scale as described in Appendix B
vi. Coat within 4-hours (immediately) with given Shop Primer as per
MDL/OEM instructions. These plates are to be vertically stacked and
stored on hard ground, under covers, before use.
8. Blast Cleaning of Steel after fabrication into units/blocks/various areas

(except those defined in para 9, 10 and 11 below) for Application of Heavy
Duty Paint Coating
i.
All sharp edges, weld splatter, etc. on the steel structure is to be rounded
off prior to abrasive blasting as a preparation for the application of Heavyduty paint coatings.
ii. All surfaces where abrasive blasting and heavy-duty paint is not required
are first to be thoroughly cleaned of all dirt, oil, grease and other foreign
matters by thoroughly washing with labolene solution, scrubbing with
short bristle brushes followed by rinsing with clean fresh water and then
dried.
iii. The steel surfaces are to be abrasive blast cleaned to Sa2 of Swedish
standards using chilled iron/steel grits conforming to DS Cat NO.
5350-000139 and 5350-000140 to produce a blast cleaned surface profile
of 50 to 75 microns.
iv. After the abrasive blasting has been carried out to the required standard,
the surfaces are to be thoroughly cleaned of all dust arising and spent
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abrasive using suitable industrial type vacuum cleaner fitted with brush
attachment to ensure that the arising are removed before applying the
specified paint system.
v. Once cleaned, the surfaces are not to be allowed to oxidise or become
contaminated in any way prior to the application of the specified paint
system.
9. Internal Underwater Areas and Tanks
Machinery Bilges, Void Spaces, and Ballast Tanks
Internal tanks for Fresh Water, AVGAS/AVCAT, Diesel Oil, Water
Compensated Diesel Oil, FFO, Hydraulic oil, Acid store, Battery Charging
Room (except Battery Pits), Oil Drains and Oil Sullage.
i.
The surface preparation for application of the paint scheme on the steel
substrate except Machinery Bilges shall be Sa2 conforming to Swedish
Standards. However, the surface preparation standard shall be St3 for
Machinery Bilges.
ii. For Sa2 standards, the steel surfaces are to be vacuum/abrasive blasted
using chilled iron/steel grits (DS Cat No. 5350-000139 or 5350-000140) to
produce a blast cleaned surface profile of 50 to 75 microns. For St3
standards, the steel substrates are to be prepared using power tools/wire
brushing.
iii. After the abrasive blasting has been carried out to the requisite standard,
the surfaces are to be thoroughly cleaned of all dust arising due to spent
abrasive by means of suitable compressed air.
iv. For Tanks-steel work, All sharp edges to be broken or rounded off. Holes in
welding seams, undercuts, etc. may necessiate extra stripe coating or
filling. All loose and dense weld splatters to be removed.
10. External Underwater Areas(Steel Substrate)
i.
Steel Substrate. The surface preparation for application of the paint

scheme on the steel substrate shall be Sa2 conforming to Swedish
Standards.
(a) For Sa2 standards, the steel surfaces are to be vacuum/abrasive
blasted using chilled iron/steel grits (DS Cat No. 5350-000139 or
5350-000140) to produce a blast cleaned surface profile of 50 to 75
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microns. Copper slag, if used as an abrasive, should render a surface

profile confirming to Sa2, which is to be duly inspected and approved
by the inspector.
(b) After the abrasive blasting has been carried out to the requisite
standard, the surfaces are to be thoroughly cleaned of all dust arising
due to spent abrasive by means of compressed air at suitable air
pressure.
11. Vertical Above Water Areas of Shipside and Super Structure (both Steel and
Aluminium)
i. Aluminium Substrate. The surface for application of the paint scheme on
the Aluminium substrate is to be prepared using hydroblasting to achieve
a surface finish conforming to NACE 5/SSPC-SP-12 condition WJ-2L.
ii. Steel Substrate. The surface preparation for application of the paint
scheme on the steel substrate shall be Sa2 conforming to Swedish
Standards. After the abrasive blasting has been carried out to the requisite
standard, the surfaces are to be thoroughly cleaned of all dust arising due
to spent abrasive by means of compressed air. Alternatively, the surface
preparation by means of hydroblasting as per Para 6 above can also be
adopted for steel substrate.
12. Blast Cleaning of Minor Structural Fitting and Attachments
i.
Surface preparation of all miscellaneous items is to be carried out as per

