Painting Spec - Mechanical

JICA Assisted Orissa Integrated Sanitation Improvement Project (ID-P187)
Bid Document for Construction of New Sewage Treatment Plants & Volume II SECTION 5
Pumping Stations In Bhubaneswar Sewerage District-VI and Cuttack Technical Specifications
Sewerage Districts I, II (Package no. JICA/OWSSB/OISIP/03)
PART-5
GENERAL PAINTING AND PROTECTION REQUIREMENTS
Orissa Water Supply & Sewerage Board 5.5 - 1 01/03/2012

Table of Contents
5.1. General ...................................................................................................................... 3
5.2. Painting System Failure ............................................................................................. 4
5.3. Colour Coding and Labeling of Pipes and Equipment ................................................ 5
5.4. Cleaning and Preparing at Place of Manufacture ........................................................ 5
5.4.1 Cleaning .................................................................................................................... 5
5.4.2 Preparation ................................................................................................................ 5
5.5. Painting and Finishing at Place of Manufacture ......................................................... 6
5.6. Painting at Site .......................................................................................................... 9
5.6.1 Painting System Requirements ................................................................................ 10
5.6.2 Painting System ....................................................................................................... 10
5.7. Fusion-bonded epoxy powder coatings .................................................................... 11
5.8. Plant and Pumping Stations Finish ........................................................................... 12
5.8.1 Welding and Flame Cutting ..................................................................................... 13
5.8.2 Castings................................................................................................................... 13
5.8.3 Covers. .................................................................................................................... 13
5.8.4 Flanges and Beadings .............................................................................................. 13
5.8.5 Items to be Chromium Plated................................................................................... 13
5.8.6 External Screws, Boltheads, Nuts and Washers........................................................ 13
5.8.7 Gauges .................................................................................................................... 13
5.9. Materials ................................................................................................................. 13
5.10. Workmanship .......................................................................................................... 16
5.11. Application of Painting Systems: ............................................................................. 17

PART- 5 GENERAL PAINTING AND PROTECTION REQUIREMENTS
5.1. General
The preparation, application and conditions for work shall comply with the recommendations of
BS: 5493 and BS: 6150 or if the protection is of a special nature, in accordance with the
manufacturer's directions.
Paints, primers and undercoats shall be obtained from the same manufacturer and except where a
definite time is specified between mixing and application, shall be ready mixed for use. They
shall be compatible with one another.
Paints shall be delivered in sealed containers bearing the manufacturer's name, batch number, etc.
and shall carry a label giving details of quality and instructions for use.
No site painting shall be carried out unless the surface to be painted is dry, the air temperature
above 4C and the relative humidity less than 85% or as otherwise specified by the paint
manufacturer, whichever is minimum. The Engineer shall approve the methods for removing all
dirt, oil, grease, etc, before Site painting commence.
Test plates carrying finishes from the actual coating used may be required by the Engineer for
inspection and test purposes.
To facilitate inspection, no consecutive coats of paint shall be of the same shade except in the
case of white.
Priming to two mating surfaces shall be applied prior to assembly.
All items of the Plant and pumping stations shall be delivered to Site with the shop paint finish
applied unless specified otherwise. A further coat of final finish paint shall be applied at Site, of
sufficient thickness to produce a uniform colour and appearance. Such painting shall be carried
out within one month of successful acceptance trials for the Plant and pumping stations.
All paint thicknesses shall be checked using an Elcometer or equivalent instrument, supplied by
the Contractor, for each layer of paint, to the requirement of the Engineer.
All coatings applied to any part of the plant in contact with water to be used for drinking,
washing or cooking shall be non-toxic, non-carcinogenic, shall not impart taste, odour, colour or
turbidity to the water or foster microbial growth. No manufacturers name-plate identification,
vented filler plugs in gearboxes or grease nipples shall be painted over. Lead based paints shall
not be used.
The Contractor shall liaise closely with the plant manufacturer who shall provide full facilities
for him to inspect and check the preparation and painting during all stages. The Contractor shall
report on his inspections to the Engineer.

The Contractor shall ensure that all coatings are free from defects and adequate in all respects for
the purpose intended.
Surfaces to be painted:
In general following surfaces are to be painted:
1. All exposed piping and metal surfaces, interior or exterior,

2. All submerged metal surfaces.
3. All structural and miscellaneous steel, including Tanks,
4. The interior of process Tanks, Channels, launders and pits as specified in the painting
schedule and as required after equipment installation.
5. The interior of structures as specified in the painting schedule and required after
equipment installation.
6. Equipment furnished with and without factory finished surfaces, except as specified
below.
7. All interior and exterior exposed surfaces of buildings.
Surfaces not to be painted:
The following surfaces in general shall not be painted:

1. Concrete surfaces subject to pedestrian traffic.
2. Plastic surfaces.
3. Non-ferrous metal unless otherwise noted or indicated (Galvanized metal shall not be
considered a non-ferrous metal).
4. Mechanical Equipment with approved factory finished as specified herein.
5. Electrical Equipment with approved factory finished as specified herein,
6. Piping which is specified as galvanized.
In no case shall any concrete, wood, metal or any other surface requiring protection be left
unpainted even though not specifically defined herein.
Submittals:
Material specifications, surfaces preparation and application instructions, and colour sample
cards shall be submitted to the employer for approval.
Paint to be Provided to Employer:
The contractor shall leave on the job site at the conclusion of the contract a minimum of four (4)
liters of each type and colour of finish paint used on the work. Each container shall be properly
labeled for identification.
5.2. Painting System Failure
The painting system shall be deemed to have failed if:
1. After painting, damage has been caused by handling, impact, abrasion or welding;

