Water Pull 0ff PDF

Assets Delivery Group
Engineering
DESIGN STANDARD 95
Selection, Preparation, Application, Inspection and Testing of

Protective Coatings on Water Corporation Assets
VERSION 2
REVISION 0
MARCH 2018
Design Standard DS 95
Selection, Preparation, Application, Inspection and Testing of Protective Coatings on Water Corporation Assets
FOREWORD
Design Standards are prepared to ensure that the Corporation’s staff, consultants and contractors are informed as to
the Corporation’s design standards and recommended practices. Design standards are intended to promote
uniformity so as to simplify design and drafting practice and have as their ultimate objective the provision of safe
and functional plant at minimum whole of life cost.
The Corporation design standards and recommended practices described in this design standard have evolved over
a number of years as a result of design and field experience and these have been investigated and documented.
Deviation, on a particular project, from the design standards and recommended practices may be permitted in
special circumstances but only after consultation with and endorsement by the Principal Engineer Mechanical in
the Corporation’s Mechanical and Electrical Services Branch. Users are invited to forward submissions for
continuous improvement to the Principal Engineer or Manager, Corrosion Control Section, Water Corporation who
will consider these for incorporation into future revisions.
This document contains colour pictorials. For optimum resolution colour printing is recommended.
Head of Engineering
This document is prepared without the assumption of a duty of care by the Water Corporation. The document is not intended
to be nor should it be relied on as a substitute for professional engineering design expertise or any other professional advice.
Users should use and reference the current version of this document.
© Copyright – Water Corporation: This standard and software is copyright. With the exception of use permitted by the
Copyright Act 1968, no part may be reproduced without the written permission of the Water Corporation.
Uncontrolled if Printed Page 2 of 83

Ver 2 Rev 0
© Copyright Water Corporation 2012-2018
DISCLAIMER
Water Corporation accepts no liability for any loss or damage that arises from anything in the
Standards/Specifications including any loss or damage that may arise due to the errors and omissions of any person.
Any person or entity which relies upon the Standards/Specifications from the Water Corporation website does so
that their own risk and without any right of recourse to the Water Corporation, including, but not limited to, using
the Standards/Specification for works other than for or on behalf of the Water Corporation.
The Water Corporation shall not be responsible, nor liable, to any person or entity for any loss or damage suffered
as a consequence of the unlawful use of, or reference to, the Standards/Specifications, including but not limited to
the use of any part of the Standards/Specification without first obtaining prior express written permission from the
CEO of the Water Corporation.
Any interpretation of anything in the Standards/Specifications that deviates from specific Water Corporation
Project requirements must be referred to, and resolved by, reference to and for determination by the Water
Corporation’s project manager and/or designer for that particular Project.

Ver 2 Rev 0
REVISION STATUS
The revision status of this standard is shown section by section below:
REVISION STATUS
SECT. VER./ DATE PAGES REVISION DESCRIPTION RVWD. APRV.
REV. REVISED (Section, Clause, Sub-Clause)
1 1/0 12/12/12 All New Version KR BG

2/0 14/03/18 42 Table 12 moved to Appendix 2 GP GP

2/0 14/03/18 42-45 Tables re-numbered and GP GP
references updated

Ver 2 Rev 0
2/0 14/03/18 46-50 Tables re-numbered and GP GP
references updated

2/0 14/03/18 52 Table 18 re-numbered and GP GP
references updated
App 1 1/0 12/12/12 All New Version KR BG

2/0 14/03/18 70-72 Individual specifications GP GP
replaced with a list of
specifications

Ver 2 Rev 0
ABBREVIATIONS
Paint/Coating Associations
ACA Australasian Corrosion Association
ANSI American National Standards Institute
APAS Australian Paint Approval Scheme
AS/NZS Australian Standards
ASTM American Society for Testing Materials
BS British Specification
ISO International Standards Organisation
NATA National Association of Testing Authorities
NACE National Association of Corrosion Engineers
NSF National Sanitation Foundation
PCCP Painting Contractors Certification Program
SSPC Steel Structures Painting Council
WJTA The WaterJet Technology Association
Corrosion/Coating Abbreviations
CP Cathodic Protection
DFT Dry Film Thickness
TDFT Total Dry Film Thickness
WFT Wet Film Thickness

Ver 2 Rev 0
Basic coating Formulas
WFT (microns) = DFT x 100  % Volume Solids

WFT (microns) = DFT x (100 + % thinner added)  % Volume Solids
2
Theoretical Coverage (m /litre) = % volume solids x 10
DFT (microns)
WFT (microns) = 1000
Coverage (m 2 /litre)
% Volume Solids = DFT (microns) x Coverage (m 2 /litre)
10
Amount of Paint (Litres) = Area (m 2 )
Coverage (m 2 /litre)
Volume (Litres) = Area (m 2 ) x DFT (microns) x 10
% Volume Solids x (100 - % losses)
Basic conversions
Pressure
1 psi = 6.9 kPa
1 atmosphere = 101.3 kPa
1 kPa = 0.145 psi
1 MPa = 145 psi
Linear
1 mm = 1000 micron
1 Thou (mil) = 25.4 micron

Ver 2 Rev 0
DESIGN STANDARD 95
Selection, Preparation, Application, Inspection and Testing of Protective
Coatings on Water Corporation Assets
CONTENTS
Section Page
1 SCOPE ...........................................................................................................................................11
1.1 Purpose of the Document............................................................................................................... 11
1.2 Approved Applicators.................................................................................................................... 11
1.3 Coating Inspector ........................................................................................................................... 12
1.4 Coating Supervisor ........................................................................................................................ 12
1.5 Coatings in Contact with Drinking Water ..................................................................................... 12
1.6 Cathodic Protection (CP) System Compatibility ........................................................................... 12
1.7 Australian Paint Approval Scheme (APAS) .................................................................................. 12
1.8 Referenced Documents .................................................................................................................. 13
2 CORROSION OF STEEL ...........................................................................................................16
2.1 Nature of Corrosion ....................................................................................................................... 16
2.2 Electrode Reactions ....................................................................................................................... 16
3 FUNDAMENTALS OF COATING ............................................................................................18
3.1 Components of Coating ................................................................................................................. 19
3.1.1 Solvent ............................................................................................................................................19
3.1.2 Binder .............................................................................................................................................19
3.1.3 Pigment ...........................................................................................................................................19
3.1.4 Filler ...............................................................................................................................................19
3.2 Types of Coating ........................................................................................................................... 20
3.2.1 Organic Coatings ............................................................................................................................20
3.2.2 Inorganic Coatings ..........................................................................................................................20
4 CONDITIONS OF STEEL SURFACES ....................................................................................21
5 SURFACE PREPARATION STANDARDS ..............................................................................21
5.1 Surface Contamination Analysis Test on the Blast Cleaned Surface ............................................ 24
5.1.1 Surface Contamination Analysis Test ............................................................................................24
5.1.2 Conductivity Measurement .............................................................................................................24
5.1.3 Dust and Embedded Abrasive ........................................................................................................24
5.1.4 Moisture ..........................................................................................................................................24
5.1.5 Oil and Grease ................................................................................................................................24
5.1.6 Mill Scale........................................................................................................................................24

Ver 2 Rev 0
5.2 Surface Preparation Specification.................................................................................................. 25
5.3 Safety Considerations during Abrasive Blasting ........................................................................... 25
6 COATING INSPECTION ...........................................................................................................26
6.1 Surface Profile of the Blast Cleaned Surface................................................................................. 26
7 COATING APPLICATION ........................................................................................................27
8 TESTS ON APPLIED COATING ..............................................................................................28
8.1 Wet Film Thickness Test ............................................................................................................... 28
8.2 Dry Film Thickness Test ............................................................................................................... 28
8.2.1 DFT - Severe Environments ...........................................................................................................29
8.2.2 DFT - Atmospheric Environment ...................................................................................................29
8.2.3 DFT Measurement Frequency ........................................................................................................30
8.3 Testing for Coating Film Continuity ............................................................................................. 31
8.4 Low Voltage Continuity Testing ................................................................................................... 31
8.5 High Voltage Continuity Testing (Spark Testing) ......................................................................... 31
8.6 Degree of Curing of the Coating ................................................................................................... 33
8.7 Adhesion Test of the Coating ........................................................................................................ 33
8.8 Adhesion Test of the Coating – Pull-off (Dolly) ........................................................................... 34
8.9 Coating Personnel Qualification .................................................................................................... 34
9 RECORDS AND INSPECTION REPORT................................................................................35
9.1 Ambient Conditions ....................................................................................................................... 35
9.2 Equipment Report .......................................................................................................................... 35
9.3 Coating Inspection Report ............................................................................................................. 35
10 PROTECTIVE COATINGS COLOUR .....................................................................................36
11 WATER CORPORATION COATING SPECIFICATIONS ...................................................37
11.1 DS 95 Compliance ......................................................................................................................... 37
11.1.1 Choosing the Right Specification ...................................................................................................37
11.1.2 Coating Thickness Deviation..........................................................................................................37
11.2 Group B - Inorganic Zinc Silicate ................................................................................................. 37
11.3 Group C - Zinc Rich Epoxy Primer ............................................................................................... 38
11.4 Group D – High Build Epoxy ........................................................................................................ 38
11.5 Group E – Epoxy Mastic ............................................................................................................... 38
11.6 Group F – Mineral Filler Epoxy .................................................................................................... 39
11.7 Group G - Fusion Bonded Epoxy Powder ..................................................................................... 39
11. 8 Group H – Galvanising .................................................................................................................. 39
11. 9 Group I – Elastomeric Polyurethane (Polyurea, Polybrid) ............................................................ 39
11. 10 Group J – Anti-graffiti Coating ..................................................................................................... 39
11. 11 Group K – Water Based Acrylic Coating ...................................................................................... 39

Ver 2 Rev 0
11. 12 Group L – Tape Wrapping and Heat Shrink Sleeve ...................................................................... 40
11. 13 Group M – Miscellaneous Coating ................................................................................................ 40
12 COATING SYSTEMS FOR NEW WATER CORPORATION ASSETS ..............................42
13 PIPELINES COATING – BELOW & ABOVE GROUND ......................................................46
13.1 Below Ground (Buried) Pipework ................................................................................................. 46
13.1.1 Buried Pipework (Workshop Manufacture) .................................................................................. 46
13.1.2 Coating Requirements (Workshop Manufacture) .......................................................................... 46
13.1.3 Buried Pipework (Field Applied) ...................................................................................................49
13. 2 Above Ground (Exposed) Pipework.............................................................................................. 50
13. 2.1 IZS Primed Pipes & Fittings ...........................................................................................................50
13. 2.2 Sintakote Coated Pipes & fittings .................................................................................................. 50
13. 3 Miscellaneous Pipework Configuration Coating ........................................................................... 51
14 VALVES COATING ....................................................................................................................51
14.1 Introduction to Valves ................................................................................................................... 51
14.2 Coating of Valves .......................................................................................................................... 51
15 PUMPS COATING ......................................................................................................................51
15.1 Introduction to Pumps ................................................................................................................... 51
15.2 Coating of Pumps .......................................................................................................................... 51
16 MAINTENANCE COATING .....................................................................................................52
16.1 Criteria for Assessment and Repair ............................................................................................... 52
16.2 Degree of Rusting (Measles Chart) ............................................................................................... 52
16.3 Flow Chart for Coating Condition Assessment ............................................................................. 54
17 COATING FILM FAILURES ....................................................................................................58
17.1 Coating Film Failures (Cosmetic Failure) ..................................................................................... 58
17.2 Coating Film Failure (Finish Coating Failure) .............................................................................. 61
17.3 Galvanised Coating Film Failure (Finish Coating Failure) ........................................................... 64
18 APPENDIX 1 – INSPECTION, TESTS AND PLAN (ITP)......................................................66
19 APPENDIX 2 - SURFACE PREPARATION AND PROTECTIVE COATING
SPECIFICATIONS ......................................................................................................................70
20 APPENDIX 3 - COMMOLY USED COATINGS IN POTABLE WATER AND
WASTEWATER INFRASTRUCTURES ..................................................................................73
21 APPENDIX 4 - GLOSSARY .......................................................................................................74

Ver 2 Rev 0
1 SCOPE
The scope of this standard is to provide Water Corporation designers, asset maintainers, design consultants and
coating contractors with information to assist with the selection, design, monitoring and maintenance of coating
systems for the conveyance, storage and treatment of potable and wastewater, and associated infrastructures.
The standard is intended to:
1. Ensure consistency in the application of coating systems on all relevant classes of assets.
2. Ensure that designs meet Water Corporation requirements and comply with relevant Australian Standards
and International Standards.
3. Provide for standardisation of coating testing procedures including methods of recording and reporting
results.
4. Provide consistency in the interpretation of coating measurement results thus minimising the possibility of
errors, disputes of results and rework.
5. Provide procedures for personnel involved in the operation and maintenance of coating.
Promote co-operation between all interested parties through a common understanding of the complex principles
and practices associated with coating applications.
This standard shall be used in conjunction with Water Corporation coating specifications Group A-M available
through the IDB/MESB technical standard website. This document also refers to, and shall be used in conjunction
with, relevant Australian Standards (AS/NZS), International Standards Organisation (ISO), National Association of
Corrosion Engineers (NACE) and Society for Protective Coatings, formerly Steel Structures Painting Council
(SSPC) standards.
For technical queries regarding coating issues, contact Manager, Welding and Corrosion Control Section,
Mechanical and Electrical Services Branch, Water Corporation.
1.1 Purpose of the Document

The asset designer, pre-qualified painting contractor (Applicator) and asset maintainer shall use this document to
specify, select and apply the appropriate coatings. If the designer, applicator or maintainer intends to deviate from
this Design Standard, then the proposed deviations should be approved in writing by the Manager, Welding and
Corrosion Control.
1.2 Approved Applicators

Surface preparation and coating application shall be undertaken by an approved Applicator. The Applicator shall be
accredited by the Painting Contractors Certification Program (PCCP) to the class relevant to the work to be
undertaken. Where assets are procured from an overseas supplier, the applicator shall be approved under an
equivalent scheme.

Ver 2 Rev 0
1.3 Coating Inspector

Applicators shall nominate a coating inspector as their Quality Control Officer supervisor to carry out inspections,
undertake the required testing and maintain appropriate records for all work performed.
The Applicator’s Coating Inspector shall be certified by either:
 Australasian Corrosion Association (ACA) - Coating Inspector
 National Association of Corrosion Engineers (NACE) minimum NACE CIP Level I Coating Inspector
1.4 Coating Supervisor

The Applicator shall nominate a Coating Supervisor to prepare Quality Assurance documentation, control and
take responsibility for the work. The Coating Supervisor shall be certified by either:
 Australasian Corrosion Association (ACA) - Coating Inspector
 National Association of Corrosion Engineers (NACE) minimum NACE CIP Level I Coating Inspector
1.5 Coatings in Contact with Drinking Water

Any coating in contact with drinking water shall be certified to comply with AS/NZS 4020 by a NATA accredited
laboratory. Overseas coatings tested and approved with ANSI/NSF 61 or BS 6920 certificates shall be submitted to
the Water Corporation Drinking Water Quality Branch. This will be referred to the Department of Health for
acceptance of the product in the specific application prior to use. Design consultants, asset maintainers and coating
contractors shall refer to Schedule 5-List of products approved for use in Drinking Water issued by the Department
of Health, Western Australia requested through the Water Corporation.
1.6 Cathodic Protection (CP) System Compatibility

If the structure to be protected has a CP system installed on it, then the coating system nominated shall be suitable
for use on CP applications. For more information on CP, reference shall be made to Water Corporation Design
Specification DS 91- Cathodic Protection of Steel Structures.
1.7 Australian Paint Approval Scheme (APAS)

Where a suitable APAS approved product is available, it shall be used. If a suitable APAS approved product is not
available and it is necessary to use a non-APAS product, then this product shall be referred to the Water
Corporation for acceptance prior to use. APAS approved products shall in addition meet the requirements of
Clause 1.5 where applicable.