Paint Scheme of the Ship.
ii. Wherever the paint scheme is silent on surface preparation international

standards like SSPC, NACE, ISO & Naval Standards are to be followed in
consultation with MDL/OEM representative.
iii. Scrapping, Wire Brushing, Sanding, and Papering to St1, St2 and St3
standards are to be used for removal of rust.
iv. Grease, Oil & other foreign substances are to be cleaned by using Labolen
detergent solution.
v. However, before fitting in position, all minor attachments and fittings such
as pipes, clips, electric cables, carrier plate stools, ventilation trunk stools,
brackets and seating for supporting equipment etc., the structural surfaces
are to be cleaned free of all oil, dirt, grease and other foreign matters by
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washing and scrubbing with labolene solution in hot fresh water,

thoroughly rinsed with fresh water, dried and then abrasive blast cleaned
to Sa2 of Swedish standards and immediately coated with approved
prefabrication primer or as per instructions received from MDL/OEM
representative.
vi. Work done on above shall be certified by MDL/Inspection Agency in
accordance with the details recorded on daily log register in conjunction
with the quality check and control parameters of DFT, etc. recorded
therein.
Painting
All Painting shall be applied as per the Paint Scheme applicable using the
methods indicated in the scheme under OEM Supervision or MDL
instructions :
1. Spraying Method
i. All paints are to be applied by airless spray in general, except for stripe
coats where brush or roller can be used in consultaion with MDL/OEM
representative.
ii. Efficient Mechanical Stirrers for correct mixing of the paint must be used.
iii. Air Pressure and Capacity for Spray equipment should be atleast
5.5 kg/cm2 and 1.4m3/min (80 psi and 50 cfm).
iv. All spray equipments must be in good working order and be capable of
performing to the output requirements defined in the OEM provided Paint
product technical data sheets.
v. Airless spray pump ratios of minimum 40:1 and greater should be used
depending on the paint solids and DFT required.
vi. Tips should be the size stipulated on the product technical data sheet, or
as agreed with MDL/OEM representative on site. Tips must not be in a
worn condition. It is very important to have a proper, uniform distance of
the spray gun to the surface, 30-50 cm should be aimed at.
vii. A continuous, pinhole-free paint film must be obtained at application of
each spray applied coat. Application technique which ensures good film
formation on all surfaces must be adopted.
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viii. The finished coating must be applied homogeneously and as close to the
specifications as possible. Care must be taken to avoid exaggerated film
thickness.
ix. Great care must be taken to cover edges, openings, rear sides of stiffeners
etc. even though these areas must also be stripe coated.
x. Wet film thickness shall be regularly checked and recorded during paint
application.
xi. Both during and following the application of paint, all operatives entering
the confines of coated tanks/compartments/passage/decks must wear
soft-soled shoes or overshoes.
2. Manual Method
i.
A Brush can be used for areas difficult to spray.
ii. A good quality brush must be used for stripe coating on welding seams, on
all edges before application of full coats with airless spray.
iii. Rollers should only be used for applying a cosmetic coat on an already well
protected surface.
iv. If Rollers must be used for application of primer or intermediate coats,
apply evenly without 'stretching' the paint.
v. Several (2-4) coats may be necessary to substitute one coat applied by
spray.
vi. Special attention must be paid to areas difficult to reach and coat. These
include all edges, welding seams, corrugated areas, behind bulb angles,
behind hand rails, mouse holes, underside of coamings, etc. etc. Stripe
coating and extra coats on such spots are a must.
3. Stripe Coats
i.
Stripe Coats are to be applied by brush or roller depending upon items and
or area concerned.
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ii. The stripe coat must be applied as a coherent film showing good film
formation and no visible defects such as pores or un-wetted areas.
iii. The coating should be applied as a regular film without excessive
brush/roller marks in order to avoid cratering by entrapped air.
iv. Typical areas where stripe coats must be applied include :
(a) Behind bars
(b) Plate edges
(c) Cut outs i.e. Scallops, manholes etc.
(d) Welds
(e) Areas of difficult access
(f) ladders and hand rails
(g) small fitments of difficult configuration
(h) areas
(i) etc. etc.
4. Feathering(Tapering)
i.
Feathering is used for transition of applying a fresh coating system to an

