Kme 0000 SP MD 0003

Contents page
1. Scope 4
1.1 General 4
1.2 Abbreviations 4
1.3 Definitions 4
2. Reference documents 5
2.1 Regulations 5
2.2 Codes and Standards 5
2.3 Referenced Specifications 6
2.4 Conflicts in standards 6
3. Pre-application Requirements 7
3.1 Environmental Conditions 7
3.2 Workmanship 7
3.2.1 Competence of the painter 7
3.3 Equipment 7
3.4 Fabrication Defects 7
3.5 Pre-Cleaning 8
3.6 Surface Preparation 8
4. Application requirements 10
4.1 General 10
4.2 Materials 10
4.3 Coating System 10
4.3.1 Coating System 1 10
4.4 Finish Colour 13
4.5 Methods Of Application 14
4.5.1 Spray painting 14
4.5.2 Brush application 15
4.5.3 Roller application 15
4.5.4 Conditions of Application 15
4.6 Special Treatment for Certain Areas 16
4.6.1 Edges 16
4.6.2 Sprayed Applications 16
KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 2 of 24

4.6.3 Areas to Remain Unpainted 16
4.7 Thickness and Adherence of Coatings 16
4.7.1 General 16
4.7.2 Wet Film Thickness 16
4.7.3 Dry Film Thickness 17
4.7.4 Inspection Location 17
4.7.5 Number of DFT Readings 17
4.7.6 Marking Defective Areas 17
4.7.7 Discrepancies 17
4.7.8 Pin Holes 17
4.7.9 Adherence of Coatings 17
4.7.10 Edges 17
4.8 Multiple Coat Applications 17
4.8.1 General 17
4.8.2 Preparation of Surfaces Between Coats 18
4.8.3 Timing of Coatings 18
4.9 Protection of Surrounding Areas 18
4.10 Coating System Selection 18
4.11 Reinstatement of Damaged Areas 18
4.11.1 Painted Surfaces 18
4.11.2 Galvanised Finished Surfaces 19
5. Galvanising Requirements 20
5.1 General 20
5.2 Preparation 20
5.3 Dipping Process 20
5.4 Appearance 21
5.4.1 Number of DFT Readings 21
5.4.2 Marking Defective Areas 21
5.5 Threaded Fasteners 21
5.6 Inspection 21
5.7 Packing, Storage and Transport 21
6. Handling and Transport 22
7. Post-application requirements 23
7.1 Inspection and Paintings 23
7.2 Application Records 23
7.3 Guards 24

1. Scope
1.1 General
This Standard Specification applies to the requirements for the surface preparation, priming
and painting of mechanical and electrical equipment and machines, structural steelwork and
platework, pipework and other surfaces exposed to the atmosphere for the Kestrel Mine
Extension.
It also defines the requirements for galvanising of fabricated steel items.
It supplements and shall be read in conjunction with the Technical Specification, Standard
Specifications, Data Sheets and Drawings where the scope of work includes the supply of
Painting and Protective Coatings.
1.2 Abbreviations
DFT Dry Film Thickness
ITP Inspection and Test Plan
QA Quality Assurance
QC Quality Control
RH Relative Humidity
1.3 Definitions
Applicator Person or company responsible for carrying out surface treatment work
Profile blast Blasting operations carried out to achieve a desired profile, usually the final
blast prior to coating, or surface treatment
Spot blast Blasting operations carried out to remove localised corrosion, or damage, to
otherwise sound coatings
Stripe coat Brush applied coating, usually to edges, welds, and other areas susceptible to
coating breakdown.
Substrate Base material over which a protective coating is applied
Whip blast Light blasting carried out to abrade a surface, with minimal removal of the
substrate