Ver 2 Rev 0
1.8 Referenced Documents
Australian Standards
AS/NZS 1214 Hot dip galvanized coatings on threaded fasteners
AS/NZS 1627.0 Part 0: Method selection guide
AS/NZS 1627.1 Cleaning using liquid solvents and alkaline solutions
AS/NZS 1627.2 Power tool cleaning
AS/NZS 1627.3 Flame descaling
AS/NZS 1627.4 Abrasive blast cleaning
AS/NZS 1627.5 Pickling, descaling and oxide removal
AS/NZS 1627.6 Chemical conversion treatments of metals
AS/NZS 1627.7 Hand tool cleaning of metal surfaces
AS/NZS 1627.9 Pictorial surfaces preparation standards for painting steel surfaces
(endorsement of ISO 8501-1:1988)
AS/NZS 1650 Hot-dipped galvanized coatings on ferrous articles
AS/NZS 2105 Inorganic zinc silicate paint
AS/NZS 2310 Glossary of paint and paint terms
AS/NZS 2312 Guide to the protection of iron and steel against exterior atmospheric
Corrosion
AS/NZS 2700 Colour standards for general purposes
AS/NZS 3894.0 Site testing of protective coatings
AS/NZS 3894.1 Non-conductive coatings - Continuity testing - High voltage (‘brush’) method
AS/NZS 3894.2 Non-conductive coatings - Continuity testing - Wet sponge method
AS/NZS 3894.3 Determination of dry film thickness
AS/NZS 3894.4 Assessment of degree of cure
AS/NZS 3894.5 Determination of surface profile
AS/NZS 3894.6 Determination of residual contaminants
AS/NZS 3894.7 Determination of surface temperatures
AS/NZS 3894.8 Visual determination of gloss
AS/NZS 3894.10 Inspection report-Daily

Ver 2 Rev 0
AS/NZS 3894.11 Equipment report
AS/NZS 3894.12 Inspection report-Coating
AS/NZS 3978 Non-destructive testing-visual inspection of metal products and components
AS/NZS 4020 Testing of products for use in contact with drinking water
AS/NZS 4158 Thermal-bonded polymeric coatings on valves and fittings for water industry
purposes
AS/NZS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles
American Society for Testing and Materials (ASTM) Standards
ASTM D4940 - 10 Standard Test Method for Conductimetric Analysis of Water Soluble Ionic
Contamination of Blasting Abrasives
ASTM D 4541 Standard Test Method for Pull-Off Strength of Coatings Using Portable
Adhesion Testers
Standard Test Method for Pull-Off Adhesion Strength of Coatings on
ASTM D723405
Concrete Using Portable Pull-Off Adhesion Testers
ASTM Standard Test Method for Tensile Strength of Concrete Surfaces and the
C1583/C1583M-04 Bond Strength or Tensile Strength of Concrete Repair and Overlay Materials
by Direct Tension (Pull-off Method)
International Organization for Standardization (ISO)
ISO 11126-10:2000 Preparation of steel substrates before application of paints and related
products -- Specifications for non-metallic blast-cleaning abrasives -- Part 10:
Almandite garnet

Ver 2 Rev 0
Steel Structures Painting Council (USA) Standards
The following, except for visual (Vis) standards, are published in Steel Structures Painting Manual,
Volume 2
SSPC SP1 Solvent cleaning
SSPC SP2 Hand tool cleaning
SSPC SP3 Power tool cleaning
SSPC SP5 White metal blast cleaning
SSPC SP6 Commercial blast cleaning
SSPC SP7 Brush-off blast cleaning
SSPC SP8 Pickling
SSPC SPl0 Near-white blast cleaning
SSPC SPl1 Power tool cleaning to bare metal
SSPC Vis 1 Visual standard for abrasive blast cleaned steel
SSPC Vis 2 Evaluating degree of rusting on painted steel surfaces
SSPC Vis 3 Visual standard for power- and hand-tool cleaned steel
SSPC PA2 Measurement of dry paint thickness with magnetic gauges
NACE International (USA) Standards

NACE RP0172 Surface preparation of steel and other hard materials by water blasting prior to
coating or recoating
NACE RP0l78 Fabrication details, surface finish requirements and proper design considerations
for tanks and vessels to be lined for immersion service
NACE RP0287 Field measurement of surface profile of abrasive blast cleaned steel surfaces using
a replica tape
NACE RP0l88 Discontinuity (holiday) testing of protective coatings
NACE RP0288 Inspection of linings on steel and concrete
NACE TM0l70 Visual standards for surfaces of new steel airblast cleaned with sand abrasive
NACE TM0175 Visual standard for surfaces of new steel centrifugally blast cleaned with steel grit
and shot

Ver 2 Rev 0
2 CORROSION OF STEEL
2.1 Nature of Corrosion
Corrosion may be defined as a destructive phenomenon, chemical or electrochemical, which affects the aesthetic
appeal of an object; and in extreme cases may cause structural failure. The corrosion of iron, better known as
rusting, is an oxidation-reduction process that destroys iron objects left out in open, moist air.
Different metals possess different levels of free energy and therefore different corrosion potentials. When
contacted with a common electrolyte (e.g. water or moist soil), electrochemical couples are set up. The areas of
more active electrochemical potential act as anodes where metal dissolves into the electrolyte as ions. The
electrons from the metal are released into the electrolyte, which then flow to the adjacent cathode areas. During
this process, corrosion current is setup [Refer Figure 1]. As the corrosion current increases, so does the corrosion
(rust) of the metal.
H2O
H2O O2 H2O O2 H2O
O2 H2O H2O O2
O2 WATER
Fe2O3.x H2O Fe2O3.x H2O
2+ 2+
Fe Fe
RUST RUST
ANODE
CATHODE CATHODE
2+ -
Fe à Fe + 2e
Fe2+ à + Fe+3 + e- O2+2H2O + 4e- à 4OH-
IRON
Figure 1 – Electrochemical corrosion mechanism.
2.2 Electrode Reactions

Corrosion is an electrochemical reaction. The mechanism is based on anode and cathode reactions in an
electrolyte. Corrosion takes place at the anode with the release of hydrogen gas or the formation of hydroxyl ions
at the cathode. These hydroxyl ions may react with metal ions dissolved at the anode and form metal hydroxides or
hydrated oxides. If these are insoluble they will deposit on the metal surface and may reduce the rate of corrosion.
The rate of the corrosion reaction depends on its environment. The chemical reaction at the anode (where the
dissolution of the metal takes place) in the case of iron, is shown in Equation 1.
Fe  Fe2+ + 2e- (1)
The exact nature of the reaction at the surface of the cathode (in which electrons released in anodic dissolution are,
in turn, consumed) depends upon the nature of the environment and is shown in Equations 2-4. Under neutral and
alkaline (high pH) conditions, the reaction involves oxygen and proceeds as follows
2H2O + O2 + 4e-  4OH- (2)
Under acidic conditions (low pH), if oxygen is present, the reaction may proceed
O2 + 4H+ + 4e  2H2O (3)
Under acidic conditions where oxygen is not present, hydrogen gas may form
2H+ + 2e  H2 (4)
Ver 2 Rev 0
2.3 Prevention of Corrosion

For corrosion reaction to continue there must be an anode, a cathode and an electrolyte, joined by an external
current circuit [Refer Figure 2].
Corrosion can be prevented by removing one of the parameters in the triangle such as the anode, cathode,
electrolyte or the conductive path. It is practically impossible to remove the electrolyte. But, a barrier can be
placed between the metal and the electrolyte. This can be achieved by introducing a “coating” which is discussed
in the following section.
Electrolyte
Anode Cathode
Conductive Path
Figure 2 – Components of a Corrosion Cell.
A properly applied coating is the primary barrier against corrosion. Cathodic Protection (CP) is the secondary
barrier against corrosion; CP does not negate or diminish the need for proper applications of coating systems. For
more details on CP, references shall be made to Water Corporation Cathodic Protection Design Standard DS 91.

Ver 2 Rev 0
3 FUNDAMENTALS OF COATING
Steel usually rusts when it is exposed to water and oxygen through the formation of tiny electrical cells on the
surface. Protective coatings provide a barrier to oxygen, moisture and other corrosive elements.
For optimum protection, the barrier should be as impermeable, adequately thick, and continuous as practical. The
surface to be coated is called the substrate. The coatings applied on the substrate can be made of a single coat or
multiple coats [Refer Figure 3].
Impervious to ions, oxygen, Moisture Absorption in Dynamic &

carbon dioxide Equilibrium Environments
Low Moisture Transmission
Top Coat (2nd Coat)
Barrier Coat (1st Coat)
Primer
Steel (Substrate)
Strong Adhesion – Physical as well as Chemical Adhesion
Figure 3 – Schematic drawing of a typical three coat system.

Ver 2 Rev 0
3.1 Components of Coating

The three main components of a coating are shown in Figure 4. They are described as follows:
3.1.1 Solvent
Solvent is used to dissolve the resin material that actually forms the coating film. It also reduces the viscosity of the
product to permit easier application, as well as affecting its levelling, drying, durability, and adhesion.
3.1.2 Binder
Binder (normally a resin) is the film-forming part of the coating that is responsible for most of the properties of the
coating. Thus, coatings are identified by the generic types of their binders. The binder and the solvent portions of
coatings are sometimes called the non-volatile and the volatile vehicle, respectively, and are sometimes referred to
collectively as the vehicle.
3.1.3 Pigment
Pigment constitutes the solid portion of a coating. It is generally heavier than the liquid vehicle portion and may
settle out on prolonged standing. Pigments also provide colour, improve adhesion and weather resistance, decrease
moisture permeability, and control gloss.
The pigment and the resin portions are sometimes called the “solids” portion, since they remain after all the solvent
has evaporated. In general, the greater the volume solids, the higher the coating thickness that can be achieved.
There are many additives that can be added to coatings to improve their application and performance.
3.1.4 Filler
A compound used to extend or bulk a coating to provide extra body or hiding power. “Hiding Power” is an optical
property used to describe the light-scattering efficiency of a white pigment
Resin
Filler (Binder)
Coating Thickness
(microns)
Substrate
Coloured
Anti-Corrosion Pigment
Pigment
Figure 4 – Schematic drawing of barrier effect of coating against diffusion of moisture and atmosphere to
substrate thereby preventing corrosion.

Ver 2 Rev 0
3.2 Types of Coating
3.2.1 Organic Coatings

Organic coatings are coatings that contain carbon atoms. Organic coatings are usually liquid applied coatings that
are converted to a solid film after application e.g. epoxies.
3.2.2 Inorganic Coatings

In-organic coatings are a generic term for metallic coatings. Metallic coatings are thin films of metal applied to a
substrate. These coatings can be applied by dipping the metal to be coated in a molten metal bath (e.g.,
galvanising), by electroplating or by spray application.
3.2.2.1 Hot Dip Galvanized Coatings
A process whereby the article to be protected is dipped in a bath of molten zinc to produce a sacrificial coating as
defined in AS/NZS 4680. For smaller components such as bolts the process may include centrifuging to remove
excess coating after immersion.
The following Tables 1 and 2 shall be used as a guide for the recommended coating thickness for different gauges
of steel section*.
Table 1 - Requirements for Coating Thickness and Mass

for Articles that are Not Centrifuged
Local coating
Steel Section Thickness Average coating Average coating
minimum thickness
(mm) thickness (Microns) (mass g/m2)
(Microns)
1.5 mm or less 35 45 320
Over 1.5 to 3 mm 45 55 390
Over 3 to 6 mm 55 70 500
Over 6 mm 70 85 600
Note: As a general guide 10g of zinc applied to 1m2 of steel will produce a coating thickness of approximately
1.4 microns.
Table 2 - Requirements for Coating Thickness and Mass

for Articles that are Centrifuged
Article Thickness (mm) Local coating Average coating Average coating

minimum thickness thickness (microns) mass (g/m2)
(microns)
Less than 8 mm 25 35 250
8 mm and over 40 55 390
* http://www.gaa.com.au/index.php?page=coating-thickness-and-factors-influencing-thickness

Ver 2 Rev 0
4 CONDITIONS OF STEEL SURFACES

New or used unpainted steel may be categorized in any one of four general conditions, described and illustrated in
pictorial standards SSPC-Vis 1 and ISO 8501-1. The general conditions are Rust Grades A, B, C, and D, as
described in the following Table 3.
Table 3 – General Conditions of Rust Grades
Rust Grade A Steel surface largely covered with mill scale, but little or no rust
Rust Grade B Steel surface covered with both mill scale and rust that has begun to
flake off
Rust Grade C Steel surface completely covered with rust; little or no pitting visible
Rust Grade D Steel surfaces completely covered with rust; pitting visible
5 SURFACE PREPARATION STANDARDS

The primary purpose of surface preparation is to produce a surface that is clean and free of any material which may
cause premature failure of the coating (e.g. Osmotic Blister). If the surface has contamination such as mill-scale,
rust, salt, moisture or oil, then any subsequent coating will not be as adherent to the surface. Mill-scale remaining
on the surface can cause Galvanic Corrosion.
Another aspect of surface preparation is to produce an adequate profile to the substrate. This is a measure of the
height and depth of the “Hills and Valleys” produced on the surface. The greater the profile, the more surface that
is presented to the coating for it to adhere to, so the better the adhesion. The roughness also allows the coating to
lock into or key into the surface. However, if the profile is greater than the coating thickness, then peaks will
protrude from the surface allowing spot rusting to occur. Profile must be in the correct range for the coating type
and its thickness.
The most common way of producing a suitable profile and to remove rust, mill scale, or other surface contaminants
is by abrasive blast cleaning. This is achieved by projecting a highly concentrated stream of relatively small
abrasive particles at high velocity against the surface to be cleaned. The abrasives used for blast cleaning shall
comply with stringent requirements of ISO11126-10:2000. The Australian and International Standards for blast
cleaning are summarised in Table 4. The surface preparation by substrate is given in Table 5.
All Water Corporation coating surface preparation standards shall comply with White Metal Blast, SA3 in
accordance with AS/NZS 1627.4. The surface profile shall be determined in accordance with AS/NZS 3894.5.
Visual standards (SSPC-Vis 1, ISO 8501-1) are used as pictorial examples that can be used to judge and compare
blast cleaned standards with work on site.

Ver 2 Rev 0
Table 4 – Comparative listing of Surface Preparation standards for Cleaned Steel Surfaces.
System SSPC NACE AS/NZS ISO 8501-1 Intended Use

Solvent Clean SSPC.SP1 AS/NZS Removal of oil and grease prior to further cleaning by
1627.1 another method.
Hand Tool Clean SSPC.SP2 AS/NZS St. 2 Removal of loose mill scale, rust, and paint. It is not
1627.7 (approx.) intended that adherent mill scale, rust and paint be
removed by this process.
Water-jetting SSPC.SP12 NACE No. 5 Water jetting will not produce a profile; rather, it
exposes the original abrasive-blasted surface profile.
Power Tool Clean SSPC.SP3 AS/NZS St. 3 Faster removal of loose mill scale, rust, and coatings
1627.2 than hand tool cleaning.
Pickling SSPC.SP8 AS/NZS Removal of mill scale and rust from steel (e.g.
1627.5 immersing in acid).
Power Tool Cleaning to Bare SSPC.SP11 Removal of visible contaminants (surface is
Metal comparable to SSPC SP 6, also provides profile).
Brush Off Blast/Light Blast SSPC.SP7 NACE No. 4 AS/NZS Sa 1 Removal of loose mill scale, rust, and paint (loose
Cleaning (Whip Blast) 1627.4 paint can be removed with a putty knife).
(Class 1)
Thorough Blast SSPC.SP6 NACE No. 3 AS/NZS Sa. 2 Removal of all visible contaminants except that one
Cleaning/Commercial Blast 1627.4 third of a steel surface may have shadows, streaks, or
(Class 2) stains.
Near White Blast SSPC.SP10 NACE No. 2 AS/NZS Sa. 2 ½ Removal of visible contaminants except that 5% of
1627.4 steel surfaces may have shadows, streaks, or stains.
(Class 2½)
White Metal Blast SSPC.SP5 NACE No. 1 AS/NZS Sa. 3 Removal of all visible contaminants on steel surfaces;
1627.4 highest level of cleaning for steel.
(Class 3)

Ver 2 Rev 0
Table 5 - Surface Preparation by Substrate Material Type.
Cast Iron Galvanized Aluminium Plate Metals Stainless Non- Plastic Concrete Previously
Substrate or Steel (e.g. Tin plate) Steel Ferrous PVC/FRP Painted
Cleaning Surfaces
SSPC-SP1 Solvent Clean         
SSPC-SP2         
Hand Tool Cleaning
SSPC-SP3         
Power Tool Cleaning
SSPC-SP11         
Power Tool Cleaning
SSPC-SP7/NACE 4         
Brush-Off Blast (Whip)
SSPC-SP6/NACE 3         
Commercial Blast
Cleaning
SSPC-SP10/NACE 2         
Near-White Blast
Cleaning
SSPC-SP5/NACE 1         
White Metal Blast
Cleaning
SSPC-SP12/NACE 5         
High and Ultra high-
Pressure Water Jet
SSPC-SP13/NACE 6         
Surface Prep. of
Concrete

Ver 2 Rev 0
5.1 Surface Contamination Analysis Test on the Blast Cleaned Surface

5.1.1 Surface Contamination Analysis Test
The Surface Contamination Analysis Test (SCAT), method of testing for soluble salts such as chloride shall be
used as defined in AS/NZS 3862.6 Section 6.3.
5.1.2 Conductivity Measurement

Measurement of the conductivity of wash liquids from the blast cleaned surfaces shall be carried out in accordance
with ASTM Standard D4-940.
5.1.3 Dust and Embedded Abrasive

The level of dust or other residues present on an abrasive-blasted surface is determined by pressing a length of
adhesive tape to the prepared surface. The tape is then removed and examined against a dark and a light
background for adhering dust particles. The level of dust removed is rated by comparison with a visual standard as
stated in AS/NZS 3862.6 Section 8.1. The tested area shall be wiped with solvent to ensure the tape glue is
removed completely.
5.1.4 Moisture
Visual assessment is employed to determine the presence of moisture. A little talcum powder can be sprinkled on
the surface. If it can be blown away easily then the surface is dry. Also, pressing clean absorbent paper on the
surface and visually examining may show the presence of moisture.
5.1.5 Oil and Grease

Oil and grease are difficult to detect visually. Under normal backlighting, oil and grease will appear as translucent
spots. Oil may fluoresce when viewed under UV light. AS/NZS 3894.6 describes the method to determine the
extent of oil and grease on the blast cleaned surfaces.
5.1.6 Mill Scale

Mill scale is normally visible to the naked eye and extra tests are not usually required. On completely clean
surfaces (Class 3 blast) residual mill scale is revealed as black patches if the surface is swabbed with a pad
containing slightly acidified 4% copper sulphate solution. The surface must be re-blasted after carrying out this
test. This test is described in AS/NZS 3894.6.