area with an intact coating system that is not removed. To do this, visible
areas of defective old paint shall be removed until an area of completely
intact and adhering paint is attained (Overlap Zone) around the defective
area by feathering (tapering) the edges of tightly adhering old paint at an
approximate 30 degree slope into the newly prepared bare metal surface
thereby preventing application of new paint over loose or cracked paint.
ii. Overlap zones of paint must be feathered (tapered) with great care.
iii. Consecutive layers of paint coatings must be given larger and larger
overlaps.
iv. Overlap area shall be considered for calculating the cost of feathering.
5. Paint Application
i.
A typical Painting Process shall consist of the following steps:

(a) Containment/Wrapup to control dust and debris, and protect
sensitive items.
CHECKPOINTContainment
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(b) Appropriate Surface Preparation

CHECKPOINTSurface Prep, Surface Profile
CHECKPOINTDust Tape Test, Conductivity
(c) Apply Paint System (e.g. in a 2 coat system-)
i. Prime
CHECKPOINTVisual, Film Thickness
ii. Stripe Coat (welds and edges)
CHECKPOINTVisual
iii. Top Coat
CHECKPOINTVisual, Film Thinckness
(d) CHECKPOINTEnvironmentals, Throughout the process...
ii. Proper masking of surrounding area/equipements, wherever and
whenever required, must be undertaken.
iii. Roughening must be carried out when the maximum recoating interval is
exceeded with sand paper grain size 80, free cut paper or as advised by
MDL/OEM.
iv. DFT is to be achieved with specified number of coats as per paint
specifications, however if extra coats are required to be given to achieve
the specified DFT no extra payment will be made for such extra coats.
v. Any application defect arising e.g pinholes, bubbles, gun spittings, voids,
visible abrasives residues, shall be marked up and appropriate repair
effected at contractors expense.
vi. Pneumatic based equipments are to be used for surface preparation and
painting.
vii. The painting and preceeding surface preparation(including blasting) may
have to be carried on board in MDL, Naval Dockyard or MbPT premises.
viii. Some of the items are to be painted out side the ship as well as in the
various MDL shops/areas prior to taking the item on board the ship.
ix. Painting of Machinery units, Furniture items, Electrical units, Weapon
equipment, pipes & pipes supports, Ventilation trunks, seats, cable trays,
insulation framework, insulation sheets like Aluminium perforated/nonperforated sheets, galvanized sheets, platforms in the machinery
compartments, weathers decks & weather deck fittings are to be carried
out as per instructions received from MDL/OEM representative.
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x. Filling and draining of paint/bituminous solution in the rudders, bilge keels

and other such areas of the ship including inaccessible voids are to be
carried out as per instructions received from MDL/OEM representative.
xi. Special guns may be required to spray paint in specific area like application
of Non-Skid type of paints in the weather deck areas. Such guns when
required shall be provided by the contractor as per MDL/OEM
specifications.
6. Maintenance Painting
The touch-up/maintenance painting requirements shall be met as per the
following procedure :
i.
For the purpose of costing, Touchup shall be defined as preservation

operations on cumulative surface areas less than one percent of the total
area (e.g., bilge, tank, space, etc.) being preserved, with no individual area
greater than 10 square feet. Included under touchup operations are new
and disturbed areas of less than 10 square feet.
ii. In case of preservation, of a section of an entire space or location, partial

preservation rates shall be applicable.
iii. Remove loose paint from areas, which are rusty, or the paint work is
defective by scraping or wire brushing up to intact paint film/primer/bare
metal whichever is observed first.
iv. Wash down thoroughly with labolene solution, rinse with fresh water and
dry with a clean sponge or cloth.
v. Preparation shall be done in squares or rectangles as straight edges make
removal of overlaps easier.
vi. Protection at the edges must be used to avoid damage of intact areas.
vii. Sander may be used for areas of light damage.
viii. Touch up the bare areas with the appropriate priming scheme and allow
drying.
ix. For touch up and maintenance of burnt/damaged/modification affected
areas, surface will be prepared upto St3 standards.
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x. In case of bare metal as in keel block areas, the surface is to be prepared