2. Reference documents
2.1 Regulations
The design and installation shall comply with all applicable statutory regulations and be
subject to approval by the regulatory authorities.
The latest revision of the following publications shall be fully applicable, unless otherwise
stated in the act or regulation:
• Queensland Coal Mining Safety & Health Regulations
• Queensland Coal Mining Safety & Health Act
• Workplace Health and Safety Regulation
• Environmental Protection Regulation
2.2 Codes and Standards

Equipment shall be designed, manufactured and tested in accordance with latest relevant
Australian Standards, Codes and Regulations, except where modified by this specification.
Where Australian Standards, Codes and Regulations do not exist, those of International
Standards Organisation (ISO) or other International Standards shall apply, subject to approval
by the Company.
AS 1214 Hot dip galvanised coating on threaded fasteners
AS 1580 Paints and related materials - Methods of test
AS 1627 Metal finishing - Preparation and pre-treatment of surfaces
AS 1627.1 Metal Finishing – Preparation and pre-treatment of surfaces – Removal of

oil, grease and related contamination
AS 1627.4 Abrasive Blast cleaning of steel
AS 1627.7 Hand tool cleaning of metal surfaces
AS 2331 Methods of test for metallic and related coatings-Method selection guide
AS 2700 Colour standard for general purposes
AS 3750.9 Paints for steel structures - Organic zinc-rich primer
AS 3894.3 Site testing of protective coatings - Method 3 - Determination of dry film

thickness.
AS 3894.10 Site testing of protective coatings - Inspection report - Daily surface and
ambient conditions

AS 3894.11 Site testing of protective coatings - Equipment report
AS 3894.12 Site testing of protective coatings - Inspection report - Coating
AS/NZS 4680 Hot-dip galvanised coatings on fabricated ferrous articles
2.3 Referenced Specifications

KME-0000-SP-MD-0001 Site Information
2.4 Conflicts in standards

Conflicts between referenced documents shall be identified to the Company’s Representative
in writing for resolution. In general the order of precedence shall be:
• Queensland Coal Mining Safety and Health Act and Regulations
• This Specification
• Australian Standards
• International Standards.

3. Pre-application Requirements
3.1 Environmental Conditions

Ambient conditions such as temperature, relative humidity and substrate temperature
prevailing at the location where surface preparation and coating system application is to take
place, will have significant impact on mixing and application of coating materials.
Ambient conditions likely to occur at shop and site during coating applications, shall be taken
into full account when setting schedules for the nominated coating system.
Refer to KME-0000-SP-MD-0001 for Site Information and section 4.6 of this specification for
the application requirements.
3.2 Workmanship
3.2.1 Competence of the painter
All surface preparation, coating application and inspection shall be performed by persons who
are specialists in this particular field. They must produce evidence of satisfactory and lengthy
experience. Applicators holding current Painting Contract Certification (PCCP) will be given
preference. The applicator shall be certified for the site or shop application of high
performance coatings under Class 3 or higher of the PCCP approval scheme or approved by the
Company’s representative as a pre-qualified applicator.
The Supplier or Contractor shall provide all safety equipment necessary for performing the
work. Without detracting from the laws and regulations of the statutory authorities having
jurisdiction, and the Conditions of Contract particular attention is drawn to the following
areas:
• Working at heights.
• Working in confined spaces.
• Safe handling and storage of paints and materials.
• Noise.
3.3 Equipment
Equipment, including air compressors, shall be supplied and maintained by the Supplier or
Contractor. Compressors shall be of adequate size for the work to be done and in good repair.
Air shall be free of oil and water. Suitable water and oil traps shall be fitted to air lines and
regularly maintained.
3.4 Fabrication Defects

All substrate surface defects including flux residues, weld spatter, slag, burrs, fins, sharp edges
to a minimum radius of 2.0 mm and the corrosion product shall be removed. This shall also
include the repair of all laminations, cracks and welding defects.
The protective coating applicator shall inspect the work for this compliance and arrange for
corrective action to be carried out at the expense of the fabricator. Any rework shall be carried
out by the contractor to conform to this specification.