Ver 2 Rev 0
5.2 Surface Preparation Specification

For any protective coating scheme, suitable surface preparation is important. The surface preparation is to remove
oil, grease, old coatings and surface contaminants (such as mill scale and rust on steel, laitence on concrete and zinc
salts on galvanised surfaces).
Surface preparation of Steel or Cast Iron substrates shall be carried out to Class 3 cleanliness using either steel
shot/grit or garnet. Australian Manufactured Garnets with maximum allowable total chlorides of 10-15 ppm (max
25 ppm) shall be used. The blast abrasive shall clean deep into the cavities and pitted areas down to bare metal,
thoroughly removing all rust, soluble salts and other contaminants. The abrasive used shall achieve a surface
profile in accordance with the requirements of the relevant coating to be applied, and shall not be re-used.
List of Water Corporation surface preparation specifications are given in Table 6 and detailed surface preparation
specifications are attached in the Appendix 1.
Table 6 - List of Water Corporation Surface Preparation
System Surface Preparation Specification

Designation
A1 Surface Preparation for the Application of Protective Coating on Steel or Cast Iron
A2 Surface Preparation for the Application of Aesthetic Coating on Stainless Steel
A3 Surface Preparation for the Application of Protective Coating on Galvanised Steel
A4 Surface Preparation for the Application of Protective Coating on Aluminium
A5 Surface Preparation for the Application of Protective Coating on Concrete
A6 Surface Preparation for the Application of Protective Coating on Plastics
A7 Surface Preparation for the Application of Protective Coating on Fusion Bonded
Polyethylene (Sintakote®)
5.3 Safety Considerations during Abrasive Blasting

Prior to undertaking blast cleaning of coatings on existing assets, where the age of the coating is estimated to be
over 30 years, the coating shall be tested by removing a layer of the coating down to the substrate and testing the
area using a lead paint test kit (available from hardware stores). If the test is positive to the presence of lead then
appropriate controls shall be put in place. Reference: Water Corporation Safe Work Method Statement (SWMS)
WC-OSH-SWMS-032-Removal of Paint Containing Lead.
On larger jobs it is recommended that a coating sample be extracted by making a cross hatched cut with a sharp
knife and removing a sample of the coating. The sample should be sent to a laboratory for testing to detect the
presence of lead or other hazardous elements.
For more information on the handling of lead based coating refer to the Department of Health Western Australia
webpage http://www.public.health.wa.gov.au/3/1141/2/lead.pm.

Ver 2 Rev 0
6 COATING INSPECTION
Coating inspection gauges shall be calibrated in accordance to the manufacturers recommended practices and
interval. Calibration certificates shall be witnessed by the Water Corporation coating inspector prior to the start of
the inspection.
Proper and effective control of the environment and conditions during the curing stage of all coating layers are to
be maintained. Ideal air temperature for painting is between 15°C and 30°C. It is important to note that final
surface preparation and/or coating application shall not take place when any one of the following conditions are
exist:
(1) The relative humidity is above 85%
(2) The substrate temperature is less than 3°C above the dewpoint;
(3) The substrate temperature is below 10°C;
(4) The substrate temperature is above 55°C;
(5) The surface to be coated is wet or damp;
(6) The full prime coat application cannot be carried out before the specified cleanliness of the surface
deteriorates;
(7) The weather is deteriorating or is unfavourable for application or curing; or
(8) The pot life of the paint has been exceeded.
6.1 Surface Profile of the Blast Cleaned Surface

Surface profile is the determination of the roughness of the surface and for painting purposes involves depth of the
profile, peak density and angularity of the profile.
To determine the profile height or anchor pattern of an abrasive blast cleaned surface, one of the more commonly
used methods is the Replica Tape method (TESTEX PRESS-O-FILM) as described in AS/NZS 3894.5 [Refer
Figure 5].
Figure 5 – Blast Cleaned Surface Profile Measurement using TESTEX Tape.

Ver 2 Rev 0
7 COATING APPLICATION
Coating materials shall have Australian Paint Approval Scheme (APAS) approval unless approved otherwise by the
Principal, be suitable for attaining the specified standard and accepted by the Superintendent before coating
commences.
Prior to the application of coating, oil or dirt shall be removed prior to any blast cleaning operations and surfaces
not required to be coated shall be protected with masking materials. After the completion of the coating operation,
masking shall be completely removed by the Contractor.
Coating shall not be applied to any prepared surface(s) exhibiting “flash corrosion” or that has been abrasive
blasted more than 4 hours ago. Mixing, thinning, application and curing of protective coating materials shall be in
accordance with the protective coating manufacturer's recommended practice for the on-site conditions. Applied
coatings shall be protected from rain or moisture until cured.
Welding slag, weld spatter, sharp edges and any other surface irregularities which may impair the appearance or
performance of the protective coating shall be removed. Sharp edges shall be radiussed to a minimum of 2 to 3
mm. Welds, edges, crevices, seams, joints and corners shall be brush (stripe) coated before commencement of
spray application of the coating.
The coating components shall be thoroughly mixed in the specified proportions. Material so prepared shall be used
within the “pot-life” period claimed by the manufacturer.
Coating specifications and Inspection Test Plans (ITPs) submitted by the paint suppliers shall be reviewed and
approved by the Principal prior to the application.
The finished coating shall be of uniform thickness, colour, appearance and gloss. It shall be fully cured, insoluble,
adherent, coherent and free from mud cracking, holidays, laps, sags, blistering, checking, wrinkling, overspray,
patchiness and any other defects that may impair the performance and/or appearance of the coating.
After completion of coating follow the APAS guideline on the minimisation of waste paint and effective disposal
or reuse. For more information on the reducing the wastage of paint refer AS/NZS 2311 and APAS webpage
http://apas.gov.au/ss3.htm.

Ver 2 Rev 0
8 TESTS ON APPLIED COATING

8.1 Wet Film Thickness Test
A Wet Film Thickness (WFT) gauge is required during paint application to minimise the possibility of low dry film
thicknesses.
WFT is usually checked with a notch or comb gauge. The gauge should be used in accordance with AS/NZS
3894.3 to measure the WFT. For example, if the 50 micron step is wetted but the 75 micron one is not, the WFT is
between 50 and 75 microns.
8.2 Dry Film Thickness Test

The Dry Film Thickness (DFT) is defined as the thickness of the coating measured, at any location of the coated
substrate above the peak of the profile [Refer Figure 6]. The readings should be taken and recorded in accordance
with AS/NZS 3894.3.
Dry film thickness measurements are made using a dry film thickness gauge which has been selected and calibrated
in accordance with AS/NZS 3894.3 [Refer Figure 7].
Dry Film Thickness Coating
Profile
Figure 6 – Schematic drawing on the DFT of the coating.
If the measured DFT is less than three times the profile height, a Magnetic Base Reading (MBR) should be
subtracted from the DFT reading. To achieve the MBR, the following steps should be applied:
 Zero the DFT gauge on the smooth steel surface (As per AS/NZS3894.3) and;
 Take a number of readings on the blasted surface to obtain an average reading. This average reading is
known as the Magnetic Base Reading (MBR). If MBR is not recorded, then the acceptable approximation
is one third of the profile height.
Note: For thicker coatings the above procedure is not required.

Ver 2 Rev 0
Nominal Dry Film Dry film thickness specified for each coating layer or for the whole
thickness (NDFT) coating system
Minimum Dry Film Minimum acceptable dry film thickness for each coating layer or for
thickness the whole coating system.
Maximum Dry Film Highest acceptable dry film thickness for each coating layer or for
thickness the whole coating system above which the performance of the
coating layer or system could be compromised.
Gauge “Spot” A single DFT reading taken at one point.
measurement
Gauge, “mean” Arithmetic average of three gauge readings made within a circle of
measurement approximately 12 cm diameter.
8.2.1 DFT - Severe Environments

For surfaces that are to be exposed to severe environments such as immersed, buried or subjected to severe
chemical or marine environment, a minimum film thickness should be specified and achieved. This means any
area outside specification should be marked for restoration.
8.2.2 DFT - Atmospheric Environment

AS/NZS 3894.3 and SSPC PA2 require the average of the five spot readings taken over 10 m2 as described above,
to be greater than the specified coating thickness. No single point reading should be less than 80% of the specified
thickness.
If three readings were averaged to produce a point reading, an individual reading may be less than 80% of the
coating thickness.
Figure 7 – Measurement of DFT using electronic gauge.

Ver 2 Rev 0
8.2.3 DFT Measurement Frequency

For areas of flat or uniformly curved coated surfaces, five separate point readings, evenly spaced throughout,
should be made in each 10 m2 area examined. The 10 m2 inspection areas should be selected as shown in Table 7:
Table 7 – Large and Small Surface Areas and DFT Measurement
No. Area of the Structure DFT Measurement

1 Less than 30 m2 Each 10 m2 area
2 Structures not exceeding 100 m2 Three 10 m2 areas should be chosen at random
3 Structures exceeding 100 m2 First 100 m2 area should be measured in
accordance with Option (2), and for each
additional 100 m2 area, a 10 m2 area should be
chosen at random
5 For critical or small surface areas More readings will be required [discretion of the
Principal & Contractor]
6 For flat areas less than 10 m2 Minimum of 3 point readings for each m2
7 Pipework Based on pipe diameter, 2, 4 or 6 point readings
should be taken every metre of pipe run, evenly
round the circumference [Refer Table 8].
8 Beams and angles One reading should be taken on each flat face
less than 300 mm width for each linear metre.
9 If the total area of pipework, beams or angles Five separate point readings, evenly spaced
exceeds 10 m2 throughout, should be made in each 10 m2 area
examined.
Note:
If the coating thicknesses measurement for any 10 m2 area, chosen in accordance with option (2) or (3) does
not meet the required specification, then each 10 m2 area of surface should be measured.
Table 8 – Nominal Pipe Size and DFT Measurement
Nominal pipe size, mm Number of Circumferential readings

150 2
>150300 4
>300600 6
≥600 10

Ver 2 Rev 0
8.3 Testing for Coating Film Continuity

A fully-cured coating should be tested for film continuity and for defects such as pin holes, misses and damage,
subjected to immersed or buried environments. There are two methods of continuity testing: (1) Low Voltage &
(2) High Voltage.
8.4 Low Voltage Continuity Testing

Non-conductive coatings of thickness up to 250 microns shall be tested using wet sponge method in accordance
with AS/NZS 3894.2 [Refer Figure 8].
Figure 8 – Low Voltage Test Continuity Test using Wet Sponge method.
8.5 High Voltage Continuity Testing (Spark Testing)

Non-conductive coatings of thickness above 250 microns shall be tested in accordance with AS/NZS 3894.1 using
a high voltage test unit. In this method voltages up to 20,000 volts or more can be applied. The test voltages are
selected in accordance with the following equation:
250 T
V=
F
Where,
V = test voltage applied, in volts

T = specified dry film thickness of cured coating, in micrometres
F = rating of a coating’s generic type and the volume solids content (Refer Table 9).
Where the actual film thickness exceeds the specified film thickness (T) by 25 %, the test voltage (V) should be
recalculated using the actual thickness of that area.

Ver 2 Rev 0
Table 9 - Coating film rating (F) from coating type and volume solids content
Type of Coating Volume Solids % Rating (F)

(V/V)
Chlorinated rubber, Vinyl 15 to 39 4
Low-build epoxy, Tar epoxy 40 to 59 3
High-build epoxy, Tar epoxy 60 to 79 2
Polyester-vinyl ester, Solventless epoxy 80 and greater 1
Note 1: For thermal bonded polymeric coatings (thermoplastic and thermosetting coating) continuity testing shall
be carried out in accordance with Table 3.3 in AS/NZS 4158.
Note 2: High Voltage Spark Tester must be calibrated using a Crest meter prior to use for detecting pin holes in the
coatings [Refer Figures 9-11].
Figure 9 – High Voltage Spark Tester calibrated using a Crest meter.
Figure 10 – Detecting pin holes on a high build epoxy coated steel substrate using high voltage spark testing.

Ver 2 Rev 0
Figure 11 – Pin holes detected during the spark testing.
8.6 Degree of Curing of the Coating

Test methods for the determination of the degree of cure of coatings are given in AS/NZS 3894.4 and AS/NZS
1580. The most commonly used test for curing of the coating within the Water Corporation is the Solvent Rub test
[AS/NZS 3894.4 Method C].
8.7 Adhesion Test of the Coating

The adhesion strength of the coating shall be carried out in accordance with AS/NZS 3894.9 and AS/NZS 1580.
Various methods are associated with this standard and can be referenced in Table 10. The most commonly used
adhesion test in the Water Corporation is the Pull-off (dolly) test [AS/NZS 1580 Method 408.5].
Table 10 – Methods of Adhesion Test
Methods of Adhesion Test Australian Standard Coating Thickness

(microns)
Parallel cut method AS/NZS 1580 Method 408.2 Method > 100 microns
A
Intersecting cut method AS/NZS 1580 Method 408.2 Method Any thickness
B
Cross-cut test AS/NZS 1580 Method 408.4 Up to 125 microns
Chisel adhesion test ----- >750 microns of UHB
epoxies
Pull-off (dolly) AS/NZS 1580 Method 408.5 Any thickness

Ver 2 Rev 0
8.8 Adhesion Test of the Coating – Pull-off (Dolly)

Pull-off adhesion testing is used to measure the force required to pull a specified diameter of coating away from its
substrate. This measured pull-off force provides a direct indication of the strength of adhesion between the coating
and the substrate.
The test location and number of test points shall be agreed upon by the Contractor and the Principal prior to the
start of attaching the dollies to the substrate.
The report shall include test results, general failure modes categorised substrate failure, adhesion failure, cohesion
failure and glue failure. Water Corporation preferred mode of failure for coatings on concrete is “substrate failure”
and “cohesive failure” for Steel.
Minimum acceptable adhesion value of Epoxy coating on Concrete and Steel shall be 3 MPa and 4 MPa
respectively. For elastomeric polyurethane (Polyurea/Polibrid) the minimum acceptable adhesion value on
Concrete shall be 3 MPa.
Coatings with unacceptable adhesion test results shall be removed and reinstated. The Contractor shall spot repair
all areas subject to adhesion testing and retest upon full cure of the repair coating.
For further details on the theory and requirements of pull-off testing refer ASTM D 4541, ASTM D7234-05 and
ASTM C1583/C1583M-04 standards.
Note: References shall be made to the pull-off test requirements of individual coating specifications.
8.9 Coating Personnel Qualification

Personnel engaged in testing and verification of coating application shall hold minimum NACE Level I or ACA
Coating Inspection certification. Personnel engaged in the management and supervision of inspection personnel
related to protective coatings shall hold NACE Level I or ACA Corrosion Inspector certification.