upto the requisite standards and boundaries of intact paint to be
feathered with sander to provide requisite surface for proper joining of
edge of old paint film with new paint films.
xi. Rub down the whole surface with abrasive paper carefully chamfering
down the edges of the patches, which have been touched up.
xii. The edge of the areas should be coated by roller to act as masking for the
overspray, so that the rest of the area can be sprayed.
xiii. Restore the scheme by applying undercoats and finishing coat as
appropriate under the supervision of OEM/MDL instructions.
xiv. If surface smoothening is required to be done, fillers/putty is to be used
for filling as a part of surface preparation.
xv. In case of complete scheme renewal, or major rework otherwise, methods
of surface preparation and painting outlined in and above, shall be
followed, in consultation/directives of MDL/OEM representative. Full
Preservation rates or normal rates shall be admissible in this case.
xvi. Great care must be taken in masking of areas like the sonar dome, echo
sounder, anodes, etc. when undertaking repairs, since these need to be
protected from the blasting grit.
Safety
1. Material Safety
i.
The contractor shall ensure that paint handed over to it for usage is safely
stored in a suitable container.
ii. The supplier shall maintain material safety as follows :

(a) Maintain a clean, tidy and orderly store.
(b) Tins must be stored and stocked such that they do not turn over
and leak.
(c) Lids shall be used to cover tins containing coatings or solvents.
(d) Fumes must be watched for and ventilated if necessary.
(e) Product Data Sheets and Safety Data Sheets are kept accessible
and up-to-date.
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iii. Material brought in and taken out to be maintained in a log register

indicating the quantity of paint used, when and where.
2. Equipment Safety
The contractor must ensure the following :
i.
Airless spray must always be earthed as static electricity can develop

within the system and be the cause of explosion.
ii. All couplings must be of a close fit, especially on high pressure equipment.
iii. Replace damaged hoses.
iv. During airless spraying the paint is under an immense hydraulic pressure.
Release of the pressure through the spray gun or any leaks of the
equipment is dangerous, and a stream of paint may easily penetrate
human skin, in which case immediate medical aid is required.
3. Personal Safety
The safety of personnel is of prime importance.
i.
The contractor shall ensure that its personnel have minimum contact of
paint with skin.
ii. Sensible working clothes must be provided which can cover as much as
possible.
iii. Hand Gloves, Safety Shoes and eye protection must always be worn during
work.
iv. Usage of a suitable barrier cream on exposed skin must be considered.
v. Air fed hood/mask or respirator in confined spaces must be used.
vi. Safe access and adequate lighting must be ensured.
vii. Tidying up, as work proceeds, must be followed - good housekeeping
contributes to safety.
viii. Yard safety regulations must be respected and followed.
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4. Job Site Safety

On site safety can be enhanced by small measures, such as:
i.
Tidy and clean surfaces in general.
ii. Immediate removal of spillage. Good housekeeping standards must be

maintained at all times.
iii. The area where blasting or painting is being carried out must be provided
with proper, visible safety barriers or signs.
iv. in any job above 1.5 meter or more, the contractor must ensure fall
prevention, fall protection, supervision and provide proper personal
protective equipment and training to their employees.
v. Ladders exceeding a height of 8 feet must be tied off at the top to prevent
inadvertent shifting. Ladders must be in a good state/condition. Step
ladders between 8 and 12 feet in height may be used without tie off
provided a second person is present on the ground to continuously
stabilise the ladder. All ladders must be provided with non-skid shoes. All
ladders and scaffolding must be approved by MDL Safety.
Contractor to ensure that a Safety Representative is always present during
work execution to understand and implement the above safety requirements.
5. Fire Hazard
Most paints contain flammable solvents. Hence
i.
Never allow Naked flames - matches - cigarettes -in the same area where
paint is being applied or stored.
ii. Always thoroughly ventilate any area where paint is spilled. Clean up
immediately and dispose of the cleaning material in a closed metal
container.
iii. And if a fire should occur, do not attempt to put it out with water - use
powder or carbon dioxide (CO2) type of fire extinguishers.
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Quality Assurance
i.
Blasting, Painting and other Application Details shall be maintained in a