3.5 Pre-Cleaning
All surfaces shall be cleaned and free of contaminants prior to preparing the surface for the
application of protective coatings. The surface shall be free of welding slag, spatter and flux
residues, paint, dust, dirt, grease, oil, chemicals and salts.
The minimum standards employed shall be in accordance with AS1627.1. All surfaces affected
with salt or acid contaminations shall be washed down by the Supplier or Contractor
responsible for surface preparation. This washing shall be by scrubbing the surface with rags
or brushes and liberal quantities of potable water. The water used for washing down shall be
frequently changed with fresh water. Where hosing is used, the size and velocity of the water
stream shall be of an adequate size to the satisfaction of the Company’s representative.
Any detergents used shall be non-ionic type.
3.6 Surface Preparation

All surfaces to be coated shall be prepared in accordance with the coating manufacturer’s
recommendations.
In addition to, or as part of these recommendations, the following minimum surface

preparation provisions shall apply:
(a) Surfaces to be coated shall be free of welding slag, spatter and/or other imperfections
(b) All sharp edges and surface irregularities shall be removed.
(c) Deposits of oil and grease shall be removed prior to abrasive blasting by solvent
cleaning in accordance with AS1627.1
(d) Unless specified otherwise by the coating system, all fabricated steelwork, pipe work
1
and plate work shall be abrasive blasted in accordance with AS1627.4 Sa 2 2
(e) Galvanized surfaces requiring painting shall be lightly abrasive blast cleaned to AS
1627.4 Sa 1. The light blast cleaning is to remove all zinz corrosion product, “spangle”
and shine and to impart a surface roughness profile no greater than 10 microns. The
following criteria1 should be observed:
• Abrasive blasting air pressure 280 kPa (40 psi) maximum
• Abrasive grade 0.2 - 0.6 mm (GMA Premium or speed blast Garnet)
• Angle of blasting to surface 45º
• Distance of blast nozzle from the galvanized surface 300 - 400 mm
• Blasting nozzle type min 10 mm Venturi type
(f) Abrasive cleaned surfaces shall be primed within four hours of blasting and prior to
any subsequent surface deterioration (flash rusting etc.). Any contamination of the
1 Reference: Galvanizers Association of Australia web site.

blasted surface will require the entire surface to be reblasted. No night time blasting is
permitted
(g) Steel shall be brushed or blown down to remove dust and similar contamination prior
to coating

4. Application requirements
4.1 General
Paint shall be applied to yield the specified dry film thickness unless otherwise agreed in
writing by the Company Representative.
Paint shall be applied so that an even film of uniform thickness, tint and consistency covers
the entire surface, and is free of pin holes, runs, sags, cracks, lack of adhesion, incomplete
curing/hardening, mechanical damage, nibs, excessive brush marks or similar defects.
4.2 Materials
Paints and thinners shall be brought to the point of usage in unopened original containers
bearing the manufacturer's brand name and colour designation.
Handling, storage and use of paints and thinners shall be in accordance with the
manufacturers instructions and the requirements of the statutory authorities have jurisdiction.
Particular attention shall be paid to the health and safety requirements.
All batch numbers and use by dates for all materials used shall be recorded for inspection by
the engineer at any stage.
Paints shall be ready-mixed unless otherwise specified. Where a 2-pack system is supplied by
the manufacturer, it shall be mixed at the site of application in the manner prescribed by the
manufacturer. Mixed paint remaining unused after the manufacturer's stated pot life shall be
discarded.
All final coat paints shall be suitable for re-coating during the life of the structure.
The Supplier or Contractor shall use the paint and materials specifically nominated in the
specification. Different brands of paints shall not be used on successive coats unless approved
in writing by the Company Representative.
Alternative paint systems shall only be used with written approval of the Company
Representative.
4.3 Coating System