Ver 2 Rev 0
9 RECORDS AND INSPECTION REPORT

The contractor shall keep detailed records and reports covering all environmental conditions and on-site tests
carried out on painted work, as required by the applicable specification. To supplement these records, prior to any
works commencing, an Inspection Test Plan (ITP) shall be forwarded to the Water Corporation for review a
minimum of ten working days prior to the commencement of work. Refer: Appendix 1 for a sample copy of
ITP.
The inspector’s responsibility is to audit the coating inspection documents for conformance to relevant Australian
Standards. The following items should be included, but not limited to, in the standard report:
9.1 Ambient Conditions

The report shall include details of prevailing weather conditions, including surface temperature, relative humidity,
dew point and general weather observations etc., during the application process, in accordance with AS/NZS
3894.10.
9.2 Equipment Report

The report shall include details of all production and test equipment used during application and inspection in
accordance with AS/NZS 3894.11.
9.3 Coating Inspection Report

The report shall include details of all coatings applied, the results of quality control testing for all paints, coatings
and their component parts including solvents and thinners, for each stage of the work in accordance with AS/NZS
3894.12.

Ver 2 Rev 0
10 PROTECTIVE COATINGS COLOUR

Protective coatings colour shall comply with AS/NZS 2700 - Colour Standards for General Purposes. All work
shall comply with AS/NZS 2700 colour code as shown in Table 11. Equivalent German colour code (also known
as RAL colour space system) is also included in Table 11. It should be noted that colours will be displayed
differently depending upon the computer and screen settings. Therefore they should be treated as a guide only.
If a suitable approved colour is not available, then the proposed colour shall be referred to the Water Corporation
for acceptance prior to use. Also, references shall be made to Water Corporation colour code drawing No. EG71-1-
1, REV E for details.
Table 11 – Pipeline Colour Code Identification
Pipeline Identification AS/NZS 2700 RAL Colour Space Colour Reference

Colour System
Water G21 Jade RAL 6032
Steam N43 Pipeline Grey RAL 7001
Oil-flammable or combustible X53 Golden Tan RAL 8001

liquids
Gases - gaseous or liquefied Y44 Sand RAL 1002
Acids & Alkalis P23 Lilac RAL 4009
Air B25 Aqua RAL 5012
Drainage pipes (wastewater) N61 Black RAL 9011
Fire Fighting Materials R13 Signal Red RAL 3001
Hazardous Services Y14 Golden Yellow RAL 1004
Electricity X15 Orange RAL 2000
Communications N14 White RAL 9010

RAL is a colour matching system used in Europe.

Ver 2 Rev 0
11 WATER CORPORATION COATING SPECIFICATIONS

11.1 DS 95 Compliance
Design Standard DS 95 is aligned with AS/NZS 2312 for both Atmospheric and Non-Atmospheric type coatings.
Atmospheric environments are classified into corrosivity categories (Very Low - A to Inland Tropical - F) based on
the corrosion rates of mild steel given in International Standard Organisation (ISO) 9223. Non-atmospheric
environments fall into the category of potable water immersion, sewerage immersion, soil etc.
The alignment of DS 95 to AS/NZS 2312 will assist corrosion engineers, design consultants and coating inspectors
to understand and select the correct specification for the various Water Corporation applications. To further assist
asset designers and maintenance planners a library of surface preparation and coating specifications have been
developed for typical Water Corporation applications and are included in Appendix 2 and 3. It is the intention of
the MESB team to expand on this list of specifications based on future requirements.
11.1.1 Choosing the Right Specification

In order to choose the right specification for various Water Corporation assets, atmospheric and non-atmospheric
conditions are sub-divided into immersed or non-immersed micro environments. In simple terms, coating systems
consisting of metallic zinc or compounds of zinc are used only for non-immersed environments with or without top
colour coat.
On the other hand, coating systems such as high build epoxies and elastomeric urethanes, where no zinc is present
are applied for immersed environments without top coats. There are exceptions where a coating system can be
used in both the immersed and non-immersed environments e.g. Epoxy Mastic.
Careful consideration shall be given to some coating systems where the specified nominal dry film thickness is
greater than the AS/NZS 2312 or equivalent to the ISO 9223 standard.
11.1.2 Coating Thickness Deviation

It is the responsibility of the design consultant to ensure that the specified thickness in the specification will not
impede the tolerances and clearances of various mechanical components. The design consultant should discuss the
coating requirement thickness with the Manager, Welding and Corrosion Control, MESB, Water Corporation.
The Water Corporation recommends use of the following coating types on potable/wastewater infrastructures.
11.2 Group B - Inorganic Zinc Silicate

Inorganic Zinc Silicate also known as IZS consists of finely divided metallic zinc dispersed in a self-curing
inorganic alkyl (ethyl) silicate medium. IZS coatings react with steel to form a chemical bond.

Ver 2 Rev 0
The zinc dust metal provides galvanic corrosion protection to the mild steel substrate. If the IZS coating is
damaged, the zinc silicate film repairs itself and protects steel substrate by sacrificial cathodic protection. IZS
coating are mainly used for non-immersed environments.
IZS coatings are porous by nature. When an electrochemical reaction occurs on the IZS only coated surface, its
corrosion products gradually fill the porosity, and forms a barrier coating. Due to porosity of IZS, a “Tie Coat” is
required if and when top coat like Acrylic or Polyurethane is applied. Without a tie coat, the IZS coating system
will fail by creating pinholes in the topcoat. Also, too thick a coating of IZS, will result in “Mud Cracking”.
11.3 Group C - Zinc Rich Epoxy Primer

Zinc Rich Epoxy primer is an organic coating and depends on physical rather than chemical bonding to steel. It
contains zinc in powdered metallic form dispersed in organic base (Epoxy) and curing agent (Polyamide).
Zinc rich epoxy is easier than IZS to apply without mud cracking. Top coat is easier to apply and cures at a faster
rate compared to IZS. The advantage of zinc rich epoxy is that it is more surface tolerant compared to IZS. Zinc
Rich Epoxy primers are mainly used for non-immersed environments.
The Epoxy Primers with very little zinc (zinc phosphates) offer reasonable anti-corrosion and excellent adhesion
properties to all substrates.
11.4 Group D – High Build Epoxy

Epoxies consists of an epoxy base with an amine adduct or polyamide curing agent as the resin binder. The colour
range is limited, usually flat or low gloss. May be used as finish coat but their main disadvantage is they chalk and
discolour with UV radiation but this has little detrimental effect on performance. This can be overcome by
applying a polyurethane or acrylic epoxy topcoat to give a glossy finish for extra protection.
Epoxy primers are applied over galvanised structures prior to High Build Epoxy coating for immersed
environments.
Epoxies are hard, tough coatings with good chemical and solvent resistance. In situations, where more than 1000
microns thickness of coating is required then Ultra High Build Epoxy is preferred. High Build Epoxies are mainly
used for potable water and wastewater immersed environments.
11.5 Group E – Epoxy Mastic

Consists of an epoxy resin base with an adduct or polyamide curing agent with evaporative hydrocarbon and
alcohol, or ketone or glycol ether solvent (or combinations of each). Hand or power tool cleaned steel substrate can
be coated with Epoxy Mastic and hence referred to as ‘surface tolerant epoxy’. Epoxy Mastic coatings can be
brushed or rolled.
Epoxy Mastics are mainly used as maintenance coatings and can be used for both immersed and non-immersed
potable water and wastewater environments.

Ver 2 Rev 0
11.6 Group F – Mineral Filler Epoxy

Mineral flake coatings contain microns thick mineral flakes which make the coating much tougher than ordinary
industrial paint. Glass flake particles form dense, inert barriers within the paint film. Overlapping layers of glass
resist water and chemicals permeating into the paint film. The addition of glass also increases the flexibility,
hardness and abrasion resistance of coatings.
Glass flake coatings can be used for both immersed and non-immersed potable water and wastewater environments.
11.7 Group G - Fusion Bonded Epoxy Powder

FBE powder coating is applied on the surface by pre-heating the substrate. The epoxy resin forms cross-linking
reaction which is irreversible i.e. after the curing, the coating cannot be returned to its original form by any means.
The coating can be used for pipelines buried in soil, immersed and non-immersed environments in both potable
water and wastewater assets.
11. 8 Group H – Galvanising

Galvanising is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The zinc coating
protects the substrate by the Galvanic method and is mainly used for non-immersed environments.
11. 9 Group I – Elastomeric Polyurethane (Polyurea, Polybrid)

Polyurea is a type of elastomer that is derived from the reaction product of an isocyanate component and a
synthetic resin blend.
Polyurethane and polyurea elastomeric membranes are exceptionally tough and flexible to compensate for the
movement and cracking of substrates – particularly concrete. They are mainly used for potable water and
wastewater immersed environments.
11. 10 Group J – Anti-graffiti Coating

Anti-graffiti coatings can be invisible to the naked eye. It is a sacrificial coating which forms a clear coat over the
wall or surface being protected. If the surface is vandalized, the coating can be removed (sacrificed) using a high-
pressure washer taking the graffiti with it. The coating then must be reapplied. The anti-graffiti coating replaces
the usual polyurethane top coats.
11. 11 Group K – Water Based Acrylic Coating

Water based coatings can be applied to damp surfaces and are used for decorative purposes. Also used to maximise
resistance to weathering and hence retain colour well with time. These paints also emit low amounts of Volatile
Organic Compounds (VOCs), which is good for the environment. The disadvantage is if there is excessive
moisture on the material being coated, then the adhesion of the paint is reduced resulting in failure of paint due to
blistering.

Ver 2 Rev 0
11. 12 Group L – Tape Wrapping and Heat Shrink Sleeve

Tape wrapping is a form of corrosion protection for pipelines, valves, gear boxes etc., using a heavy duty,
reinforced, bitumen based adhesive tape. It is fast and relatively simple to apply by hand.
Heat Shrink Sleeves are heat shrinkable polyethylene sleeves which provide extremely tough anti-corrosion
protection for welded pipeline joints and factory coating repairs. They are compatible with all commonly used pipe
coatings and are suitable for operation from -20°C up to 80°C.
11. 13 Group M – Miscellaneous Coating

The above type of coating systems are applied to pipework, pipelines and other assets that encounter concrete and
other types of assets.
Figure 12 shows the coating selection matrix for a new potable and wastewater structure. Appendix 2 shows the
Water Corporation coating specifications that are suitable for various potable and wastewater assets.

Ver 2 Rev 0
Coating Application for New Structure
Carbon Stainless FBE

Cast Iron Concrete Aluminium Plastics
Steel Steel Sintakote
- Grey Cast Iron
- Ductile Iron
No
Does the structure
require coating? Aluminium & Stainless Steel:
No coating is needed for Aluminium and Stainless Steel
assets. Contact : Manager, MESB Corrosion Control Group,
Review design documents/ Water Corporation for technical review & acceptance.
drawings again to confirm if Yes
coating is not required Plastics:
Coating of plastic pipes shall be carried out in accordance to
Water Corporation Specifications A6 & K1 .
For colour coding structures, Refer: AS 2700, RAL gGmbH Colour

Will the coated structure be Space System and Water Corp. drawing No. EG71-1-1, Rev E.
Immersed/Non-Immersed?
Immersed
Non-Immersed
No Potable Water Yes
Carbon Steel/Cast Iron:

[A1 & B1], [A1 & C1], [A1 & C2], [A1 & D2*] [A1 & E1*],
Is the proposed coating [A1 & F2*], [A1 & G1*], [A1 & G2*], [A1 & J1], [A1
spec AS 4020 Compliant? &K1], [E2 & H2]
[A7 & E3], [A4 & G1*], [A3 & H1], [A3 & H2]
Yes Concrete:
[A5 & D4], [A5 & I1*], [A5 & J2]
No
Plastics:
[A6 & K1]
Has it been approved by Water Quality FBE:

Branch? (Verify Schedule 5 - Potable [A7 & E5]
Water Approved Materials List)
No
Does it have any other No
Yes compliance certificate BS®,
EU®, AWWA® ?
Yes
Carbon Steel/Cast Iron: Reject
[A1 & D1], [A1 & D2], [A1 & Refer to Water Corporation Drinking
D3*] [A3 & D1], [A1 & E1*], [A1 Water Quality Branch for technical
& G2*] [A4 & G1*] review for acceptance and update
Yes * used for both immersed & non-immersed
approved materials list
environments
Concrete:
Not on list ® BS - British Standards
[A5 & I1*]
® AWWA - American Water Works
Reject Association
® EU - European Union
Figure 12 - Coating selection matrix for a new potable and wastewater structure.

Ver 2 Rev 0
12 COATING SYSTEMS FOR NEW WATER CORPORATION ASSETS

Tables 12 and 13 provide appropriate coating systems for the common structures found in Water Corporation,
water and wastewater treatment facilities. The tables also contain the assets common materials of construct and
their typical exposure condition. Some assets may not have been listed or may be known by some other name.
If a substrate is left uncoated or a coating is intended for protection against specific chemicals, ensure that the
material has an adequate corrosion resistance for the specific environment.
Pipes, valves, fittings that have factory-applied fusion bonded external/internal coating or suitable cement lining
typically do not require additional coatings.
Any coating in contact with drinking water shall be certified to comply with AS/NZS 4020 by a NATA accredited
laboratory. Design consultants, asset maintainers and coating contractors shall refer to Schedule 5 – List of
products approved for use in Drinking Water issued by the Department of Health, Western Australia requested
through the Water Corporation.
If there is any doubt in the selection of coatings, then the matter should be referred to the Manager, Welding and
Corrosion Control Section, Water Corporation.
Refer Appendix 3 for commonly used coatings in potable water and wastewater infrastructures. The coating
industry technical terms are included in Appendix 4.

Ver 2 Rev 0
Table 12 – Examples of typical coatings for assets associated with potable water
Surface Prep. Coating Micro

Item Substrate Specification Specification Environment Comments
Above Ground/Below
Butterfly Valves (size > 600mm) Carbon steel A1 D2 Ground/Immersed
Control Valve (size < 600mm) Carbon steel A1 E2 or G2 Above Ground
Control Valve (size > 600mm) Carbon steel A1 E2 Above Ground
Non-Return Valve (All size) Carbon steel A1 D1 Above Ground
Pumps Carbon steel A1 F3 Immersed
Hand rails Galvanised Steel A3 E4 Above Ground
Hand rails Carbon steel A1 C2 Above Ground
Hand rails Carbon steel H2 Above Ground No Coating Required
Hand rails Aluminium Above Ground No Coating Required
Ladders Carbon steel A1 H2 Above Ground No Coating Required
Ladders Aluminium Above Ground No Coating Required
Ladders FRP Immersed No Coating Required
Inlet pipe, scour pipe grating FRP Immersed No Coating Required
Wind Girders Carbon steel A1 C2 Above Ground
Roof Sheeting Zincalum Above Ground No Coating Required
Access/Ventilation Hatch Aluminium Above Ground No Coating Required
Access/Ventilation Hatch Stainless Steel Above Ground No Coating Required
Pipes Carbon Steel A1 B1 Above Ground
If top colour coat is required for
Pipes Carbon Steel A1 C2 Above Ground aesthetic purposes
Fusion Bonded If top colour coat is required for
Polyethylene aesthetic purposes on Sintakote
Pipes (Sintakote) A7 E5 Above Ground pipe/fittings
Fusion Bonded
Polyethylene Immersed or Below
Pipes (Sintakote) Ground No Coating Required

Ver 2 Rev 0
Table 12 - Examples of typical coatings for assets associated with potable water (continued…)
Surface Prep. Coating Micro

To protect against UV rays
Pipework Plastic A6 K1 Above Ground
Nuts Washers and Bolts Stainless Steel (316 SS) Immersed No coating required
Above Ground/Non-
Nuts Washers and Bolts Carbon steel H2 Immersed No coating required
Steel Tank internal Carbon steel A1 D1 Immersed
Above Ground/Non-
Steel Tank external Carbon steel A1 C2 Immersed
Above Ground/Non-
Tank roof beams Carbon steel H2 Immersed No coating required
Above Ground/Non-
Angles, Cleats Carbon steel H2 Immersed No coating required
Above Ground/ Non-
Building Structural Beams Carbon steel A1 B1 Immersed
Above Ground/ Non-
Building Structural Beams Carbon steel H2 Immersed Hot Dip Galvanised
Structural beams (high Above Ground/ Non-
level tanks) Carbon steel A1 C2 Immersed
Above Ground/ Non-
Z-purlins, Bridging pieces Carbon steel H2 Immersed Strip Galvanising
Columns (below water
level) Carbon Steel A1 D1 Immersed
Columns (above water
level) Carbon Steel H2 Hot Dip Galvanised