Daily Log Register and endorsed by concerned MDL Executive within one
day of work execution.
ii. Blasting record shall contain the machine details with which the area was
blasted and will include compressor air pressure, nozzle air pressure,
nozzle size, grit type, grit size, quantity of grit used(fresh & recycled), etc.
iii. Records of Film Thickness Measurements(Wet and Dry), Cross cut
Adhesion Testing, Porosity Detection, and climatic condition
testing(surface temperature, Relative Humidity and Dew Point) must be
monitored to ensure timely corrective actions.
iv. Rework on account of defective surface preparation and faulty application
will attract a penalty on the contractor by redoing the job; No cost shall be
paid for this additional rework and moreover the cost of paint so
consumed shall be recovered from the contractor at actuals.
v. In case of excess DFT applied (80/20 rule method), the cost of excess paint
consumed shall be recovered from the contractor.
vi. The Blasting, Surface preparation, Painting, Number of coats and other
parameters affecting painting will be checked by MDL/Naval agency or any
other inspecting authority as per Paint Specification/paint manufactures
approved procedures.
vii. The Contractor will have to offer the completed work to the inspection
authority for inspection & certification as advised by MDL.
viii. Areas will be jointly measured and certified by MDL/Naval authorities.
ix. The Contractor has to follow the schedule given strictly in order to
maintain the overall progress of the Ship. LD shall be applicable in case of
delays non-attributable to any convincing reasons.
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MDL Scope of Supply

i.
Paint Scheme of the area concerned.
ii. Paint and thinner as per requirements. Monthly material renconcilliation

report is to be produced for all items issued free to the contractor. A
maximum of 10% loss shall be construed as handling losses and cost of
material for quantities in excess shall be recovered as penalty from the
contractor.
iii. Open space for office and store usage.
iv. Premises for keeping portable Sintex type tank (only during the period of
washing activities) duly authorised by the PS or GM(SB-Works). The tank
shall be immediately withdrawn from MDL premises as soon as washing
activity is completed. Rental Charges for area occupancy will be levied on
the contractor on failing to comply with the removal of the tank within 2
days of work completion as per real-estate rates in and around MDL area.
v. Crane facility for lifting and shifting of heavy material/equipments
weighing more than 100 Kg except at Anik Yard, Chembur where loose
plates and sections are blasted and painted.
vi. Electric power supply.
vii. Staging material in way of stern and forward area in way of highly curved
shape (at the discretion of Ship Manager.)
viii. Vacuum Blasting Machine, airless spray painting machines, and pneumatic
stirrers may be provided at MDL's discretion. However, if the situation
warrants the usage of any of these machines, and MDL is unable to
provide, then it is upto the contarctor to complete the job using his own
machines. Work not finished by the given completion date shall attract LD,
and non-availability of Machine on account of MDL or contractors inability
to get his own machine approved by MDL, shall not be construed as a
reason for non-applicability of LD on the contractor.
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Contractors Scope of Supply

1. Man
Painting is a very specialised job and painters need to have certain skill sets
and understanding, about these high-end quality, advanced and expensive,
marine coatings.
i. Thus the contractor must have qualified, competent and designated
employees including project Manager, job supervisors, maintenance and
safety supervisors.
ii. Manager and Supervisors shall be technically qualified having completed
successfully minimum a diploma or above in relevant field
( Painter/Mechanic/Electrician/Safety).
iii. Blasters and Painters, mechanic and electrician should have their
respective trade certificates.
iv. A list of such employees and their qualifications will have to be furnished,
which shall be taken into account while evaluating the technical
competence of the firm.
v. The Contractor shall maintain a competent and qualified supervisory staff
at the Site for the supervision, coordination, scheduling and administration
of the Work.
vi. A list of dedicated managers, supervisors and workmen shall be furnished
before start of work/work mobilisation on any of the ships for review and
approval. Gate Passes shall be issued to this approved personnel list. No
appointment, substitution or reassignment of the Supervisory Job-Site
Staff shall be made by the Contractor without prior written consent of
MDL, unless such personnel leaves the employment of the Contractor. Any
proposed appointment, substitution or reassignment, the Contractor shall
submit to MDL a detailed justification supported by the qualifications of
any proposed individual.
vii. Failure of a Contractors Manager/Supervisor to attend meetings or
execute instructions of MDL shall constitute a basis for dismissal of such
Supervisor from the Project. Upon request of MDL, dismissal will take
Paint Shop
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effect within 24 (twenty four) hours and a new Supervisor will be