4.3.1 Coating System 1
Application Areas: Structural steelwork – CHPP, Conveyor steelwork, trusses, take-up steelwork,
transfer station structural steel, drive frame and loop take-up steelwork.
Surface Preparation: Abrasive blast clean to AS 1627.4 Class 2½.
Prime Coat: Apply one (1) coat of an approved High Build Rapid Cure Epoxy Zinc Phosphate
Primer ( with a volume solids > than 70% ) at a dry film thickness of 150 microns.
Example: Jotun Penguard Express ZP
Finish Coat: Apply one (1) coat of an approved High Build Polyamide Cured Epoxy Finish (
with a volume solids > than 60% ) at a dry film thickness of 150 microns.
Example: Jotun Penguard FC
Total DFT 300 micrometers

Colour: Light Grey N35 - CHPP Steelwork
Cream Y34 - Conveyor Steelwork
Handling: The freshly coated steel is to be left to cure for at least 24 hours prior to handling
onto transport.
Touch Up Damage: Spot coat to achieve a minimum DFT of 300 micrometers.

Application Areas: External large flat or curved surfaces – Surge bins, Dump hoppers, thickener
tanks and stockpile machines.
Finish Coat: Apply one (1) coat of High Build Catalysed Acrylic Gloss Finish (with a volume
solids > than 55%) at a dry film thickness of 100 microns.
Example: Jotun Hardtop CA
Colour: Cream Y34
onto transport.

Application Areas: Coal preparation plant pipe work, coal handling plant and other pipe work as
needed.
Finish Coat: Apply one (1) coat of an approved High Build Catalysed Acrylic Gloss finish ( with
a volume solids > than 55% ) at a dry film thickness of 75 microns.
Colour: Instrument Air – LIGHT BLUE

Fire Systems – RED
Potable Water – GREEN
Other Systems – as NOMINATED
onto transport.

Application Areas: Internals of coal preparation plant thickener tank, rake arms and clarified water
tank.

Surface Preparation: Abrasive blast clean to AS1627.4 Class 2.5 to achieve a 50-75 micron surface
profile.
Prime Coat: Apply one (1) coat of an approved High Build High Solids Glass Reinforced
Abrasion Resistant Epoxy coating ( with a volume solids > than 75% ) at a dry film
thickness of 250 microns.
Example: Jotun Marathon
Finish Coat: Apply one (1) coat of an approved High Build High Solids Glass Reinforced
Total DFT 500 microns
Colour: Grey
onto transport.
Touch Up Damage: Spot coat to achieve a minimum DFT of 500 microns.

Application Areas: Abrasion resistant areas (non tiled areas of sumps, underpans, launders & all
chutes).
Surface Preparation: Abrasive blast clean to AS 1627.4 Class 2.5 to achieve a surface profile height of
between 50-75 microns.
Prime Coat: Apply one (1) coat of an approved High Build High Solids Glass Reinforced
Abrasion Resistant Epoxy coating ( with a volume solids >than 75% ) at a dry film
Finish Coat: Apply one (1) coat of an approved High Build High Solids Glass Reinforced
Colour: Grey
onto transport.

Application Areas: Galvanized roof purlins, wall girts, bridging and concrete structural decking
(condek)
Surface Preparation: Solvent wash to remove of all surface contamination and abrasive blast clean to
AS 1627.4 Class 1 (brush blast).
Prime Coat: Apply one (1) coat of an approved High Build High Solids Polyamine Cured Epoxy
Finish ( with a volume solids > than 70% ) at a dry film build of 150 microns.
Example: Jotun Jotacote Universal
Colour: Light Grey

onto transport.
Touch Up Damage: Spot coat to achieve a minimum DFT of 150 micrometers..