Ver 2 Rev 0
Table 13 - Examples of typical coatings for assets associated with Wastewater
Surface
Prep. Coating Micro
Pumps Carbon steel A1 F3 Immersed
Above Ground or
Hand rails Galvanised Steel H2 Non-Immersed No Coating Required
Hand rails Aluminium Above Ground No Coating Required
Stainless Steel (316 grade Above Ground or
Ladders ) Immersed No Coating Required
Above Ground or non-
Pipes (odour control areas) FRP immersed
To protect against UV rays
PVC/CPVC/MPVC pipeworks Plastic A6 K1 Above Ground
Nuts, Washers and Bolts Stainless Steel (316 SS) Immersed No coating required
Steel Tank internal Carbon steel A1 D1 Immersed
Above Ground/Non-
Steel Tank external Carbon steel A1 C2 Immersed
Coating shall extend down to a level
Immersed/Non- 500 mm below the lowest service
Concrete Tank Concrete A5 D3 Immersed water level in the structure
Immersed/Non-
Concrete Tank Concrete A5 I1 Immersed

Ver 2 Rev 0
13 PIPELINES COATING – BELOW & ABOVE GROUND

13.1 Below Ground (Buried) Pipework
13.1.1 Buried Pipework (Workshop Manufacture)
Where MSCL pipes with fusion bonded polyethylene coating (Sintakote®) are used to fabricate pipe fittings the
coating shall be stripped back a minimum of 75mm away from the actual weld. On completion of welding the
stripped areas in the case of Sintakote pipe or fittings fabricated from rolled plate shall be coated as per the
requirements shown in Table 14.
13.1.2 Coating Requirements (Workshop Manufacture)

Prior to application of the protective coating system, surfaces shall be prepared such that rust and any other
deleterious material are removed, in accordance with the coating manufacturer’s requirements.
In all circumstances, clean and prepare the surface to be protected. The minimum surface preparation requirements
shall be degreasing and mechanical wire brushing to obtain Class 2 cleanliness in accordance with AS/NZS1627
Part 2 for heat shrink sleeve and tape wrapping installation. A Class 3 blast finish is required for the application of
Epoxy Mastic spray applied coatings in accordance with AS/NZS1627 Parts 4 and 9.
Fusion bonded medium density polyethylene coatings shall be applied in accordance with AS/NZS 4321. Pentair
Water & Environmental Systems® (formerly Tyco Flow Control®) is the Corporation’s approved applicator.
Contractors seeking to use other applicators shall seek approval from the Superintendent.
Canusa-CPS Aquashield® heat shrink sleeves are acceptable corrosion protection barriers. Canusa-CPS
Aquashield® products as shown in Tables 15 and 16 are suitable for both workshop and field installations.

Ver 2 Rev 0
Table 14 – External Coating Buried Pipework – Workshop Fabricated fittings
APPLICABLE COATINGS
Option 1 Note 4 Option 2 Note 4 Option 3 Note 4 Option 4 Note 4
FITTING TYPE Sintakote® Heat Shrink Sleeve Epoxy Mastic Coated Tape Wrapping
Coating (L2) (Spray Applied)
Straight Section Joints & Segmented Bends Yes Yes NA NA

(Fabricated from Sintakote Pipe or rolled plate) Refer Note 3 Canusa-CPS®, AQW-HS®
Refer Note 3
Flanged Connections NA NA NA Yes
(straight section) (Petrolatum 4® step System)
Refer Note 2 &3
Crotch Plated Tees Yes NA Yes NA
Refer Note 3 Refer Note 3
Valve to Pipe Flanges NA NA NA Yes
(Petrolatum 4® step System)
Refer Note 2 &3
Access / Inspection Opening Yes NA Yes Yes
(Note 1 & 3) Refer Notes 1 & 3 (Petrolatum 4® step System)
Refer Note 2 &3
Air Valve Off-take / spigot Yes NA Yes NA
(Note 1 & 3) Refer Notes 1 & 3
Scours Off-take / spigot Yes NA Yes NA
(Note 1 & 3) Refer Notes 1 & 3
Notes:
1. Scours, inspection openings and air valve fittings where ‘Sintakote’ coated or epoxy mastic coated shall be coated to within 75 mm of the rear face of the flange.
2. The Petrolatum 4 step system comprises of the application of a primer, packing with mouldable / profiling mastic, wrapping with grease-impregnated tape and final
wrapping with a self-adhesive PVC overwrap. Superlight Profiling Mastic (P410100) shall be used for flange connections. Petrolatum wrappings shall be applied
as per the manufacturer’s recommendation.
3. Pipe work assemblies that are corrosion protected as per Table 14 above and where the period of storage on site exceeds 6 months shall be adequately protected
against ultraviolet and direct sunlight to prevent the coating systems from deterioration.
4. Options for coatings shall be selected in the order of priority, Option 1 being the most effective and Option 4 the least effective.

Ver 2 Rev 0
Table 15 – External Coating Buried Pipework – Field Installation
APPLICABLE COATINGS
Option 1 Note 4 Option 2 Note 4
FITTING TYPE Heat Shrink Sleeve Tape Wrapping
(L2)Note 3 (L1)Note 3
Straight Section Joints & Segmented Bends Yes Yes
(Fab. from Sintakote Pipe or rolled plate) Canusa- CPS®, AQW-HS® Densopol 80® (Rockrap 4000®) (As per note 2)
Flanged Connections Yes Yes
Canusa- CPS®, AQW-FPK® (Petrolatum 4® step System) (Note 1)
Valve To Pipe Flanges NA Yes
(Petrolatum 4® step System) (Note 1)
Access / Inspection Opening NA Yes
Air Valve & Off-take / Spigot NA Yes
Scour Off-take / Spigot NA Yes
Magflow Meter Flanges (Only) NA Same as for Valve assembly spooling
Field Patch Repairs Yes NA
Canusa CRP® (Repair Patches)
Notes:
1. The Petrolatum 4 step system comprises of the application of a primer, packing with mouldable / profiling mastic, wrapping with grease-impregnated tape and final
wrapping with a self-adhesive PVC overwrap. Superlight Profiling Mastic (P410100) shall be used for all flange connections. Petrolatum tape wrapping shall be applied
as per the manufacturer’s recommendation.
2. The following coating strip widths for Densopol product shall apply:
- ≤ DN 300 Radius Bends - Strip Width equals 50 mm;
- ≥DN 300 ≤ DN 600 Radius Bends - Strip Width equals 100 mm;
- ≥DN 600 Radius Bends - Strip Width equals 150 mm.
3. Reference to Water Corporation Specifications.
4. Options for coatings shall be selected in the order of priority, Option 1 being the most effective.

Ver 2 Rev 0
Heat shrink sleeves shall only be installed by Canusa® accredited and trained applicators. Contractors seeking to
use other suppliers of heat shrink sleeves shall seek approval from the Superintendent. Heat shrink sleeves shall be
applied in accordance with Corporation’s Technical Specification L2 Heat Shrink Sleeve Requirements.
Epoxy mastic coatings shall be applied to fittings and large assemblies as shown in Table 14. The coating shall be
applied as per the Corporation’s surface preparation specification “A1” and the paint manufacturer’s
recommendation.
The epoxy mastic coating thickness shall be 500 microns DFT minimum. Epoxy mastic coating shall overlap
Sintakote coatings on pipe sections by 100 mm and 50 mm on pre-coated valves. Epoxy Mastic coatings shall be
APAS approved and shall not be susceptible to cathodic dis-bonding.
Coating data sheets shall be provided to the Superintendent for coating acceptance and approval, a minimum of 2
weeks prior to the commencement of work. Coating data sheets shall verify that the proposed epoxy mastic
coatings has been tested in accordance with AS/NZS 4352 – Testing for coating resistance to cathodic dis-bonding.
Coatings shall be spray applied. Coating applicators shall be PCCP approved. The contractor shall seek the
Superintendent’s approval for use of non-PCCP approved coating applicators. Epoxy coated fittings shall be
thoroughly inspected prior to installation on-site to identify transportation and construction damage to the coating.
All site coating repairs shall be undertaken by an approved applicator and spark tested to the test parameters noted
in Table 16.
Tape wrapping shall be carried out as per the Corporation’s specification ‘L1’ as applicable. The wrapping shall
overlap the polyethylene coating (Sintakote) by a minimum of 100 mm.
During fabrication, the internal cement mortar lining shall be stripped back to a minimum of 50 mm away on either
side of the actual weld to prevent damage to the existing lining. On completion of welding the internal cement
lining shall be reinstated in accordance with the Water Corporation’s specification M8.
Temporary lifting lugs shop welded to assist with manufacture and transportation of pipe fittings shall be removed
and dressed back prior to field coating/wrapping.
Fittings that are not covered in Table 14 schedule and cannot be epoxy mastic coated or heat shrink sleeve wrapped
shall be Petrolatum® tape wrapped as per Option 4.
All coatings, wrappings and shrink sleeves shall be spark tested by the Contractor and witnessed by the
Superintendent using high voltage brush methods to AS/NZS 3894.1 prior to backfilling. Spark testing equipment
shall be within 2 years of calibration. Spark testing Voltage parameters shall be as per Table 16.
13.1.3 Buried Pipework (Field Applied)

Prior to application of the protective coating system, surfaces shall be prepared such that rust and any other
deleterious material are removed in accordance with the coating manufacturer’s requirements. Refer Table 14 for
requirements of typical coating applications.
In all circumstances, clean and prepare the surface to be protected. The minimum surface preparation requirements
shall be degreasing and mechanical wire brushing to obtain Class 2 cleanliness in accordance with AS/NZS 1627
Part 2.
Coating for “even” surfaces at field welded butt joints, SSJ, RRJ, RRJ-WR, flat and convex banded connections
(Per AY58-19-1) shall be made using the Canusa-CPS® Aquashield AQW-HS® product or tape wrapping as per
Table 15. Application of heat shrink sleeves shall be in accordance to the Corporation’s specification M2.
Joints in ‘Uneven’ surfaces that will result in voids under the protective coating such as bends, tees, flanges, flange
bolts and valve body assembly bolts shall be tape wrapped or heat shrink sleeve fitted with Canusa Aquashield
AQW-FPK®. Where tape wrapping or heat shrink wrap is selected as per Table 15, the area with abrupt profile
Ver 2 Rev 0
changes shall be filled with a mouldable mastic to obtain a smooth even profile or alternatively a mouldable PVC
skirt can be used with the Canusa - CPS® product.
Where pipe transitions from below ground to above ground exist, tape wrapping shall extend to 100mm above
finished ground level. Tape wrapping shall be in accordance to the Corporation’s specification L2.
Damaged Sintakote pipe coatings and or heat shrink sleeves shall be repaired using the Canusa CRP ® (Coating
Repair Patches), patch repairs shall be made following the manufacturers recommended practice. Damaged epoxy
mastic coating shall be repaired using the same products and procedures as used in the workshop manufacturing
process.
Additionally minor nicks and scratches in the factory applied Sintakote coating can be repaired using extrusion
welding. Personnel carrying out the repair shall be trained and competent to PMB01 (Plastic Welding) competency
and certificated by a nationally accredited training organisation.
All wrappings and shrink sleeves shall be spark tested by the Contractor and witnessed by the Superintendent using
high voltage brush methods to AS/NZS 3894.1 prior to backfilling. Spark testing equipment shall be within 2 years
of calibration.
Table 16 – Spark Testing Parameters
Coating Process Test Voltage (Min.) Tolerance

Medium Density PE Coating 12 kV Per AS/NZS
3894.1
Heat Shrink Sleeves 12 kV Per AS/NZS
3894.1
Epoxy Mastic Coating 5 kV Per AS/NZS
3894.1
Densopol 80 (Wrapping) 12 kV Per AS/NZS
3894.1
Petrolatum 4 Step System NA NA
13. 2 Above Ground (Exposed) Pipework

Where pipes and fittings are to be installed above ground, they shall be either:
 Inorganic zinc silicate (IZS) primed, or
 Sintakote coated.
13. 2.1 IZS Primed Pipes & Fittings
Pipes and fittings shall be coated in the workshop in accordance with Water Corporation Technical Specifications A1
and C1, attached in the Appendices 2 and 3 respectively.
Welded joints and areas where inorganic zinc silicate (IZS) or galvanised coatings are damaged during transit and
installation, shall be reinstated by the application of two or more coats of epoxy zinc rich paint in accordance with
Water Corporation surface and coating specification A1 and C1 respectively.
Where specified on the drawings, a two-pack polyurethane paint topcoat to the colour nominated on the drawings shall
be applied in accordance with the Corporation’s surface and coating specification A1 and C2 respectively.
13. 2.2 Sintakote Coated Pipes & fittings

Where Sintakote coated pipe and fittings are specified for above ground application, the Sintakote shall be whip
blasted to remove the gloss surfaces and provide a surface profile. The prepared surfaces shall be coated in
accordance with Water Corporation coating specification M2. For welded joints, the joints shall be coated in
accordance with Water Corporation coating specification M2 .
Finish coating colour shall be in accordance with the AS/NZS 2700 and the Corporation’s Drawing EG71-1-1 Rev E.
Ver 2 Rev 0
13. 3 Miscellaneous Pipework Configuration Coating

For below ground to above ground pipe transitions the coating application shall be in in accordance with Water
Corporation coating specification M1. The coating procedure for clean skin pipe when permanently exposed to
atmosphere shall be coated in accordance with Water Corporation coating specification M3.
When pipe sections are joined by coupling joints (e.g. Straub®, Gibault®, Viking Johnson®, Klamflex®), then the
coating shall be applied in accordance with Water Corporation coating specification M4.
Coating of steel pipes and the Sintakote® pipes at the concrete interface shall be carried out in accordance with Water
Corporation specifications M5 and M6 respectively. Decorative coatings on galvanised steel shall be carried out in
accordance with Water Corporation specification M7. For the cement mortar relining, references shall be carried
out in accordance with Water Corporation specification M8.
Finish coating colour shall be in accordance with the AS/NZS 2700 and the Corporation’s Drawing EG71-1-1 Rev E.
14 VALVES COATING
14.1 Introduction to Valves
Valves are extremely important in the control and conveyencing of water and wastewater distribution system given
their importance.
The types of valves used in water distribution systems include gate, butterfly, globe, plug, ball, air control, check
valves, and reduced pressure zone backflow prevention assemblies.
14.2 Coating of Valves

The purpose behind coating a valve is to extend its service life. For DN 600 and below control valves are coated with
High Build Epoxy and Fusion Bonded Epoxy (FBE) in accordance with Water Corporation coating specifications D3
and E2 respectively.
For size above DN600, the existing and new control valves are coated with two or more coats of a two pack Epoxy
Mastic coating system in accordance with Water Corporation coating specification E2.
For all sizes of Non-return valves, coating shall be carried out in accordance with Water Corporation coating
specification E2.
For hard wearing applications (where abrasion, impact and chemical resistance are required), control valves are
coated with high build ceramic filled epoxy coatings in accordance with Water Corporation specification F2.
For Butterfly valves including Seal on Disc and Seal on Body, coating shall be applied by the application of two or
more coats of High Build Epoxy in accordance with Water Corporation coating specification D3.
15 PUMPS COATING
15.1 Introduction to Pumps
A pump is a device that moves fluids by mechanical action. The advantages of internal coatings are to improve the
service life of most pumps, improve chemical resistance and/or reduce wear from abrasion.
15.2 Coating of Pumps

For the wetted areas of new and existing pumps, coating shall be carried out using High Build Ceramic Filled Epoxy in
accordance with Water Corporation coating specification F3.

Ver 2 Rev 0
16 MAINTENANCE COATING
16.1 Criteria for Assessment and Repair
The assessment of existing coatings shall be undertaken as recommended in Section 16.2, Table 17 and the
decision matrix as shown in Section 16.3.
Table 17 - Repair of protective coating systems for a non-uniform breakdown
Type of Coating % Rusting

For unpainted inorganic zinc, or unpainted Repair paint when around 5-10% of the surface in any
or painted metallic coatings (galvanised and particular area is showing signs of rusting. NOTE:
zinc metal spray) Coated Surfaces Surface staining of iron/zinc alloys of unpainted
galvanized coatings should be ignored unless it is
aesthetically unacceptable.
For painted aluminium metal spray, Repair paint when around 5-10% of the surface in any
inorganic zinc or epoxy-zinc primed coating particular area is showing signs of rusting. NOTE:
systems Superficial rust staining should be ignored unless it is
aesthetically unacceptable.
For other paint coatings Repair paint when around 1% of the steel surface in any
particular area is showing signs of rusting
Note:
Repair painting is also necessary in the following typical cases:
(i) For recently painted structures where blistering or flaking is evident.
(ii) For blast-cleaned surfaces where rusting at peaks in the profile is in evidence.
(iii) For surfaces where there is evidence of rusting underneath the film.
(iv) If the rust percentage is 50% and greater, it may be more cost effective to completely recoat the structure.
Inspection shall also be carried out by Welding and Corrosion Control Section, Mechanical Electrical Services
Branch to assess for any underlying corrosion issues.
16.2 Degree of Rusting (Measles Chart)

Degree of Rusting is defined as the rating characterising the degree of rust formation (rust broken through and
visible under rust) on a coating. This assessment should be carried out under good lighting.
The degree of rust percentage is explained in the following schematic representations. These are also known as
“Measles Charts” as shown in Figure 13. References shall also be carried out to SSPC Standard, SSPC Vis 2 for
details.