substituted by the Contractor.
viii. The Contractor shall be required to take special precautions to avoid
disruption of the MDLs ongoing business operations during execution of
Blasting and Painting Works. Contractor acknowledges that MDL
employees, and other contractors will continue their own business
adjacent to the work Site and the Contractor shall :
(a) not interrupt or interfere with their normal business at such facilities
(b) limit operations to methods and procedures which will not adversely
and unduly affect the normal business operations at MDL facilities
(c) take all appropriate steps to minimize noise, drafts, odors, air pollution,
ambient discomfort, poor lighting, hazards and other undesirable
effects and conditions
(d) and at all times comply with the requirements of applicable laws and
governmental regulations.
ix. None of the foregoing shall justify any extension of the Contract Time or
increase in the Contract Sum.
x. The contractor acknowledges and accepts the fact that there could be
periods of lean work and sometimes periods of sufficient and extensive
work loads. The supplier may reduce its work force during periods of lean
work by intimating in writing to MDL and obtaining the consent of the Ship
Manager. The supplier shall make no claim on MDL for idle and wasted
manpower. The workforce must be sufficient enough to commensurate
with the work load.
xi. Contractor must promptly work additional time over regular hours,
including Saturdays, Sundays and holidays; supply additional workmen;
revise its operational procedures; or take such other steps as may be
required to bring Work on, and, as per schedule, without additional cost or
expense to MDL.
xii. All such overtime and weekend works shall be scheduled with MDL in
advance and shall be subject to MDL rules for availability of work areas and
hours within MDL's premises, or MbPT, or Naval Dockyard wherever the
ship is docked.
xiii. The Contractor will be responsible for the handling of jurisdictional
disputes at MbPT, Naval Dockyard or MDL for work stoppages which may
arise during performance of the Work. The Contractor shall promptly
utilize available remedies to effect resumption of the Work.
Paint Shop
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2. Machine
All tools and tackles, machines and equipments, gadgets and instruments,
etc., incidental to, in the execution of above work, shall be provided by the
contractor. Minimum requirements are listed below but the list may not be
complete.
i.
Blasting Machines and associated accessories.
ii. Vacuum Blasting Machine and associated accessories.

iii. Machine with associated accesories for carrying out HP/LP Jet cleaning and
washing.
iv. Pumps and hose pipes for removal of water (inside tanks).
v. Machine for grinding and rounding of edges.
vi. Hand Power tools for surface preparation.
vii. Paint Mixing Agitators like stirrers (pneumatically operated).
viii. Spray-painting machines and spray guns along with associated accessories.
ix. High compression type spray guns, suitable for painting high
density/viscosity paints like Non skid etc.
x. Heavy duty, Industrial vacuum cleaners, hoses and couplings for removing
dust.
xi. Air Compressors.
xii. Paint brushes of various sizes and Paint Pots.
xiii. Paint Film properties and Weather Condition-Testing gadgets.
xiv. Ventilation Equipment, hoses and set-up arrangement.
xv. Flameproof lamps of 110 V(shatter/blast proof).
Paint Shop
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xvi. Safety gears for workmen including breathing appratuses.

xvii.Staging/Scaffolding materials and its erection, confirming to MDL safety
norms.
xviii.The supplier to produce a preventive maintenance plan of all machines
and equipments to certify that the equipments are properly maintained.
xix. A list of owned machines and equipments indicating their quantity,
capacity, make, year of manufacturer, technical details, etc. needs to be
submitted by the contractor for evaluating the technical competence of
bidders.
xx. Machines, Equipments and tools proposed by the Contractor for use in
connection with the Work shall be subject to MDL approval. The
Contractor shall submit written requests for such approval in accordance
with the requirements of this Contract Document. Requests for approval
shall indicate the involved section of the Specifications/Contract and shall
include all technical data or technical brochures required by MDL.
3. Material
The contractor shall provide i.
Steel Shot/Iron Grit/Copper Slag as per standards of Inspection authorities

mentioned in the preceeding pages.
ii. Hoppers for storing fresh and spent/waste grits.