Application Areas: Galvanized handrail and kick plates.
Surface Preparation: Solvent wash to remove of all surface contamination and abrasive blast clean to
AS 1627.4 Class 1 (brush blast).
Prime Coat: Apply one (1) coat of an approved High Build High Solids Polyamine Cured Epoxy
Finish ( with a volume solids > than 70% ) at a dry film thickness of 75 microns.
Example: Jotun Jotacote Universal
Finish Coat: Apply one (1) coat of an approved High Build Catalysed Acrylic Gloss coating (
with a volume solids > than 55% ) at a dry film thickness of 75 microns.
Colour: Safety yellow
onto transport.

Application Areas: Behind mild steel wear plates
Surface Preparation: Abrasive blast clean to AS1627.4 Class 2.5
Prime Coat: Apply one (1) coat of an approved Inorganic Ethyl Silicate Zinc Rich coating at a
dry film thickness of 75 microns.
Example: Jotun Resist 86
Total DFT: 75 microns
Colour: Grey
Handling: All steel to be left to cure for at least 24 hours prior to handling onto transport
Touch Up Damage: Spot repair using an approved epoxy zinc rich coating
Example: Jotun Barrier
• Preference will be given to coatings with higher volume solids (low VOC).
• Preference will be given to rapid cure coatings.
4.4 Finish Colour

The colour of the finish coat shall be in accordance with Table 5.1.
Table 5.1 Coating Colours
Application Areas Colour AS2700 Number
Overland conveyor modules and drain Cream Y34

crossing beam modules; all coal handling
conveyor steelwork including terminal
frames, stringers, gantries, and bracing.

General structural steelwork of coal Light Grey N35
handling (including transfer towers,
trestles and sizer stations) and coal wash
plants excluding conveyors.
External Surfaces of Plate Work and Bins Cream Y34
Handrails, Stanchions and Kick rails Golden Yellow Y14

*
(attached to stanchions)
Ladder Safety Cages Golden Yellow Y14
Lifting Beams and Lifting Lug Golden Yellow Y14

** Light Grey N35
Floor Grating & Floor Plate
Mechanical Proprietary Items Cream Y34
Externals of Guards Golden Yellow Y14
Internal of Guards (including pulleys etc.) Marigold X13
Electrical equipment including White

Switchboards
Transformers (internal and external) Storm Grey N42
Electrical Motors White
*Kick rails which are an integral part of the steelwork shall be painted the same colour as the
steelwork.
**Unless galvanised.
4.5 Methods of Application

4.5.1 Spray painting
The spray equipment shall be suitable for the intended purpose, shall be capable of properly
atomising the paint to be applied and shall be equipped with accurate pressure regulators and
gauges. The spray gun nozzles and needles shall be those recommended by the paint
manufacturer on the relevant data sheet. The equipment shall be kept in good condition to
permit efficient and effective paint application.
The pressure on the material in the pot and of the air at the gun shall be adjusted for optimum
spraying effectiveness. The pressure on the material in the pot shall be adjusted when
necessary for changes in elevation between the gun and the pot. Hose length shall not exceed
10m. The atomising air pressure at the gun shall be high enough to properly atomise the paint
but not so high as to cause excessive fogging of paint, excessive evaporation of solvent or loss
by overspray.
Traps or separators shall be provided to remove oil and condensed water from the air. These
traps or separators shall be of adequate size and shall be drained periodically during
operation. The air from the spray gun impinging against the surface shall show no signs of
condensed water or oil.
Paint ingredients shall be kept properly mixed in the spray pots or containers during paint
application either by continuous mechanical agitation or by intermittent agitation as
frequently as necessary. Excess thinning shall not be carried out.