Ver 2 Rev 0
0% Blank 1% 2%
3% 5% 10%
15% 20% 25%
30% 40% 50%
Figure 13 – Schematic representation of estimating rust percentages.

Ver 2 Rev 0
16.3 Flow Chart for Coating Condition Assessment

It is very important not to make premature decisions on type and causes of failure until all the evidence has
been considered. The Flow chart in clause 10.7 has been developed to assist in identifying the type of coating
defect and the appropriate coating repair procedures.
Figure 14 illustrates cosmetic defects assessment only if surface damage is present, i.e., if the surface coat has
not been completely penetrated to the underlying coat or structural substrate. Figure 15 illustrates the coating
defect assessment if the film failures have completely extended through the surface coat [Ref: MIL-HDBK-
1516, Unified Code for Coatings and Finishes, 1996]. Follow the relevant flow charts for maintenance coating
decisions and specifications.
The prepared surface shall be coated before any contamination or corrosion occurs. Suitable containment such
as drop sheets and/or side tarps must be used to prevent the spread of emissions. Dust and blast media shall be
removed from the surface immediately prior to recoating by blowing with clean, dry air followed by either
vacuum cleaning or careful brushing.
The paint manufacturer shall be consulted when choosing a suitable coating repair product and procedure for
any application onto previous coatings. If the original coating type is unknown, it may be necessary to confirm
compatibility of the new coating system by applying the proposed coating to a small area, allow fully curing
and confirming adhesion.
Figure 16 shows the coating condition assessment of Water Corporation asset using rust percentages estimates.

Ver 2 Rev 0
Coating Application for Existing (In-Service) Structure

- Grey Cast Iron
- Ductile Iron
Review design documents/ No Is the

drawings again to confirm if structure
Coated? Aluminium & Stainless Steel:
coating is not required No coating is needed for Aluminium and Stainless Steel
Yes assets. Contact : Manager, MESB Corrosion Control
Contact: Group, Water Corporation for technical review &
Manager Assess the type of coating. Is acceptance.
Welding & Corrosion Control it Epoxy, Urethane etc.?
Section, Water Corporation Not Plastics:
Known Coating of plastic pipes shall be carried out in
Known
accordance with Water Corp. Specification [A6 & K1] .
For colour coding structures, Refer: AS 2700, RAL gGmbH

Can the defect be removed by
Colour Space System and Water Corp. drawing No. EG71-1-1,
No washing/cleaning with water? Rev E.
Yes Is surface smooth without

No
noticeable cracks or variation in
coating thickness?
Chalking Mud/Dirt
(Cosmetic)
Yes No
Does the crack expose

substrate/underlying coating?
Brown staining on Loss of gloss/milky
Colour Change
top coat in appearance No
What best describes Yes

the defect?
Fading/
Bleeding Blushing
Discolouration Refer: Figure 15
Irregular/Sandy Finish Curtaining/Waves Surface noted with waves/bumps Fine surface cracks
Flaking Peeling Mud Cracking Checking
Figure 14 - Inspection and assessment of coating defects for surface defects (cosmetic) for potable and
wastewater assets.

Ver 2 Rev 0
Coating Application for Existing (In-Service) Structure

- Grey Cast Iron
- Ductile Iron
Review design documents/ No Is the

drawings again to confirm if structure
Coated? Aluminium & Stainless Steel:
coating is not required No coating is needed for Aluminium and Stainless Steel
Yes assets. Contact : Manager, MESB Corrosion Control
Contact: Group, Water Corporation for technical review &
Manager Assess the type of coating. Is acceptance.
Welding & Corrosion Control it Epoxy, Urethane etc.?
Section, Water Corporation Not Plastics:
Known Coating of plastic pipes shall be carried out in
Known
accordance with Water Corp. Specification [A6 & K1] .
Is the substrate or the For colour coding structures, Refer: AS 2700, RAL gGmbH
Refer: Figure 14
No underlying coating exposed at Colour Space System and Water Corp. drawing No. EG71-1-1,
the time of inspection? Rev E.
No Is rust present?
Yes
No
Yes
What is the observed coating Is rust at localised area?

failure mode?
Yes No
Checkered pattern of cracked

Alligatoring finish exposed the undercoat Under Film
Pin Point
Rusting Corrosion
Peeling top coat to expose the

Delamination undercoat
Coating bubbling showing

Blistering broken/unbroken spots
No
What is the observed coating film

failure mode?
Splitting of film & exposing steel

Loss of coating in small areas Loss of coating in sheets
substrate
Flaking Peeling Mud Cracking
Figure 15 - Inspection and assessment of coating defects that penetrates finish coat for potable and
wastewater assets.

Ver 2 Rev 0
Does the rust percentage looks like this?
Date: Form No. Inspected By:

Asset Deficiency Asset Location:
Water Corporation Report No.
Region GPS Co- Easting: Northing:
Ordinates
GSR Material Type: Asset Wastewater Water Reservoir
Type: Pump Treatment
Station Plant
GAR Carbon Steel Tank
MWR Stainless Steel Pipeline
PR Cast Iron Pipework
SWR Concrete Valves
NWR Plastic Pumps
Functional Location: Hand

Rails
Years in Service: Walkways
Type of coating (if Crane
known):
Brand Name of the Others
Coating (if known):
10%
3% 5%
0% Blank 1% 2%
15% 20% 25% 30% 40% 50%
Figure 16 - Coating Condition Assessment of Water Corporation asset using Rust Percentages Estimates

Ver 2 Rev 0
17 COATING FILM FAILURES

17.1 Coating Film Failures (Cosmetic Failure)
PROBLEM CAUSE PHOTO
Dirt/Mud Coating carried out during the
windy day. Note: Dust settled on
the tank wall.
Runs, sags or curtains Gun too close to surface or applied

(Excessive flow on vertical too slowly.
surfaces) Improper gun adjustment.
Coating too thick or material not
brushed out sufficiently.
Environmental conditions
retarding drying.
Wrong or excessive thinner.
Dry spray (sometimes called Liquid pressure too low.
‘overspray') (Sandy or dusty Gun too far from surface or held at
surface)1 an angle- Uneven spray pattern.
High air temperature and low
humidity.
Misses, skips or thin areas Too rapid or inconsistent

(Uneven Gloss)1 application.
Insufficient overlap.
Awkward shapes.
Inaccessible areas.
Embedded dust, dirt or bugs Contaminated surface.

Dust or bugs from air.

Ver 2 Rev 0
PROBLEM CAUSE PHOTO

Bleeding (Staining of top coat) Soluble resins or pigments in
(Often over asphalt or coal-tar undercoat.
coatings)1
Blushing or blooming (Flat, Moisture condensing on coating

milky appearance; most during or immediately after
common with amine and coal application.
tar epoxies)1
Orange peel (Smooth but Paint too thick.

bumpy surface) Paint too cold.
Gun stroked too rapidly or too
close to surface.
Solvent evaporates too fast.
Insufficient air pressure.

Ver 2 Rev 0
17.1 Coating Film Failures (Cosmetic Failure)…continued
PROBLEM CAUSE PHOTO

Fading/Discolouration1
Checking, crazing, alligatoring Resin and pigment not properly

or crocodiling1 combined or excessive surface
stresses.
Top coating before undercoat has
dried that surface hardens while
underlying area remains soft.
Hard topcoat applied over soft
undercoat.
White Rust Galvanized products that are nested
together, tightly packed, or when
water can penetrate between the
items and remain for extended
periods.
Chalking (Loss of gloss or Sunlight breaks down binder-

powdery surface)1 Insufficient agitation during mixing.
Biological failure or mildew Bacteria or fungi degrading the

(Softening of coating blotchy coating.
brown or black spots)1

Ver 2 Rev 0
17.2 Coating Film Failure (Finish Coating Failure)

PROBLEM CAUSE PHOTO
Cracking (Breaks extend to Poorly formulated coating.
substrate) Expansion and contraction of
substrate.
Excessive thickness.
Mud cracking (Large cracking) Too rapid drying of highly-

filled coatings (IZS and
emulsions).
Wrinkling (Rough, crinkled Coating too thick.

surface especially with oil-based Too warm.
paints)1 Topcoat incompatible with
under coat.
Blistering (bubbles on the Poor surface preparation or

surface) poor wetting of the substrate.
Soluble pigments in the
primer.
Incompatible coatings.
Coating applied over a hot
surface.
Bubbling and pin holing of top Air escaping from pores in IZS
(applied over IZS or concrete) or concrete (often when
surface is hot or top will
penetrate pores coat too thick).

Ver 2 Rev 0
17.2 Coating Film Failure (Finish Coating Failure)…continued
PROBLEM CAUSE PHOTO

Flaking or scaling (Small, brittle Brittle coating with marginal
pieces easily removed from adhesion.
surface) Oil type coating on galvanised
surface.
Poor surface preparation or
lack of profile.
Peeling or delamination (Large Underlying surface

sheets with little or no adhesion)1 contaminated.
Top coat not compatible with
undercoat.
Pinpoint rusting (Corrosion Uneven coating or coating too

spots) thin.
Holidays.
Poor surface preparation,
fabrication, defects or profile
too high.
Film becomes soft and sticky Saponification (alkyds)

Presence of alkaline substrate
(concrete, zinc, cathodic
protection)
Spatter coat (Discrete droplets Gun needs adjustment

on surface) Insufficient overlap
Spray gun flipped at end of
pass

Ver 2 Rev 0
17.2 Coating Film Failure (Finish Coating Failure)…continued
PROBLEM CAUSE PHOTO

Pinholes or holidays (<1 mm) Liquid pressure too high and/or
randomly distributed holes in air pressure too low
coating Spray gun too close to surface
Solvent entrapment
Porous substrate (concrete or
inorganic zinc)
Cissing, crawling, bug eyes or Contamination such as oil, water,

fish eyes1 silicone, grease or dirt on surface
or in coating material
Craters Contamination such as oil, water,

silicone, grease or dirt or in
coating material.
Rain spots falling on wet paint
Air pockets trapped in wet film
Brush marks (ropiness)1 Poor workmanship or very heavy

bodied coating
Skin curing or cheesiness(dry Coating too thick (air dry -

on surface but soft below coatings)
usually air drying coatings) Poor drying conditions (low
humidity, high temperature)
References:
[1] Obtained from various corrosion journals and literatures.
[2] NACE International Materials Performance, Vol. 51, No. 8, Pages: 44 – 46, August 2012.

Ver 2 Rev 0
17.3 Galvanised Coating Film Failure (Finish Coating Failure)

PROBLEM CAUSE PHOTO3
Dull Grey A dull grey appearance is caused by growth of the
Appearance zinc-iron alloy layers through to the surface of the
galvanised coating.
Grey coatings may appear as localised dull patches

or lacework patterns on an otherwise normal
galvanized coating or may extend over the entire
surface.
Dull grey coatings usually occur on steels with

relatively high silicon content which are highly
reactive to molten zinc.
Rust Stains Rust staining on the surface of galvanized coatings
is usually due to contact with or drainage from
other corroded steel surfaces.
Steel filings or saw-chips produced during erection

and fabrication operations should be removed from
galvanized surfaces to prevent possible localised
rust staining.
Rust staining may also be caused by the weeping of

pickling acid from seams and joints causing
damage to the galvanized coating.
Lumpiness Lumps and runs arising from uneven drainage are
not detrimental to coating life.
General Rough galvanized coatings usually result from

Roughness uneven growth of zinc-iron alloys because of the
composition or surface condition of the steel.
General roughness may also be caused by over-
pickling, prolonged immersion in the galvanizing
bath, or excessive bath temperature

Ver 2 Rev 0
17.3 Galvanised Coating Film Failure (Finish Coating Failure)…continued
PROBLEM CAUSE PHOTO3

Bare Spots Bare spots may be caused by under-preparation by
the galvaniser.
Some of the factors are outside his control, and for

which he cannot be responsible, including the
presence of residual welding slags, rolling defects
such as laps, folds and laminations in the steel, and
non-metallic impurities rolled into the steel surface.
Wet storage A bulky white or grey deposit, known as wet
stain or bulky storage stain may form on the surface of closely
white deposit stacked freshly galvanized articles which become
damp under poorly ventilated conditions during
storage or transit.
Dark spots/Flux Dirt may be picked up on the surface of the

staining galvanized coating from floors and during transport
or from contact with other articles. Dirt is readily
removed by washing to reveal a sound coating.
Reference:
[3] Galvanisers Association of Australia, http://www.gaa.com.au.

Ver 2 Rev 0
18 APPENDIX 1 – INSPECTION, TESTS AND PLAN (ITP)

Ver 2 Rev 0
INSPECTION TESTS AND PLAN

Client: WA WATER CORPORATION Date: 02 / 07 / 2010
Project: ORD RIVER VALVE INTERNAL REFURBISHMENT Authorised Person:
Item Name:: Valve Internal Refurbishment Authorisation of ITP: John Citizen
Contract No M10209TO WA Ord river project Number of Pages: 3
No. Activity / Operation Specification Reference Acceptance Inspection Sign & Inspection
Document Criteria By Date Type
1 Read and fully understand the Joe Blogg Partners Joe Blogg Partners All read and responsibilities Joe Blogg WM
requirements of ITP’s, the Quality Safety / QA / Enviro Safety / QA Manual understood. Supervision
Plan, the Safety Management Plan, the Man. Plan
Environmental Plan, Work Method
Statements etc.
2. JSA’s, Preliminary Safety Inspections, Joe Blogg Partners AS/NZS 4361.1 All personnel trained and Joe Blogg H
Inductions, Training and Pre-start Safety / QA Manual inducted for site Supervision
Toolbox completed. All safety systems requirements.
and Site specific requirements to be
completed prior to work
commencement.
3 Check Ambient conditions prior to and WA Water Ord River Form QF 20 R.H.< 85% Air temp >100C HM
during all blasting and coating Project and <400C
operations - -Steel temp >100C and Joe Blogg
Record ambient conditions 2 hourly <400C Steel temp >30C Supervision
above dew point
5. Protect, mask and seal off any areas WA Water Ord River As marked by WA All non-specified areas Joe Blogg WM
which are not specified to be blasted Project Water Corporation protected from blasting and Supervision
and or painted. coating operations
6. Abrasive blast Internal Valve surfaces WA Water Ord River Class Sa 2.5 Class Sa 2.5 (ISO 8501- Joe Blogg HM
to a Class Sa 2.5 -finish – check and Project AS/NZS 1627.4 1:1988) or SSPC-SP10 Supervision
record blast profile using Testex Tape - Joe Blogg Quality finish & Profile of 75μm to
75µm to 100µm. AS/NZS 1627.4 QF 20 100μm achieved – Blast
profile checked & recorded
using Testex Tape.
7. Inspection of blasted surfaces, defects WA Water Ord River Form QF- 20 No surface defects such as Joe Blogg M H
revealed by the blasting process shall Project sharp edges, minimum 2mm Supervision
be ground, filled, and repaired. radius on all edges pits,
Apply Jotacote 410 with Valspar Filler laminations, spatter, flux,
for any corrosion pit filling or other burrs,
Ver 2 Rev 0

imperfections.
8. Mix paint as per manufacturers Jotun Technical UHB Fully mixed as per Joe Blogg MW
recommended procedure – Specifications Data Sheet manufactures instructions Supervision
RECORD BATCH NUMBERS Batch numbers on Form
QF 20 QF.20
9. Check Ambient conditions prior to and Joe Blogg Quality Form QF 20 R.H.< 85%-Air tem>100C Joe Blogg MW
during all blasting and coating Manual and <400Steel temp >100C Supervision
operations - AS/NZS 1627.4 and <400C
0
Record ambient conditions 2 hourly -Steel temp >3 C above
10. Apply a stripe coat of Jotun UHB,MTO Form QF -20 All specified surfaces Joe Blogg HOLD - M
to all edges– monitor WFT regularly JOTSPEC coated, no runs, sags, drips Supervision
during application and record ambient Wa Water Ord River excessively thick coating,
conditions every 2 hours on Form Project etc. minimum
QF.20
12. Check Ambient conditions prior to and Joe Blogg Quality Form QF 20 R.H.< 85%-Air tem>100C Joe Blogg W M
during all blasting and coating Manual and <400Steel temp >100C Supervision
operations - AS/NZS 1627.4 and <400C
0
Record ambient conditions 2 hourly -Steel temp >3 C above dew
point
13. Mix paint as per manufacturers Jotun Technical Form QF -20 Fully mixed as per Joe Blogg W M
recommended procedure – Specifications manufactures instructions Supervision
RECORD BATCH NUMBERS Batch numbers on Form
QF 20 QF.20