2. Any portion of the paint film separates from any other or the parent metal;
3. After painting the total dry-film thickness is less than that specified.
Failure shall not include:
1. Loss of gloss;
2. Variation of shade, not affecting the anti-corrosive properties of the system.
5.3. Colour Coding and Labeling of Pipes and Equipment
All pipes and equipment shall be colour coded to a schedule to be agreed with the Engineer
before any site painting starts, or earlier if necessary to suit manufacturing procedures.
Valves and fittings shall be painted in the same colour as of the pipe of which they form a part.
Where a pipe enters or leaves a piece of equipment the pipe colour shall extend up to but not
including the flange attached to the equipment.
All pipelines shall be identified by stick-on 90 micron thick vinyl film labels showing the name
of the material to be carried by the pipeline and an arrow indicating the direction of flow. Letters
of titles shall be pre-spaced on carrier tape and the complete title protected by one piece
removable liners. Titles shall be at intervals not less than 8 m, but shall in any case be provided
in every space through which the pipe passes. Locations of labels shall be subject to prior
approval by the Engineer. Lettering sizes shall be between 16 mm and 75 mm in height
depending on the size of the pipe.
Pipes smaller than 22 mm outside diameter shall be labeled by the use of tags instead of labels.
Tags shall be made of brass no smaller than 65 mm x 16 mm by 1.5 mm thick, with lettering
etched and filled with black enamel.
Titles shall also be provided on all equipment in locations and in sizes to be approved by the
Engineer.
5.4. Cleaning and Preparing at Place of Manufacture
The Contractor shall be responsible for the cleaning and preparation for painting, priming or
otherwise protecting as specified of all parts of the Plant at the place of manufacture prior to
packing.
5.4.1 Cleaning
Parts shall be cleaned prior to testing at the manufacturer's works. Parts subject to hydraulic test
shall be tested before any surface treatment. After test all surfaces shall be thoroughly cleaned
and dried out if necessary by washing with an approved dewatering fluid prior to surface
treatment.
5.4.2 Preparation
Bright parts: Bright parts and bearing surfaces shall be thoroughly polished and protected from
corrosion by the application of rust preventive lacquer or high melting-point grease, as
approved by the Engineer, before the parts are packed. A sufficient quantity of the correct

solvent for removal of the protective compounds shall be supplied and packed with each
particular part.
Embedded parts: Embedded parts or those parts of an assembly which will be embedded in
concrete shall be thoroughly de-scaled and cleaned to the requirement of the Engineer and
before being packed shall be protected by a cement wash or other approved method. No
cast iron or steel work shall be bitumen or tar coated where it is to be cast into the concrete
and provision shall be made for cleaning off any portions so coated.
Grit or shot blasted parts: Grit or shot blasting shall be carried out in accordance with BS:
7079 to a standard between `First Quality' and `Second Quality' given in Table 1 of BS: 7079
after which the maximum amplitude of the surface shall not exceed 0.1 mm.
Cast Iron and Steel pipework: All ungalvanised steel pipework including pump suspension
mains, bearing spiders and tunnel tubes shall be prepared internally and externally by grit or
shot blasting as specified in clause 5.2 above and the surfaces primed as specified within four
hours of blasting.
5.5. Painting and Finishing at Place of Manufacture
This Clause governs the methods for the protective coatings to be applied to structural steel,
metal work and ironwork as corrosion protection systems. The systems designed as specified
here shall be applied as specified under Protective Coatings. Protective coating specified
elsewhere for particular works such as pipes and cladding shall firstly be designed in accordance
with particular requirements specified elsewhere and secondly in accordance with any
requirements herein which are not overridden elsewhere. This specification makes reference to
the following standard BS: 5493 "Code of Practice for the Protective Coating of Iron and Steel
against Corrosion"
Protective Coating:
The Contractor shall design each protective coating system and shall submit details of each
system to the Engineer for approval. Submissions shall, where possible, be in the format of
which examples are given at the end of this section at clause 5.5.2 with such additional
information and samples as the Contractor may provide or the Engineer may require to enable the
system to be assessed.
Protective coating shall be designed in accordance with BS: 5493 to have a long life, generally of
at least 10 years to first maintenance. Protection systems shall be chosen to be easily maintained
in the future and to allow non-specialist on-site re-coating where necessary using single part
paints.
For the purposes of system design the general environment shall be as specified in BS: 5493
Table 3 Part 2 `Exterior exposed polluted inland. Bulkhead gates and stop logs shall be
assumed to be exposed to a Table 3 Part 8 `Non-saline water environment unless otherwise
approved by the Engineer.
Interior spaces shall be considered to be dry in administration areas open to continuous access
and damp or immersed in other spaces. The protective coating of components or structures