iii. Container for storing the issued paint and a porta cabin for Office usage.
iv. Tarpaulins and other coverings to cover dry dock channels / pump pits,
compressor house, nearby electrical installation, Machineries and
equipments which may be affected by carrying out blasting or painting.
v. Fresh-Water for washing/cleaning.
vi. Consummables like cotton waste, rags, brushes, rollers, gloves, masks,
emery paper, grinding wheels, maskings, etc.
vii. Any other material, tool, machine and equipment, gadget, etc. incidental
to, and not mentioned herein, shall be in the scope of the contractor.
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4. CONTRACTOR PROJECT MANAGEMENT

Contractor Project Management includes project planning, monitoring,
controlling and reporting as specified by MDL. Project Manager is expected to
execute this project within agreed timings and quality. Project Manager is
expected to coordinate and cooperate with other affected and involved
departments to achieve the most effective project approach. This shall
involve :
i. Ship Blasting and Painting Program Management
ii. Contract Execution in accordance with this agreed contract and relevant
blasting and painting standards with MDL.
iii. Populating a team with the correct technical and people skills
iv. Schedule Control and Progress Control of released jobs
v. Project Reports; Daily, Weekly and Monthly
vi. Communication & Documentation procedures
vii. On-Site Coordination and support for Off-Site activities
5. Services
The contractor shall provide incidental services, free of cost, associated in
executing the above work for MDL namely but not limited to:
i.
Cleaning of the slipway, drydock, surrounding areas, machines and

equipments, etc. of dust immediately after blasting has taken place.
ii. Removal of spent/excess and reusable grits within 7 days from the date of
work done.
iii. Transportation of paint drums from store to point of use.
iv. Removal of empty paint drums and cartons from work site to disposal area
on daily basis.
v. Empty paint tins of Component B of size 6l and below are to be returned
to Paint Shop without damaging them and the quantity of such tins shall
be mentioned and tallied in the Material Reconciliation Report. Such tins
are intended for reuse by MDL. Loss of tins shall attract penalty equivalent
to the cost of procurement of fresh empty tins by MDL on the contractor.
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vi. Scaffolds if provided and used of MDL, must be dismantled and put in
place as instructed by the dealing executive.
vii. Neither MDL nor the Naval agencies nor the OEM nor any other Inspection
Agencies shall be responsible to supervise or direct the Work or the
activities of Contractors employees.
viii. However, the Contractor shall participate with MDL and, if MDL elects, the
OEM/Naval agencies or any other Inspection authority, in performing full
job walk-throughs whenever required by MDL. The purpose of such walkthroughs is to check that the Work performed are in accordance with the
Specifications and other Contract Documents and that the Work on the
Project is progressing in accordance with the Schedule.
ix. The Contractor shall assist MDL personnel and Inspection/OEM autorities,
if any, when they perform inspections. The Contractor shall furnish a
detailed report to MDL of observed discrepancies, deficiencies and
omissions in the Work performed by the contractor and the actions being
taken to correct such discrepancies, deficiencies and omissions in the
Work. Unless MDL directs the Contractor to correct such discrepancies,
deficiencies or omissions within 24 hours, the Contractor shall correct nonconforming or defective work within seven (7) days of any report issued
(including reports issued by the MDL or the Naval/OEM/Inspection
authorities) unless such non-conforming or defective work cannot be
corrected within such time, in which case Contractor shall commence
corrective action and furnish MDL its written plan for correcting such nonconforming or defective work within such seven (7) day period and shall
report its progress with respect thereto whenever requested by MDL.
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Supplier Information
The contractor shall submit the following additional information for evaluating
the technical competence of the firms :
i.
Company safety policy.
ii. Service Quality Assurance plans.

iii. Proposed Manpower to be deployed and their qualifications.
iv. Manpower loading schedule during lean and peak work loads. (include
Manager, supervisors, safety supervisor, blasters, painters, mazdoors, etc.)
v. Tools and Equipment details and brochures proposed by the contractor for
use in connection with the Work.
vi. Tools and Equipments Loading plan during lean and peak work loads.
vii. Back up team support, if required.
viii.Other relevant information as asked in preceeding pages.
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Appendix A
Method of Preparation of Labolene
(MDL Supply)
1. Labolene is a liquid detergent and is a proprietary product of Glaxo India Ltd.
2. The solution is to be prepared by mixing 6 ml of the detergent in one litre of
fresh water.
3. The solution is applied on the surface with brush or cotton rags or sponge and
allowed to react with the contamination for about 10 minutes.
4. Subsequently, this is to be washed down twice with fresh water and the
surface should be dried with clean sponge or cloth.
Note:
1. Do not wash dirty paint work with alkali or soap solution, as it is harmful for
the paint film.
2. Residual alkali/soap on painted surfaces results in poor inter coat adhesion
when a fresh coat is applied.
3. This leads to flaking of the fresh paint film and promotes discolouring of paint.
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Appendix B
Test for Presence of Mill Scale
1. The copper sulphate solution is to consist of 4% copper sulphate and 1%