Ver 2 Rev 0

18. Apply a Full coat of Jotun UHB to all Jotun Fully mixed as per Joe Blogg HOLD W
the specified surfaces – monitor WFT Jotspec WA Water Ord River manufactures instructions Supervision
regularly during application and record Project Batch numbers on Form
ambient conditions every 2 hours on WFT= 2085µm Form QF -20 QF.20
Form QF.20 DFT=2000µm Final DFT of 2000µm
achieved
19. Holiday test the completely cured Wa Water Ord River Form QF.23 Holiday testing of coating Joe Blogg HOLD W
coating – as per AS/NZS 3894.1– Project complete, repairs carried out Supervision
repair as required and record results on Minus 25% of 3984.1 and retested, test results
form QF.23. Table D2 recorded on QF.23
Test Voltage set at less 25%
AS/NZS3894.1 Table D2 2000 µm
8.39 VOLTS
20. Dolly-Test (Adhesion test of cured AS/NZS 3894.9 Form QF.24 Refer Table 3, AS/NZS Joe Blogg HOLD W
coating on the substrate) as per Section 4.2 3894.9 Supervision
AS/NZS 3894.9.
21. A final Joe Blogg / Client inspection is Form QF.22a All project work has been Joe Blogg H - Release
carried out and the Client to sign-off completed, inspected and Supervision WA
upon final acceptance of completed found satisfactory per Water
work. requirements Corporation Rep
Comments:
Blasting to Class 3 ISO 8501-1:1988) or SSPC-SP10 finish – check and record using TESTEX TAPE.
Should surface oxidation occur after blasting, the surfaces shall be reblasted to the specified AS/NZS1627.4 Class Sa2.5 (ISO 8501-1:1988) or SSPC-SP10 Standard
Batch numbers to be recorded for all paint used during application
Ambient conditions checked on regular intervals during complete project
NO Painting shall be undertaken when the Relative Humidity is greater than 85%.
Client to sign off ITP on completion of works
H = Hold Point. W = Witness Point. M = Monitor Regularly

Ver 2 Rev 0
19 APPENDIX 2 - SURFACE PREPARATION AND PROTECTIVE COATING SPECIFICATIONS
SYSTEM
DESIGNATION GROUP – A (SURFACE PREPARATION)
A1 Surface Preparation for the Application of Protective Coating on Steel or Cast Iron
A2 Surface Preparation for the Application of Aesthetic Coating on Stainless Steel
A3 Surface Preparation for the Application of Protective Coating on Galvanised Steel
A4 Surface Preparation for the Application of Protective Coating on Aluminium
A5 Surface Preparation for the Application of Protective Coating on Concrete
A6 Surface Preparation for the Application of Protective Coating on Plastics
A7 Surface Preparation for the Application of Protective Coating on Fusion Bonded Polyethylene (Sintakote®)
SYSTEM COATING SPECIFICATIONS

DESIGNATION
GROUP – B (INORGANIC ZINC SILICATE)
B1 Inorganic Zinc Silicate Coating on Steel or Cast Iron
B2 Inorganic Zinc Silicate, Epoxy Primer Mist-Coat, Two Pack Acrylic Top Coat on Steel or Cast Iron
GROUP – C (ZINC RICH EPOXY PRIMER)
C1 Zinc Rich Epoxy Primer Coating on Steel or Cast Iron
C2 Zinc Rich Epoxy Primer, Epoxy Mastic Coat, Polyurethane Top Coating on Steel or Cast Iron
C3 Zinc Rich Epoxy Primer, Epoxy Mastic Coating on Steel or Cast Iron
C4 Zinc Rich Epoxy Primer, Polyurethane Top Coating on Steel or Cast Iron
GROUP – D (HIGH BUILD EPOXY)
D1 High Build Epoxy Coating on Steel or Cast Iron
D2 High Build Epoxy Coating on Butterfly Valves
D3 High Build Epoxy Coating on New and Old Concrete
GROUP – E (EPOXY MASTIC)
Ver 2 Rev 0

DESIGNATION
E1 Epoxy Mastic Coating on Steel or Cast Iron
E2 Epoxy Mastic Coating on New and Existing Control Valves
E3 Epoxy Mastic, Polyurethane Top Coating on Steel or Cast Iron
E4 Epoxy Mastic, Polyurethane Top Coating on Galvanised Steel
E5 Epoxy Mastic, Polyurethane Top Coating on Fusion Bonded Polyethylene (Sintakote)
GROUP – F (MINERAL FILLER EPOXY)
F1 Glass Flake Epoxy Mastic Coating on Steel or Cast Iron
F2 High Build Ceramic Filled Epoxy Coating on Existing Control Valves
F3 High Build Ceramic Filled Epoxy Coating on New and Existing Pumps
GROUP – G (THERMAL BONDED POWDER)
G1 Thermostatically Applied Polyester Powder Coating for Aluminium Sheet Metal Cabinets
G2 Thermal Bonded Polymeric Coating On Valves And Fittings for Water Industry Purposes
GROUP – H (GALVANISING)
H1 Repair of Galvanised Coating
H2 Hot-Dip Galvanising of Steel Structures
GROUP – I (ELASTOMERIC POLYURETHANE)
I1 Elastomeric Polyurethane Protective Coating on Concrete
DESIGNATION
GROUP – J (ANTI-GRAFFITI)
J1 Anti-Graffiti Coating on New and Old Steel Structures
J2 Anti-Graffiti Coating on New and Old Concrete Structures
GROUP - K (WATER BASED ACRYLIC)
K1 Aesthetic Finish Coating on Above Ground PVC Pipes and Fittings
GROUP L - WRAPPING AND HEAT SHRINK SLEEVE
L1 Tape Wrapping Requirements

Ver 2 Rev 0

DESIGNATION
L2 Heat Shrink Sleeve Procedure
GROUP - M (MISCELLANEOUS)
M1 Above Ground to Below Ground Pipeline Transitional Area and Concrete Encasement Coating Procedure
M2 Coating Procedures for Above Ground Sintakote® Pipe and Steel Pipe Joints
M3 Coating Procedures for Clean Skin Pipe Permanently Exposed to Atmosphere
M4 Coating Procedure for Coupling Jointed Joints
M5 Coating Procedure for Steel Pipe at the Concrete Interface
M6 Coating Procedure For Steel Pipe at the Concrete Interface & Sintakote® Pipe Joint
M7 Coating Procedure on Galvanised Steel for Decorative Purposes in Low Corrosive Environments
M8 Cement Mortar Lining Requirement

Ver 2 Rev 0
20 APPENDIX 3 - COMMOLY USED COATINGS IN POTABLE WATER AND WASTEWATER INFRASTRUCTURES
Code Jotun Paints International Paints Dulux Paints Wattyl Paints Sigma Paints Ameron PPG Paints
PRIMER
IZS Resist 5 WF Interzinc 86 Zincanode 304 Galvit ES600 SigmaZinc 170 (D9) Ameron D9
Resist 8 6AU Interzinc 22
ZINC RICH EPOXY PRIMER
ZRE Barrier Interzinc 42 Zincanode 202 Galvit EP 100 SigmaZinc 109 HS Amercoat 471
Interzinc 52 Zincanode 402 Galvit EP 102 SigmaZinc 102
EPOXY PRIMER
EP Penguard Express ZP Intergard 345 Durepon P14 Epinamel PR 360 SigmaCover 256 Amercoat 182 ZPK
Penguard Special Duremax GPE ZP SigmaPrime 200
BARRIER COAT
EM Jotamastic 87/90 Interseal 670HS Durebild STE Epinamel DTM985 SigmaCover 640 Amerlock 400
Jotacote 605* Interplus 1180 Durebild STE (MIO) SigmaCover 435 (MIO)
Penguard Express (MIO) Interplus 356 (MIO) SigmaCover 640 (MIO)
HBE Tankguard 412* Interline 975* Durebild HSE* Epinamel TL710* Sigmaguard CSF 575* Amercoat CC 703/2
Penguard HB Interzone 954 Duremax GPE* Epinamel TL770SF* SigmaShield 880
GFE Marathon Interzone 505 Durebild STE GF Epinamel MF920 SigmaShield 880 Amerlock 400GF
Jotamastic 87 GF
EPUR Polybrid 705-E* Flexituff*
TOP COAT
PUR Hardtop AS Interthane 990 Luxathane R Poly U400 SigmaDur 550 Amercoat 450K/
Hardtop Flexi Poly U750 Amershield
Hardtop XP-Semi Gloss
AG Imperite 300 Interfine 878 Weathermax HBR Poly U400 Antigraffiti Clear SigmaDur 550 Clear Amershield Clear
Luxathane R
Acrathane IF
WBA Jotun Interior Primer Intercryl 525 Weathershield Gloss AquaTrim All Weather Gloss PPG Gloss Trade
Acrylic
ZRP Galvanite Interzinc 782 Zincanode 202 Galvit EP 100 Sigmazinc 109 HS Amercoat 471
Zinc Rich 1P Galvit EP 102 Styralux 220
CODE
IZS In-Organic Zinc Silicate EM Epoxy Mastic GV Galvanised
ZRE Zinc Rich Epoxy GFE Glass Flake Epoxy EPUR Elastomeric Polyurethane
PUR Polyurethane FBP Fusion Bonded Powder AG Anti-Graffiti
HBE High Build Epoxy TBP Thermal Bonded Polymer WBA Water Based Acrylic
EP Epoxy Primer ZRP Zinc Repair EM (MIO) Epoxy Mastic (Micaceous Iron Oxide)
Notes:
[1] * Complies with AS/NZS 4020 - Testing of products for use in contact with drinking water. Contractor to confirm the validity of AS/NZS 4020 certification with coating supplier before ordering.
[2] Where a coating system requires more than one product to be used (e.g. Primer and top coat) both product shall be from the same supplier unless approved otherwise by the Manager, Welding and Corrosion Control Section.
[3] The Water Corporation cannot be held responsible for the claims or performance guarantees offered by coating product suppliers.
[4] Due to continuous product development, coating contractors shall check with product suppliers to confirm that the product names and numbers are current at the time of ordering.

Ver 2 Rev 0
21 APPENDIX 4 - GLOSSARY
Abrasion Act of being worn away.

Abrasive Material used for abrasive blast cleaning; for example, sand, grit, steel shot,
etc.
Absorption Process of soaking up, or assimilation of one substance by another.
Accelerator Catalyst; a chemical material which accelerates the hardening of certain
coatings.
Acetone A fast evaporating, highly flammable organic solvent.
Acrylic Resin A clear resin derived from polymerized esters of acrylic acids and methacrylic
acid, often used in water-based paints.
Activator Catalyst or curing agent; accelerator.
Adhesion Bonding strength; adherence of coating to the surface to which it is applied.
Air Bubble Bubble in paint film caused by entrapped air.
Airless Spraying Spraying using hydraulic pressure to atomize paint.
Aliphatic Type of polyurethane resin resistant to ultraviolet light.
Polyurethane
Aliphatic Solvent Weak organic solvent, such as mineral spirits.
Alkali Caustic, strong base, high pH, such as sodium hydroxide, lye, etc.
Alkyd Resins Resins prepared from polyhydric alcohols and polybasic acids.
Alligatoring Surface imperfections of paint having the appearance of alligator hide.
Ambient Temperature or temperature of surroundings.
Temperature
Amides Possible curing agent for epoxy resins.
Amines Possible curing agent for epoxy resins.
Anchor Pattern Profile or texture of surface, usually attained by blasting.
Anhydrous Dry, free of water in any form.
Aromatic Type of polyurethane with good chemical resistance but poor urethane
ultraviolet resistance.
Aromatic Solvents Strong organic solvents, such as benzene, toluene, and xylene.
Barrier Coating Coating that protects by shielding substrate from the environment.
Batch Industrial unit or quantity of production used in one complete operation.
Binder Resin; non-volatile vehicle; film forming portion of paint, such as oil, alkyd,
latex emulsion, epoxy, etc.
Blast Cleaning Cleaning with propelled abrasives.
Bleeding Penetration of colour from the underlying surface to surface of existing paint
film, e.g., brown colour from asphalt coatings.
Blisters Bubbles in film, areas in which film has lost adhesion to substrate.
Blushing Whitening and loss of gloss of paint film due to moisture or improper solvent
balance.
Ver 2 Rev 0
Bonding Adhesion.
Bubbling A term used to describe the formation of blisters on the surface while a coating
is being applied.
Burnish To polish or rub to a smoother or glossier surface.
Caking Hard settling of pigment from paint.
Catalyst Accelerator; curing agent; promoter.
Cathode The negative terminal of an electrolytic cell which, in the corrosion process, is
protected and not attacked.
Caustic A strong base or alkaline material.
Chalking The formation of a friable powdery coating on the surface of a paint film
generally caused by exposure to ultraviolet radiation, resulting on a loss of
gloss.
Checking Cracks in the surface of a paint film.
Chemical Resistance A coating’s resistance to solvents, acids, and alkali testing done under watch
glass for 24 hours.
Chlorinated Rubber A coating resin formed by the reaction of rubber with chlorine gas. Often used
for chemical or water-resistant properties.
Cleaners A detergent, alkali, acid, or similar contamination removing material, which is
usually water borne.
Coal Tar A dark brown to black bituminous material produced by the destructive
distillation of coal.
Coal Tar Epoxy A coating in which the binder or vehicle is a combination of coal tar and epoxy
resins.
Coat The coating applied to a surface in a single application to form a film when
dry.
Coating System A number of coats separately applied, in a predetermined order, at suitable
intervals to allow for drying and curing, resulting in a completed job.
Cob webbing Premature drying of a coating during spraying causing a spider web effect.
Cohesion The forces which bind the particles of paint film together into a continuous
film.
Colour Fast Non-fading.
Colour Retention The ability to retain its original colour during weathering or chemical
exposure.
Compatibility The ability to mix with or adhere properly to other coatings without detriment.
Corrosion The decay, oxidation, or deterioration of a substance due to interaction with
the environment.
Cracking Splitting of a coating film, usually as a result of aging.
Craters The formation of small bowl shape depressions in coating films.
Cross Spraying Spraying the first pass in one direction and the second at a right angle to the
first, providing more even film distribution.
Curing Agent A hardener or activator added to a synthetic resin to develop the proper film
forming properties.
Degreaser A chemical solution or compound designed to remove grease, oil, and similar
Ver 2 Rev 0
contaminants.
Deionised Water Water which has been purified to remove mineral salts.
Delamination The separation between layers of coats due to very poor adhesion.
Descaling The removal of mill scale or rust from steel by mechanical means, sometimes
assisted by flame cleaning.
Dew Point The temperature of a surface, at a given ambient temperature and relative
humidity, at which condensation of moisture will occur.
DFT Dry film thickness.
Drier A chemical which promotes oxidation and subsequent drying of a coating film.
Primarily used in oil based coatings.
Dry Spray Overspray or bounce back, producing a sandy finish due to the sprayed
particles having partially dried before reaching the surface.
Dry Fall A coating which is designed to dry rapidly so that the overspray can be easily
removed from the surfaces below.
Dry Time Time allotted for an applied coating film to reach a set stage of cure or
hardness.
Dry to Tack Free A stage at which a coating film will form a skin to which dust will not adhere.
Dry to Touch The state of dry at which a coating film will not transfer onto an item lightly
touched against it.
Dry to Handle The degree of cure at which a film will resist deformation due to handling.
Dry to Recoat The time required for a cured film to dry prior to the application of a second
coat.
Dulling A loss of gloss or sheen.
Effervescence An effect in the film caused by rapid solvent release. This “boiling” of solvent
causes a pinholed or cratered appearance reducing gloss.
Elastic The ability of a substance to return to its original shape or volume after a
distorting force on the substance has been removed.
Emulsion A two-phase liquid system in which small droplets of one liquid are
immiscible in and are dispersed uniformly throughout a second continuous
liquid phase.
Enamel A term used to characterize a coating which has a glossy smooth finish. A
common term for alkyd coatings.
Epoxy A synthetic resin, derived from petroleum products that can be cured by a
catalyst or used to upgrade other synthetic resins to form a harder, more
chemically resistant film.
Ester Compounds formed by the reaction of alcohols and organic acids.
Etching The treatment of a surface with an acid in order to dissolve loose particles or
provide a profile.
Fading Loss of gloss or sheen.
Feather Edge Reduced film thickness at the edge of a dry coating film in order to produce a
smooth, continuous appearance.
Filler A compound used to extend or bulk a coating to provide extra body or hiding
power. “Hiding Power” is an optical property used to describe the light-
scattering efficiency of a white pigment.
Ver 2 Rev 0
Film A layer of coating.