which are continuously or infrequently immersed shall be designed for the more onerous of
these two conditions relevant to the protection system used.
All exterior exposed items to be coated shall have a final coat of good appearance of a colour and
type as approved by the Engineer.
Protective coating systems shall generally fall into one of the following basic systems:
1. Protective Coatings;
2. Galvanising;
3. Galvanising plus painting;
4. Multi-coat painting;
5. Bitumen enamel;
6. Others as proposed by the Contractor and approved by the Engineer.
The Contractor shall submit to the Engineer details of his proposals for the corrosion protection
of each of the items requiring such protection, which will generally fall into the above categories,
as follows:
1. Trash screens, flooring, ladders, access covers and frames, step irons and other
components which are inaccessible but subject to abrasion/damage;
2. Structural steelwork (including crane beams, monorails, crane structures and chassis),
bulkhead gates, stop logs, grappling beams, steel tanks and other large items readily
accessible for maintenance;
3. Valves and other corrosion-susceptible items which may be buried and are not covered
by the provisions of other specifications:
4. Other components not covered by the above for which the contractor may propose a
system which he considers to be more suitable for the duty;
5. Electrical switchgear, transformers, control panels etc.
All painting material shall be applied in strict accordance with the paint manufacturer's
instructions.
Plant supplied to site with final coating applied: Cubicles, cabinets etc. other than those specified
in elsewhere in tender document.
Before any steel work is painted, the steel must be thoroughly cleaned and an approved anti-
rusting priming coat shall be applied so that the possibility of rusting or corrosion taking
place is negligible. All surfaces should have not less than two stoved undercoats and two top
coats of air drying paint. The undercoats shall be easily distinguishable in shade or colour from
the priming and finishing coats. The two final coats shall be in a colour and finish to be advised
by the Engineer. The inside surfaces of any cubicles, cabinets etc. where condensation is
liable to occur, shall be coated with an approved anti-condensation composition. The
Contractor shall ensure that all component sections of a switch board wherever
manufactured shall have a finish of uniform texture and an exact colour match.
Chromium plated parts: Where chromium plating is specified or offered by the

manufacturer it shall comply with the requirements of BS: 1224 including the following
provisions. No blistering of any surfaces will be tolerated. The finished appearance shall be

bright. Where the base metal is steel, plating shall be applied in accordance with Table 2 of BS:
1224. Other base metals shall be plated in accordance with Tables 3, 4, 5 of BS: 1224 as
appropriate. For all base metals the service condition table number 2 shall be used.
Small bore pipes, valves and fittings etc., which are sited in architecturally finished areas of the
station and selected by the Engineer shall be chromium plated. Damage to chromium plating
shall be made good before Taking Over.
Galvanised parts: All materials to be galvanised shall be shown on the approved drawings or
specified. All punching, cutting, drilling, screw tapping and the removal of burrs shall be
completed before the galvanising process begins. Parts to be galvanised shall be shot blasted as
specified above in clause 5.3.2. Such parts shall be galvanised not more than four hours after
commencement of shot blasting.
All galvanising shall be done by the hot dip-process. No alternative process may be used without
the approval of the Engineer. No components shall be galvanised which are likely to come into
subsequent contact with oil.
The zinc coating shall be uniform, clean smooth and free from spangle as far as possible. In the
case of component parts the zinc coating shall weigh not less than 610 g/sq.m of area covered
and shall not be less than 0.090 mm in thickness.
Where hot-dip galvanising is not practicable bolts and nuts shall be sherardised, which shall
conform to BS: 4921. The Engineer may select for test as many components to be weighed after
pickling, and before and after galvanizing as he may think fit.
All galvanised parts shall be protected from injury to the zinc coating due to differential
seration and abrasion during the periods of transit, storage and erection. Damaged areas of
the coating shall be touched up with an approved zinc-dust paint or other approved flake metallic
compound as approved by the Engineer as follows:
1. Cast iron and steel pipework: (Internal surfaces)

2. The internal surfaces shall have an approved coating.
3. Where a bitumen based coating is used, it shall be in accordance with Type 2 of BS:
4147.
4. Prior to lining, the pipe shall be grit blasted and primed with an approved primer. The
lining shall be in accordance with BS: 534. After installation, the internal lining shall be
made good and satisfactorily tested with required detector.
5. The coating shall be suitable for use in contact with drinking water. The type of coating
shall be entered in Schedule L provided and the Engineer reserves the right to call for test
plates of the paint. The manufacturer shall at the time of ordering carry out the `Taste
and smell test' (Appendix E of BS: 4147) and `Effects on water test' (Appendix C of BS:
3416) and forward 3 copies of the test results to the Engineer for approval.
6. Where pipes are to be welded after the protective coatings have been applied, the
pipe surfaces shall be primed and all other coating stopped of the weld preparation.
Collars and fittings shall be primed but no other coating will be applied.
7. The manufacturer shall supply a sufficient quantity of suitable materials to repair
damage occurring during delivery to site and to provide a flush finished internal
lining at welded joints. He shall supply sufficient coating to fill in the recesses at

internal welds over the previously primed areas. The costs of these materials shall be
included in the unit rates for the supply of the pipes and specials. In case manufacturer
does not supply suitable materials to repair damage, it is the contractors responsibilities to
supply the same at his own cost and do the necessary repair.
8. The coating shall be applied in accordance with the manufacturer's instructions and with
Appendices J and K of BS: 3416. The Contractor is to ensure the same.
Machinery- (Internal surfaces) e.g. Pumps, valves, strainers, rising and suspension mains of wet
well pumps:
As for cast iron and steel pipework (Internal surfaces).
Cast iron and steel parts (External surfaces) immersed in wastewater:
1. All ungalvanised metal parts which will be immersed in Waste water shall be cleaned by
grit blasting and within four hours of blasting given a coating similar to that specified for
internal surfaces.
2. Cast iron and steel (External surfaces) in manholes and areas of high humidity.
3. Ungalvanised metal parts exposed in manholes or areas of high humidity shall be cleaned
by grit blasting and given two coats of a black bituminous solution. It is specifically
provided in Bhubaneswar as Bhubaneswar comes under high humidity area.
Plant forwarded to site for final finishing.