sulphuric acid by volume in distilled water.
2. The prepared solution is to be applied to the newly blast cleaned steel surface
using an impregnated pad about 25mm square. Bright copper is deposited on
the bare steel. The areas of mill scale and corrosion products will become
visible as dark areas.
3. If after applying the copper sulphate solution dark areas appear to a greater
extent than those specified in BS: 4232 for a first or a second quality blast
cleaned surface as appropriate to the standard required, the area is to be reblasted and re-tested until the requirement is met.
4. After testing, the copper deposit is to be completely removed from acceptably
cleaned plates and sections by grinding or re-blasting the local areas to avoid
pitting, which will otherwise occur.
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ISO 8501-Pictorial Clasiification Standard For Surface Cleanliness

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ISO 8501-Pictorial Clasiification Standard For Surface Cleanliness

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MAZAGON DOCK LIMITED

Removal of Oil and Grease

Surface Cleaning by Water

Preservation/Treatment of new steel plates

Blast Cleaning of Steel after fabrication

Internal Underwater Areas and Tanks

External Underwater Areas

Vertical Above Water Areas and Super Structure

Blast Cleaning of Minor Structural fittings

Job site safety

Blasting and Painting

MAZAGON DOCK LIMITED

MDL SCOPE OF SUPPLY

CONTRACTORS SCOPE OF SUPPLY

Contractor Project Management

Blasting and Painting

MAZAGON DOCK LIMITED

TECHNICAL SCOPE OF WORK FOR BLASTING, SURFACE PREPARATION AND

Open nozzle abrasive blast cleaning as applicable to para 7-12 is required

Blasting and Painting

MAZAGON DOCK LIMITED

iii. Iron/steel grits conforming to DS Cat No 5350-000139 & 5350-000140 shall

Blasting and Painting

MAZAGON DOCK LIMITED

MAZAGON DOCK LIMITED

Dust causes poor adhesion and hence it must be removed;

MAZAGON DOCK LIMITED

6. Surface Cleaning by Water

Low pressure water cleaning(LP WC):

upto 340 bar/5,000 psi.

ii. High pressure water cleaning(HP WC):

iii. High pressure water jetting(HP WJ):

680-1,700 bar/10,000-25,000 psi.

iv. Ultrahigh pressurewater jetting(UHP WJ): above 1,700 bar/25,000 psi.

Blasting and Painting

MAZAGON DOCK LIMITED

7. Preservation / treatment of new steel plates

8. Blast Cleaning of Steel after fabrication into units/blocks/various areas

MAZAGON DOCK LIMITED

Steel Substrate. The surface preparation for application of the paint

Blasting and Painting

MAZAGON DOCK LIMITED

microns. Copper slag, if used as an abrasive, should render a surface

Surface preparation of all miscellaneous items is to be carried out as per

ii. Wherever the paint scheme is silent on surface preparation international

MAZAGON DOCK LIMITED

washing and scrubbing with labolene solution in hot fresh water,

MAZAGON DOCK LIMITED

A Brush can be used for areas difficult to spray.

Blasting and Painting

MAZAGON DOCK LIMITED

Feathering is used for transition of applying a fresh coating system to an

A typical Painting Process shall consist of the following steps:

Blasting and Painting

MAZAGON DOCK LIMITED

(b) Appropriate Surface Preparation

Blasting and Painting

MAZAGON DOCK LIMITED

x. Filling and draining of paint/bituminous solution in the rudders, bilge keels

For the purpose of costing, Touchup shall be defined as preservation

ii. In case of preservation, of a section of an entire space or location, partial

Blasting and Painting

MAZAGON DOCK LIMITED