Film Build The dry film thickness characteristics of a coat.
Film Integrity The continuity of a coating free of defects.
Film Thickness A device for measuring either wet or dry film thickness.
Gauge
Fineness of Grind The degree of dispersion of particles within a liquid.
Fingering A broken spray pattern delivering a heavier coating to one area than another.
Fish Eyes Circular voids or separations in the coating usually caused by silicone or oily
spots.
Flammable Any substance easily ignited in the presence of a flame; any liquid having a
flash point below (37.8° C).
Flash Point The lowest temperature of a liquid at which sufficient vapour is provided to
form an ignitable mixture when mixed with air.
Flash-off Time Time which must be allowed after the application of a coating before baking in
order that the initial solvents are released, which prevents bubbling.
Flexibility The degree at which a coating is able to conform to movement or deformation
of its supporting surface without cracking or flaking.
Floating (Flooding) A concentration of one of the ingredients of the pigmented portion of a coating
at its surface giving rise to a colour change.
Flow The degree to which a wet coating film can level out after application so as to
eliminate roller marks and produce a smooth uniform finish.
Fluorescent A class of pigments which, when exposed to visible light, emits light of a
different wavelength producing a bright appearance.
Force Drying The acceleration of drying by increasing the ambient temperature.
Foreign Thinner Any thinner not recommended on the label or in published literature of the
manufacturer, which can affect the coatings performance.
Gelled A coating which has thickened to a jelly like consistency, making it unusable.
Gloss The sheen or ability to reflect light.
Gloss Retention The ability to retain the original sheen during weathering.
Glycol Ether A group of relatively slow evaporating, strong solvents commonly utilized in
epoxy coatings.
Grit An abrasive blasting media obtained from slag and various other materials.
Grit Blasting Abrasive blasting using grit as the blasting media.
Hardener An activator curing agent, catalyst, or cross linking agent.
Hard Dry Full cure of a coating usually 72 hours to 5 days.
Hiding The ability of a coating to obscure the surface to which it is applied.
High Build A term referring to a coating which can produce a thick film in a single coat.
Holiday Any discontinuity, bare, or thin spot in a painted area.
Hydrocarbon Extracts from petroleum such as gasoline, lubricating oils, solvents, etc.
Hydrophilic A substance which absorbs or has an affinity for water, water loving.
Hydrophobic A substance which does not absorb or exhibit an affinity for water.

Ver 2 Rev 0
Immersion Referring to an environment which is continuously submerged in a liquid,

often water.
Impact Resistance The ability to resist deformation or cracking due to a forceful blow.
Incompatibility Unsuitable for use together because of undesirable chemical or physical
effects.
Induction Time The period of time between mixing of two component products and the
moment they can be used.
Inert Pigment A non-reactive pigment, filler, or extender.
Inhibitive Pigment A pigment which assists in the prevention of the corrosion process.
Inorganic The designation of compounds that do not contain carbon.
Inorganic Zinc A coating based on a silicate resin and pigmented with metallic zinc which has
excellent resistance to organic solvents and general weathering.
Intercoat The presence of foreign matter such as dust or dirt between successive coats of
Contamination paint.
Intercoat Adhesion The adhesion between successive coats of paint.
Internal Mix A spray gun in which the fluid and air are combined before leaving the gun.
Ion An atom or group of atoms possessing a positive or negative electric charge as
a result of having lost or gained an electron.
Iron Oxide An oxide of iron. The natural occurring state of steel.
Isopropyl Alcohol A volatile, flammable liquid used as a solvent commonly known as rubbing
(IPA) alcohol.
Ketone An organic compound with a carbonyl group attached to two carbon atoms.
Usually indicates a strong, fast evaporating solvent.
Lacquer A coating comprised of a synthetic film forming material which is dissolved in
organic solvents and dries by solvent evaporation.
Lacquer Thinner Commonly used term used to describe a solvent blend of ethyl alcohol, ethyl
acetate, and toluene.
Latex A stable dispersion of a polymer substance in an aqueous medium; a common
term for water reducible coatings.
Lifting Softening and raising or wrinkling of a previous coat by the application of an
additional coat; often caused by coatings containing strong solvents.
Mastic A term used to describe a heavy-bodied coating.
Methyl Ethyl Ketone A low boiling, highly volatile flammable solvent with extremely good
(MEK) solubility for most vinyls, urethanes, and other coatings.
Methyl Isobutyl A medium boiling solvent commonly used in vinyls.
Ketone (MIK)
Micron A micrometer or one millionth of a meter.
Mil One one-thousandth of an inch; 0.001 inches. Commonly used to denote
coating thickness.
Mill Scale A layer of iron oxide formed on the surface of steel plates during hot rolling;
bluish in appearance.
Mineral Spirits A refined petroleum distillate having a low aromatic hydrocarbon content and
low solubility; suitable for thinning of alkyd coatings.
Ver 2 Rev 0
Miscible Capable of mixing or blending uniformly.

Mist Coat A thin tack coat usually applied to fill porous surfaces such as zinc rich
primers.
Moisture Cure Oil free urethane that dries through the reaction of temperature and humidity
Urethane and isocyanate.
Monomer A substance of low molecular weight molecules capable of reacting to form
longer molecules called polymers.
Mottled Spots of different tones and colours next to each other resulting in a blotchy
effect on the coating film.
Muriatic Acid Concentrated hydrochloric acid often diluted and used for etching concrete.
NACE National Association of Corrosion Engineers
Neutral A liquid which is neither acid nor alkali such as water; pH7
Non-drying Oil An oil which undergoes little or no oxidation when exposed to air and
therefore has no film forming properties.
Non-ferrous A term used to designate metals or alloys that do not contain iron. Example:
brass, aluminium, magnesium.
Non-flammable A compound which does not burn in the presence of a flame.
Non-volatile The portion of the coating left after the solvent evaporates; solids.
Opacity The ability of a coating film to obliterate or hide the color of the surface to
which it is applied.
Orange Peel The dimpled appearance of a dried coating film resembling the peel of an
orange.
Organic Designation of any chemical compound containing carbon.
Organic Zinc A zinc rich coating utilizing an organic resin such as an epoxy.
Overspray Sprayed coating that is dry when it hits the surface, resulting in dusty, granular
adhering particles, reducing gloss and presenting a poor appearance.
Oxidation The formation of an oxide; the curing mechanisms for alkyds.
pH A measure of acidity and alkalinity; pH 1-7 is acid and pH 7-14 is alkali.
Pass The motion of a spray gun in one direction only.
Passivate To make a surface such as steel inert or unreactive, usually by chemical
means.
Pattern The shape or stream of material coming from a spray gun.
Peeling A paint or coating lifting from the surface due to poor adhesion.
Permeability The degree to which a membrane or coating film will allow the passage or
penetration of a liquid or gas.
Phenolic A synthetic resin used for heat or water resistance.
Pigment A finely ground natural or synthetic, insoluble particle adding color and
opacity or corrosion inhibition to a coating film.
Pinholing A film defect characterized by small, pore-like flaws in a coating which extend
entirely through the film.
Plasticiser An agent added to the resin to aid in flexibility.
Polyester Resin A group of synthetic resins which contain repeating ester groups. A special
Ver 2 Rev 0
type of modified alkyd resin.
Polymer A substance of molecules which consist of one or more structural units
repeated any number of times.
Polymerisation A chemical reaction in which two or more small molecules combine to form
large molecules containing repeated structural units.
Polyurethane An exceptionally hard, wear resistant coating made by the reaction of polyols
with a multifunctional isocyanate.
Polyvinyl Chloride A hard tough plastic solid used for plastics and coatings, commonly known as
(PVC) vinyl.
Porosity The presence of numerous minute voids in a cured material.
Pot Life The length of time a coating material is useful after its original package is
opened or a catalyst or other curing agent is added.
Practical Coverage The spreading rate of a paint calculated at the recommended dry film thickness
and assuming 15% material loss.
Primer The first coat applied to a surface, formulated to have good bonding, wetting
& inhibiting properties.
Profile The term used to describe the anchor pattern of a surface produced by
sandblasting, acid etching, or similar method.
Reducer Commonly known as thinner.
Reflectance The ratio of the intensity of reflected light to that of incidental light.
Relative Humidity The ratio, expressed as a percent, of the quantity of water vapour actually
present in the air to the greatest amount possible at a given temperature.
Resin A group of organic materials either natural or synthetic, which can be moulded
or dissolved.
Roller A cylinder covered with lamb’s wool, felt, foamed plastics, or other materials
used for applying coatings.
Runs Sagging and curtaining of a coating or paint film, usually caused by improper
thinning, excessive film build, or poor application techniques.
Rust The reaction product of steel, oxygen, and water.
Salt Atmosphere A moist, heavily laden air with a high chloride concentration; used as a test for
accelerated corrosion evaluations and also present near seacoast areas.
Saponification The alkaline hydrolysis of fats whereby a soap is formed; typical reaction
between alkyds and galvanised metals resulting in peeling.
Sealer A coating used on absorbent surfaces prior to a finish coat.
Shelf Life The maximum time interval in which a material may be kept in a usable
condition during storage.
Shot Blasting Abrasive blasting with round iron shot, or any material which retains its
spherical shape, for peering purposes.
Silica Sand Clean sand made up of sharp silica particles, not containing dirt or clay, used
for abrasive blast cleaning.
Silicone Resins Resins based on silicone instead of carbon, generally used for their outstanding
heat resistance and water repellence.
Skinning The formation of a solid membrane on the top of a liquid, caused by partial
curing or drying.
Ver 2 Rev 0
Solids by Volume The percentage of the total volume occupied by non-volatile compounds.
Solids by Weight The percentage of the total weight occupied by non-volatile compounds.
Solvent A liquid in which another substance may be dissolved.
Solvent Entrapment The encapsulation of solvent within a cured coating due to improper drying
conditions; results in a non-continuous film.
Sound Rusted A rusted substrate cleaned of all loose rust and other loose materials, but not
Substrate cleaned to bare metal.
Spalling Erosion of the concrete surface, exposing coarse aggregate.
Spray Head The combination of needle, tip, and air cap.
Spray Pattern The configuration of coating sprayed on the surface.
Specification A set of instructions detailing the plan for coating of a project; a list of criteria
for a coating.
Spread Rate Coverage, usually at the specified dry film thickness.
Stress Corrosion Spontaneous cracking produced by the combined action of corrosion and static
Cracking stress.
Strong Solvent Any solvent capable of dissolving large quantities of a specified subject.
Substrate The surface to be coated.
Tack Free Completion of the initial cure process of a coating. Airborne dust and soil will
no longer be trapped in the coating.
Thermoplastic Resins having the property of becoming soft upon the application of heat but
which regain hardness after cooling.
Thermosetting Resins having the property of becoming insoluble or hard upon the application
of heat.
Thinners A liquid (solvent) added to a coating to adjust viscosity.
Thixotropic An adjective which describes full bodied material which undergoes a reduction
in viscosity when shaken, stirred, or otherwise mechanically disturbed but
which readily recovers its original full bodied condition upon standing.
Toluene An aromatic solvent with a high boiling range and low flash point classified as
a strong solvent.
Tooth The profile, mechanical anchor pattern or surface roughness.
Two-Pack A coating which is supplied in two parts and must be mixed in the correct
portions before use in order to cure.
Undercoat The coat applied to the surface after preparation and before the application of a
finish coat.
Underfilm Corrosion Corrosion that occurs under films in the form of randomly distributed
hairlines.
Vapour Barrier A moisture impervious layer which prevents the passage of water into a
material or structure.
Vehicle The liquid portion of a paint in which the pigment is dispersed. Comprised of
binder and thinner.
Vinyl Copolymer A resin produced by copolymerizing vinyl acetate and vinyl chloride.
Viscometer One of several types of instrument for measuring a liquids’ viscosity.

Ver 2 Rev 0
Viscosity A measure of fluidity of a liquid.

Viscosity Cup An efflux viscometer utilizing a measured volume of liquid flowing through a
precise orifice.
Voids Holidays or holes in a coating.
Volatile Organic A measure of the total amount of organic compounds evaporating from a
Compounds (VOC) coating film, excluding water.
Volume Solids The volume of the non-volatile portion of a composition divided by the total
volume expressed as a percent used to calculate coverage rate.
Wash Primer A thin paint, usually a chromate, designed to promote adhesion or to be used
as a barrier coat.
Water Blasting Blast cleaning of metal using high velocity water.
Water Spotting A surface defect caused by water droplets depositing a circular ring of
contaminants.
Wetting The ability of a vehicle to flow onto the surface in order to achieve a good
bond.
Wet Sandblasting The incorporation of water into the sandblasting operation in order to minimise
dust.
Wicking Action A capillary drawing action bringing oil to the surface.

Ver 2 Rev 0
END OF DOCUMENT

Ver 2 Rev 0

Water Pull 0ff PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Water Pull 0ff PDF

Uploaded by

Copyright:

Available Formats

Assets Delivery Group

Selection, Preparation, Application, Inspection and Testing of

Uncontrolled if Printed Page 2 of 83

Uncontrolled if Printed Page 3 of 83

2 1/0 12/12/12 All New Version KR BG

3 1/0 12/12/12 All New Version KR BG

4 1/0 12/12/12 All New Version KR BG

5 1/0 12/12/12 All New Version KR BG

6 1/0 12/12/12 All New Version KR BG

7 1/0 12/12/12 All New Version KR BG

8 1/0 12/12/12 All New Version KR BG

9 1/0 12/12/12 All New Version KR BG

10 1/0 12/12/12 All New Version KR BG

11 1/0 12/12/12 All New Version KR BG

12 1/0 12/12/12 All New Version KR BG

Uncontrolled if Printed Page 4 of 83

14 1/0 12/12/12 All New Version KR BG

15 1/0 12/12/12 All New Version KR BG

16 1/0 12/12/12 All New Version KR BG

17 1/0 12/12/12 All New Version KR BG

App 1 1/0 12/12/12 All New Version KR BG

App 2 1/0 12/12/12 All New Version KR BG

App 3 1/0 12/12/12 All New Version KR BG

App 4 1/0 12/12/12 All New Version KR BG

App 5 1/0 12/12/12 All New Version KR BG

Uncontrolled if Printed Page 5 of 83

ANSI American National Standards Institute

APAS Australian Paint Approval Scheme

AS/NZS Australian Standards

ASTM American Society for Testing Materials

ISO International Standards Organisation

NATA National Association of Testing Authorities

NACE National Association of Corrosion Engineers

NSF National Sanitation Foundation

PCCP Painting Contractors Certification Program

SSPC Steel Structures Painting Council

WJTA The WaterJet Technology Association

DFT Dry Film Thickness

TDFT Total Dry Film Thickness

WFT Wet Film Thickness

Uncontrolled if Printed Page 6 of 83

Basic coating Formulas

WFT (microns) = DFT x 100  % Volume Solids

1 atmosphere = 101.3 kPa

1 kPa = 0.145 psi

1 MPa = 145 psi

1 Thou (mil) = 25.4 micron

Uncontrolled if Printed Page 7 of 83

Uncontrolled if Printed Page 8 of 83

Uncontrolled if Printed Page 9 of 83

Uncontrolled if Printed Page 10 of 83

1.1 Purpose of the Document

1.2 Approved Applicators

Uncontrolled if Printed Page 11 of 83

1.3 Coating Inspector

1.4 Coating Supervisor

1.5 Coatings in Contact with Drinking Water

1.6 Cathodic Protection (CP) System Compatibility

1.7 Australian Paint Approval Scheme (APAS)

Uncontrolled if Printed Page 12 of 83

1.8 Referenced Documents

AS/NZS 1627.0 Part 0: Method selection guide

AS/NZS 1627.1 Cleaning using liquid solvents and alkaline solutions