Cast iron and steel parts (External surfaces) outside buildings: All ungalvanised metal parts
which will be exposed to the outside atmosphere shall be cleaned by grit blasting and
provided with two coats of an approved primer.
Cast iron and steel parts inside buildings: All exposed metal surfaces which will not be
immersed in waste water or exposed in areas described above shall be rubbed down, cleaned by
grit blasting and within four hours of blasting given one coat of an approved primer before
packing.
5.6. Painting at Site
Immediately on arrival at the site, all items of plant shall be examined for damage to the paint
coat applied at the manufacturers works, and any damaged portions shall be cleaned down to the
bare metal, all rust removed, and the paint coat made good with similar paint.
Steel and cast iron parts received at site shall be provided with adequate number of further coats
of coal-tar epoxy polyamine coating to a total dry film thickness of 275 microns including the
primer coats. All sharp edges, nuts, bolts and other items difficult to be painted shall receive a
brush coat of specified paint. Before application of each coat of epoxy based coal-tar paint giving
a total dry film thickness of at least 275 microns. In the case of fabricated steelwork this work
shall be done after assembly.
Before painting is commenced the Contractor shall submit for the approval of the Engineer, full
details of the paints he proposes to use together with colour charts for the gloss finishes.
After erection, such items which are not finish painted shall be finish painted, items finish
painted at the Manufacturers works shall be touched up for any damaged paint work.

5.6.1 Painting System Requirements
The painting work shall conform to the following requirements:
1. The surface preparation shall be carried out generally in accordance with IS: 1477 Part I
and IS: 6005
2. After surface preparation, two coats of primer-red oxide zinc chromate with modified
phenolic alkyd base conforming to IS: 2074 shall be applied. Dry film thickness of each
coat shall be 25 microns.
3. For finish painting, after application of primer as in (b) of clause 5.4.1 above, two coats of
synthetic enamel paint conforming to IS: 2932 shall be applied. Dry film thickness of
each coat shall be 25 microns.
4. Colours shall be selected as per IS: 5
5. No painting shall be carried out unless the item has been inspected and accepted by
Engineers at the Manufacturers works
6. The dry paint film thickness shall be measured by Elcometer or other instruments
approved by the Engineer. In order to obtain the dry film thickness (DFT) specified, the
Contractor shall ensure that the coverage rate given by the paint manufacturer will enable
this thickness to be obtained. Strength of adhesion shall be measured with an adhesion
tester and this value shall not be less than 10 kg/cm2. Painted fabricated steel Work which
is to be stored prior to erection shall be kept clear of the ground and shall be laid out or
stacked in an orderly manner that will ensure that no. poles of water or dirt can
accumulate on the surface. Suitable packings shall be laid between the stacked Materials.
Where cover is provided, it shall be ventilated.
5.6.2 Painting System
The painting procedure shall be submitted by the contractor in the following format:
1. Surface Preparation
2. Reference Standard
3. Conditions of Work
4. Type of Materials
5. Tests and inspection methods and sequence, thickness (DFT)
6. Colour in final coat
7. Total thickness of coats (DFT)
8. Other necessary data and information
The following items in the plant are required to be painted:
1. Outer surfaces of pumps, valves, pipes, fittings, motors etc., not exposed to treated waste
water
2. Steelwork exposed to weather, such as outer surface of surge vessel, valves, pipes etc.
3. Internal Plant and pipework, cranes, exhaust fans, fire extinguishers and miscellaneous
steelwork not exposed to weather
4. Steelwork exposed to weather, such as platforms, ladders, handrailing, etc.

5. Steelwork exposed to humid weather and requiring hard maintenance and repairs
6. Buried steelwork
7. Buried pipes and fittings prior to application of wrapping
8. Other equipment, as per requirement of employer.
All buried steel pipes and fittings shall be coated and unwrapped with hot or cold applied, self-
adhesive, polyethylene in accordance with AWWA C214 or equivalent Standard.
Cast iron or mild steel parts to be built into concrete shall remain unpainted. Immediately before
it is cast in-situ, it shall be made perfectly free from dirt, scale, loose rust, paint, oil limewash or
any other coating.
No blast cleaning or painting shall be applied to corrosion resistant Materials such as stainless
steels. Ni-resist cast iron, bronze and other metals used for seals, bearings, lighting fitting etc.
Machined surfaces such as gear teeth shall be coated with a thick layer of grease. Other
mechanical surfaces such as shaft ends or other bright parts shall be coated with two coats of an
anti-rust solution which can be removed easily when required. Permanently bolted mechanical
interfaces such as flanges shall be coated with a thin coat of anti-rust compound before assembly.
All primers, under coats and finishes shall be applied by brush or airless spray, except where
otherwise specified.
Consecutive coats shall be in distinct but appropriate shades. All paints shall be supplied from
the store to the painters, ready for application, and addition of thinners or any other Material shall
be prohibited. Any instruction given by the paint manufacturer shall be strictly followed.
All painting shall be carried out by the qualified, experienced & competent painters under
supervision. Paint shall be applied to the dry surface which has been prepared in compliance with
the approved procedure.
The Plant and equipment shall be inspected and reviewed at the various stages of the coating
application both at the manufacturers Works and at the Site of the Works. Samples may be
taken from the paints as delivered and submitted to such tests as are deemed necessary. The
completed paint systems shall be tested by instruments to ensure that the protection is of
adequate thickness and is free from pinholes and the direct measurement of adhesion shall be
checked by the removal of a small section of the coating. The Contractor shall supply all
instruments and apparatus required for carrying out such tests required by the Employer.
5.7. Fusion-bonded epoxy powder coatings
All fabricated steel pipework and other Plant where specified, shall have a lining and coating, not
less than 250 microns thick, of 100% solids, thermosetting fusion-bonded, dry powder epoxy
coating. All grit and dust shall be removed and coating shall be started before formation of
visible oxidation of the surface. The metal shall be pre-heated to a temperature recommended by
the manufacturer and the epoxy powder applied by immersion in a fluidised bed, after which
excess powder shall be removed. The powder shall be allowed to flow out completely before
curing. The thickness of the coating, including any repaired areas, shall be checked with a
calibrated tester. Spark testing, for pinholes, voids, contamination, cracks and damaged areas,
shall use a high-voltage spark generator. Repairs due to coating imperfections or damage shall be
done using a brush-applied compatible two-pack liquid epoxy compound. The area to be repaired

shall be cleaned to remove dirt, grease, scale and damaged coating, which shall be feathered.
Pinhole surface preparation is not required other than removal of detrimental contaminants which
could impair the adhesion of the repair material. The surface coating shall be applied by an
approved applicator. GRP covers and guards shall be pigmented to give the finished colour
without painting.
5.8. Plant and Pumping Stations Finish
A high standard of finish, defined as the Plant and pumping stations " is required for all surfaces
to be painted as detailed below.

5.8.1 Welding and Flame Cutting
A smooth neat finish, by careful grinding if necessary is required on all exterior welding and
flame cutting. All plates and bars used in fabrication shall have smooth surfaces with no pitting
or deep slag inclusions.
5.8.2 Castings
Casting surfaces shall be smooth and free from surface blowholes. Stock castings shall be
specially selected with this in mind.
All castings shall be shot blasted before machining.
5.8.3 Covers
All covers shall be firmly fixed. Weld mesh shall sit square in its frame. Where panels are
placed next to each other the patterns shall line up.
5.8.4 Flanges and Beadings
All bolt holes shall be spot faced parallel with the mating face for good seating of nuts and bolt
heads. Surplus jointing shall be removed from mating faces and peripheries.
5.8.5 Items to be Chromium Plated
Name plates, instruction plates, rotation arrows, indicators and pointers, small bore
pipework, oil level gauges and fittings, small valves (including air valves), plugs and grease
nipples, which are sited in architecturally finished areas of the station and as selected by the
Engineer, shall be chromium plated. Damage to chromium plating shall be made good, by the
contractor at his cost.
All pipes and fittings etc., shall be fitted in a straight, neat symmetrical manner so as to
present a pleasing appearance.
5.8.6 External Screws, Boltheads, Nuts and Washers
These shall be chromium plated, sherardised or made in stainless steel.
5.8.7 Gauges
All indicating gauges fitted to any machine assembly shall be of similar appearance and grouped
together to present a pleasing aspect. They shall all have chromium plated cases, bezels, cocks
and fittings.
5.9. Materials
All paint materials shall be first quality products manufactured for the exposures involved, as
approved by the Engineer. Paints which are to be in contact with water or chemical solutions shall be
completely inert and free of lead and other toxic substances.

System A Materials:
Primer : Zinc-rich epoxy primer
First Coat : Universal type primer
Finish Coat : Vinyl acrylic finish
System A1 Materials:
Primer : Etching primer
First Coat : Red lead primer or lead suboxide primer
Intermediate Coat : Long oil alkyd resin paint
Finish Coat : Long oil alkyd resin paint
System B Materials:
Primer : Epoxy primer
Intermediate Coat : Polyester epoxy enamel
Finish Coat : Same as intermediate
System B1 Materials:
Not Used
System C Materials:
Primer : Zinc-rich epoxy primer
Intermediate Coat : Epoxy polyamide coaching conforming to Steel
Structures Painting Council Paint 16-68T
System C1 Materials:
Primer : Inorganic zinc rich primer
First Coat : Epoxy primer
Finish Coat : Poly-urethane resin paint
System D Materials:
Primer : Vinyl-based cementitious block filler
Intermediate Coat : Vinyl acrylic emulsion, F.S.TT-P-19
System D1 Materials:
Primer : Epoxy resin
First Coat : Epoxy resin
Finish Coat : Epoxy resin

System D1, where required epoxy resin pain system shall be suitable for drinking water service and
paint shall be certified by recognized public health authorities for linings in potable water. The
Contractor shall submit certification of paint which is suitable for drinking water service.
System D2 Materials:
Primer : Inorganic zinc rich primer
First Coat : Epoxy primer
Finish Coat : Epoxy resin paint
System E Materials:
Primer : Epoxy polyamide masonry filler or coating
Intermediate Coat : Epoxy polyamide coating
System E1 Materials:
First Coat : Tar epoxy resin paint
Finish Coat : Tar epoxy resin paint
System E1, where required tar epoxy resin paint system shall be suitable for drinking water service
and paint shall be certified by recognised public health authorities for linings in potable water. The
Contractor shall submit certification of paint which is suitable for drinking water service.
System E2 Materials:
Primer : Organic zinc rich primer
First Coat : Tar epoxy resin paint
Finish Coat : Tar epoxy resin paint
System F Materials:
Primer : Latex base, F.S. TT-P-645
Intermediate Coat : Latex flat, F.S. TT-P-29
System F1 Materials:
System F1, paint system for galvanized surfaces shall be:
Surface preparation and primer
Surface shall be free from moisture, dust or other contaminants with use of solvent cleaning. Damaged
galvanized area shall be cleaned by using hand or power tool, and surface shall be finished as SSPC-
SP3. All galvanized surface and surface cleansed shall be painted with etching primer, minimum dry
film thickness of 20 microns.
Coating
After finishing surface preparation, painting system A1, B1, C1, D1, D2, E1 or E2 shall be applied
unless otherwise specified.

System G Materials:
Primer : Pigmented oil primer, F.S. TT-S.179
Intermediate Coat : Enamel under coat, F.S.TT-E-543
Finish Coat : Semi-gloss enamel, S.S. TT-E-508
System H Materials:
Primer : Exterior wood primer, F.S. TT-P-25
Intermediate Coat : Exterior gloss, F.S. TT-E-489
System I Materials:
Primer : For ferrous metal, red lead primer, F.S.TT-P-86
For galvanised, zinc-duct zinc-oxide primer; F.S.-TT- P641
Intermediate Coat : Exterior gloss enamel, F.S.TT-E-489
5.10. Workmanship
Protection of the Work:
The Contractor shall take the necessary steps to protect the work of others during the time his work is
in progress. The Contractor shall be responsible for any and all damage to the work. Paint shall be
applied only during periods of favourable weather.
Preparation of Paint:
All materials specified or selected for use under these specifications shall be delivered unopened at the
job site in their original containers and shall not be opened until inspected by the Engineer. Paint
containers shall be opened only when required for use. Paint shall be thoroughly stirred or agitated to
uniformly smooth consistency suitable for proper application. In all cases, paint shall be prepared and
handled in a manner to prevent deterioration and inclusion of foreign matter. No paint shall be
reduced or applied in anyway except as herein specifically called for or, if not specifically called for,
then it shall be applied in accordance with the manufacturer's recommendations.
Preparation of Surfaces:
The Contractor shall examine carefully all faces to be finished and before beginning any of his work
shall see that the work of the other trades has been left or installed in a workmanlike condition to
receive paint. Metals shall be clean, dry, and free from mill scale, rust, grease, and oil.
Workmanship:
Each coat of paint shall be applied at the proper consistency and brushed evenly, free of brush marks,
sags, runs, with no evidence of poor workmanship. Care shall be exercised to avoid lapping paint on

glass or hardware. Paint shall be sharply cut to lines. Finished paint surfaces shall be free from defects
or blemishes.
Protective Coverings:
Protective coverings or drop cloths shall be used to protect floor, fixtures, and equipment. Care shall
be exercised to prevent paint from being spattered onto surfaces which are not to be painted. Surfaces
from which such paint cannot be removed satisfactorily shall be painted or repainted, as required to
produce a satisfactory finish.
Tints:
Whenever two (2) coats of paints are specified, the first coat shall contain sufficient powered
aluminium or carbon black to act as an indicator or proper coverage, or the two (2) coatings must be
of contrasting colour.
Instructions:
All coatings shall be performed by personnel experienced in the application of said coating systems
and in accordance with the manufacturer's printed instructions. The final appearance shall exhibit a
uniformly textured and coloured coating free of excessive gloss or dull spots, blemishes, sags, runs,
pinholes, and other defects.
Ventilation:
The Contractor shall not permit painting to begin in enclosed places, until a forced draft ventilation
system of sufficient air volume has been placed in operation.
Right of Rejection:
No exterior painting or interior finishing shall be done under conditions which may jeopardise the
appearance or quality of the painting or finishing in any way. The Engineer shall have the right to
reject all material or work that is unsatisfactory, and require the replacement of either or both at the
expense of the Contractor.
5.11. Application of Painting Systems:
System A:
Un-galvanized ferrous metal subject to corrosive moisture or atmosphere and

condensation.
1. Surface Preparation: All metal surfaces shall be field sandblasted in accordance with
Steel Structures Painting Council Specification SSPC-SP-10 (Near-White Blast
Cleaning). Weld surface, edges, and sharp corners shall be ground to a curve and all weld
splatter removed.
2. Coating: Prime coat shall have a minimum thickness of 0.05 mm. An intermediate coat
shall have a minimum thickness of 0.05 mm. and finish coat shall have a minimum

thickness of 0.1 mm. The total system shall have a minimum dry film thickness of 0.2
mm.
3. Time Between Coatings: A minimum of 12 hours time is required before additional

coats may be applied to the prime coat, two hours for the intermediate coat, and two hours
for the finish coat.
System A1:
Ungalvanized ferrous metal, outdoor service, except buried, submerged and other surfaces
specifically included elsewhere.
Surface Preparation : SSPC-SP-6 or SSPC-SP-3
Coating Thickness :
Item Minimum Dry Film

Thickness (mm)
Primer : 0.02
First coat : 0.035
Intermediate coat : 0.035
Finish coat : 0.035
Total : 0.117
System B:
Ungalvanised ferrous metals not subject to chemical attack, normal indoor exposure,
except as specified otherwise.
1. Surface Preparation: All surfaces shall be freed of dirt, dust, grease, or other foreign
matter before coating. Surfaces shall be cleansed in accordance with the Steel Structures
Paint Council Specification SSPC-SP-7 (Brush-off Blast Cleaning). Weld surfaces and
rough edges shall be ground and weld splatter removed.
2. Application shall be in strict conformance with the manufacturer's recommendations. All
sharp edges, nuts, bolts, or other items difficult to coat shall receive a brush-applied coat
of the specified coating prior to application of each coat.
3. Coating System: The system shall have a minimum total dry film thickness of 0.1 mm
resulting from a prime coat and at least two finish coats.
System C:
Ungalvanised ferrous metal submerged or intermittently submerged in water or corrosive liquid.
1. Surface Preparation: All metal surfaces shall be field sand-blasted in accordance with
Steel Structures Painting Council Specification SSPC-SP-10 (Near-White Blast
Cleaning). Weld surface, edges, and sharp corners shall be ground to a curve and all weld
splatter removed, and welds neutralised with thinner.
2. Application: Shall be in strict conformance with the manufacturer's recommendations.
All sharp edges, nuts, bolts, or other items difficult to coat shall received a brush-applied
coat of the specified coating prior to application of each coat.

3. Coating System: The prime coat shall have a minimum thickness of 0.08 mm and two or
more finish coats shall have a minimum total thickness of 0.4 mm. The total system shall
have a minimum dry film thickness of 0.48 mm.
System C1:
Ungalvanised ferrous metal, outdoor service, specially specified, except buried and submerged
Surface Preparation : SSPC-SP-10
Coating Thickness :

Thickness (mm)
Primer : 0.075
First coat : 0.06 each
Finish coat : 0.03 each
Total : 0.255

System D:
Exterior or interior brick, concrete, and concrete block work exposed to view not subject to immersion
in liquids and not subject to pedestrian traffic except as otherwise specified. Interior surfaces not
specifically indicated shall not be painted. All concrete block surfaces to be painted shall be filled with
latex type block filler supplied by the paint manufacturer whose products are used prior to first or
prime paint coat.
1. Surface Preparation: All surfaces shall be freed of dirt, dust, grease, and other foreign
matter before coating. Cracks and voids shall be repaired or filled with a suitable material
compatible with the specified paint.
2. Coating: The first coat shall be applied to cover and provide a smooth base. The finish
coat shall be applied to a dry film thickness of 0.04 mm minimum.
3. Time between Coats: The filler coat may be recoated in 12 hours; the finish coat is dry
for a recoat in two hours.
System D1:
Ungalvanised ferrous metal submerged.

Coating Thickness :

Thickness (mm)
First : 0.20
Finish coat : 0.20
Total : 0.6
System D2:
Ungalvanized ferrous metal, indoor service, corrosive environment.

Surface Preparation : SSPC-SP-3 or SP-10
Coating Thickness :
Thickness (mm)
Primer : 0.075
First coat : 0.06 each
Finish coat : 0.05 each
Total : 0.295
System E:
Concrete subject to intermittent or continuous submergence, unless specified otherwise in other

sections of these specifications:

1. Surface Preparation: All surfaces shall be brush-off blasted to remove all dirt, dust,
form oil, curing compounds, and other deleterious compounds. In general, the concrete
shall be reasonably smooth, and free of pockets and cavities.
2. Coating System: The prime coat and intermediate and finish coats shall each have a
minimum dry film thickness of 0.1 mm. The total system shall have a minimum dry film
thickness of 0.3 mm.
3. Time between Coats: All coats shall be applied within 24 hours of the previous coat, or
in accordance with the manufacturer's instructions.
System E1:
Ungalvanized ferrous metal submerged or intermittently submerged in water for potable water
storage.
Coating Thickness :
Thickness (mm)
First coat : 0.2
Finish coat : 0.2
Total : 0.6
System E2:
Ungalvanized ferrous metal, submerged or intermittently submerged in wastewater, except the potable
water storage.
Coating Thickness :
Thickness (mm)
First coat : 0.2
Finish coat : 0.2
Total : 0.6
System F:
Interior concrete, masonry and plaster surfaces scheduled or directed to have a flat finish. Concrete
block masonry surfaces shall be given a coat of block filler according to system D prior to painting.
Preparation, Coating, and Time: As specified for System D.
System G:
Interior concrete, masonry, and plaster scheduled to have an enamel finish. Concrete block masonry
surfaces shall be given a coat of block filler according to System D prior to painting.

1. Surface Preparation: All surfaces shall be freed of dirt, dust, grease, and other foreign
matter before coating. Cracks and voids shall repair or filled with a suitable caulking
material compatible with the specified paint. Efflorescence shall be neutralised with zinc
sulphate solution and allowed to dry.
2. Coating: The prime coat shall be applied to cover and provide a smooth base. The
undercoat and finish coat shall be applied to a total dry film thickness of 0.075 mm
minimum.
3. Time between Coats: Each coat shall be completely dry before the next coat is applied.
System H:
Interior and exterior wood:
1. Surface Preparation: Unless already properly hand sanded, sandpaper smooth by hand
and dust clean. Neatly fill nail holes, cracks and depressions therein with approved filler,
coloured to match required finish; when dry, sandpaper and smooth.
2. Coatings: Prime coat shall be applied to cocker and provide a smooth base. Each finish
coat shall be applied to a minimum dry film thickness of 0.05 m.
3. Time between Coats: As specified for System G.
System I:
1. For interior and exterior metal not painted under System A, B, and C.
2. Surface Preparation: For ferrous metal, as specified for system B. Wash galvanised
surfaces with solvent thinner.
3. Coatings: Apply each coat to a minimum dry film thickness of 0.05 mm.
4. Time between Coats: As specified for System G.
End of Part- 5

Painting Spec - Mechanical

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JICA Assisted Orissa Integrated Sanitation Improvement Project (ID-P187)

GENERAL PAINTING AND PROTECTION REQUIREMENTS

Orissa Water Supply & Sewerage Board 5.5 - 1 01/03/2012

Orissa Water Supply & Sewerage Board 5.5 - 2 01/03/2012

PART- 5 GENERAL PAINTING AND PROTECTION REQUIREMENTS

Priming to two mating surfaces shall be applied prior to assembly.

Orissa Water Supply & Sewerage Board 5.5 - 3 01/03/2012

In general following surfaces are to be painted:

1. All exposed piping and metal surfaces, interior or exterior,

Surfaces not to be painted:

The following surfaces in general shall not be painted:

Paint to be Provided to Employer:

5.2. Painting System Failure

The painting system shall be deemed to have failed if:

Orissa Water Supply & Sewerage Board 5.5 - 4 01/03/2012

Failure shall not include:

5.3. Colour Coding and Labeling of Pipes and Equipment

5.4. Cleaning and Preparing at Place of Manufacture

Orissa Water Supply & Sewerage Board 5.5 - 5 01/03/2012

5.5. Painting and Finishing at Place of Manufacture

Orissa Water Supply & Sewerage Board 5.5 - 6 01/03/2012

Chromium plated parts: Where chromium plating is specified or offered by the

Orissa Water Supply & Sewerage Board 5.5 - 7 01/03/2012

1. Cast iron and steel pipework: (Internal surfaces)

Orissa Water Supply & Sewerage Board 5.5 - 8 01/03/2012

As for cast iron and steel pipework (Internal surfaces).

Cast iron and steel parts (External surfaces) immersed in wastewater:

Plant forwarded to site for final finishing.

5.6. Painting at Site

Orissa Water Supply & Sewerage Board 5.5 - 9 01/03/2012

5.6.1 Painting System Requirements

The painting work shall conform to the following requirements:

5.6.2 Painting System

The following items in the plant are required to be painted:

Orissa Water Supply & Sewerage Board 5.5 - 10 01/03/2012

5.7. Fusion-bonded epoxy powder coatings

Orissa Water Supply & Sewerage Board 5.5 - 11 01/03/2012

5.8. Plant and Pumping Stations Finish

Orissa Water Supply & Sewerage Board 5.5 - 12 01/03/2012

5.8.1 Welding and Flame Cutting

All castings shall be shot blasted before machining.

5.8.4 Flanges and Beadings

5.8.5 Items to be Chromium Plated

5.8.6 External Screws, Boltheads, Nuts and Washers

These shall be chromium plated, sherardised or made in stainless steel.

Orissa Water Supply & Sewerage Board 5.5 - 13 01/03/2012

Orissa Water Supply & Sewerage Board 5.5 - 14 01/03/2012

Orissa Water Supply & Sewerage Board 5.5 - 15 01/03/2012

Protection of the Work:

Orissa Water Supply & Sewerage Board 5.5 - 16 01/03/2012

5.11. Application of Painting Systems:

Un-galvanized ferrous metal subject to corrosive moisture or atmosphere and

Orissa Water Supply & Sewerage Board 5.5 - 17 01/03/2012

3. Time Between Coatings: A minimum of 12 hours time is required before additional

Item Minimum Dry Film

Ungalvanised ferrous metal submerged or intermittently submerged in water or corrosive liquid.

Orissa Water Supply & Sewerage Board 5.5 - 18 01/03/2012

Item Minimum Dry Film

Orissa Water Supply & Sewerage Board 5.5 - 19 01/03/2012

Ungalvanised ferrous metal submerged.

Item Minimum Dry Film

Ungalvanized ferrous metal, indoor service, corrosive environment.

Concrete subject to intermittent or continuous submergence, unless specified otherwise in other

Orissa Water Supply & Sewerage Board 5.5 - 20 01/03/2012