The spray gun shall be held perpendicular to the surface. There shall be 50% overlap between
passes and large flat surfaces shall receive two passes at right angles to each other.
Spray equipment shall be kept clean so that dirt, dried paint, and other foreign materials are
not deposited in the paint film. Regular purging of the spray equipment shall be performed
during application. Cleaning solvents left in the equipment shall be completely removed before
painting.
Coatings shall be wet on contacting the painted surface. Areas of dry spray shall be removed to
the satisfaction of the Engineer and the correct system re-applied.
4.5.2 Brush application

Where applied by brush, the paint shall be spread evenly over the entire area with the
minimum practical amount of brushing. The method of application and the type of brush used
shall be suitable for the paint specified and the surface being painted.
The method of "laying-off" shall be suited to the paint specified and shall be executed with the
minimum amount of brush marking.
Brushes shall be maintained in good order and condition.
4.5.3 Roller application

Where applied by roller, the paint shall be spread evenly over the entire area with a minimum
practical amount of rolling. A uniform method of application shall be adopted when painting
large areas. The rolling direction shall be towards already painted areas to minimise paint
joint build up. When roller painting edges, areas subject to possible roller damage shall be
brush-painted prior to rolling.
The rollers and paint trays shall be suitable for the purpose intended and shall be maintained
in good order and condition. After use the rollers and trays shall be cleaned by the appropriate
means.
4.5.4 Conditions of Application

The ambient conditions shall be recorded before, during and after the application of each coat.
Recordings shall include the name of the applicator(s), date, time, wet and dry bulb
temperatures, wind speed and direction, and surface temperature.
No application shall be made without the consent of the Engineer if one or more of the
following conditions is likely to exist at the time of application or during the curing period:
(a) Rain or wind borne dust, including dust from blast-cleaning operations
(b) Relative humidity above 85% or the temperature of the surface is less than 3°C above
the dew point
(c) The atmospheric conditions are windy, dusty, foggy and/or wet
(d) If there is a likelihood of a detrimental change in the weather conditions within two
hours after the anticipated completion of the coating application
(e) Metal surfaces in ambient temperature outside the range 5-40°C

(f) The ambient conditions are outside the limitations set out by the paint manufacturer
Coats which are applied over bare metal shall be applied within the allowed period from
surface preparation.
4.6 Special Treatment for Certain Areas

4.6.1 Edges
Coatings shall be worked into cracks and crevices. Brushed and rolled edges, bolts and nuts
are to be given careful attention to ensure that the minimum thickness of coating is achieved.
Special attention shall be paid to the thickness of paint along the edges of the steelwork,
particularly the toes of flanges.
4.6.2 Sprayed Applications

To prevent low film thickness all angles, welds, sharp and external edges, nuts and bolts, shall
be brush coated or strip sprayed immediately prior to each application of the coating to the
whole area.
The Supplier or Contractor shall ensure that the whole surface is covered, paint being sprayed
from both sides of obstructions such as bolts and nuts.
4.6.3 Areas to Remain Unpainted

Areas that are specified as to remain unpainted shall be adequately protected from surface
preparation and paint application. Damaged to these areas shall be corrected at the Supplier’s
or Contractor’s expense.
Connections on structural steelwork shown as tight friction bolting shall be blast cleaned and
the taped to keep the area free of paint and other contaminants. If inorganic zinc silicate
primers are being used, the joint contact area shall be taped after primer application.
Areas adjacent to welding areas which are yet to be completed shall be left unpainted for a
distance of 50 mm back from the weld area.
Areas on mechanical equipment specified as not requiring paint shall be coated with a
corrosion resistant compound which can be easily removed. ie Mobilarma 633 or equivalent.
4.7 Thickness and Adherence of Coatings

4.7.1 General
The minimum coating thickness shall be as specified for each coat of the paint system. The
maximum thickness in any one application must not exceed that recommended by the paint
manufacturer. If the required thickness is not obtained in the specified number of coats, extra
coats shall be applied until the required thickness is reached. The last coat shall be the final
coat.
4.7.2 Wet Film Thickness

Except with the Engineer's written authority, the wet film thickness of each coat and the
amount of thinners used in its application shall be as specified by the paint manufacturer.
Operators shall make frequent checks on the applied wet film thickness by means of approved
gauges.

4.7.3 Dry Film Thickness
The dry film thickness (DFT) of the coating shall be carried out in accordance with AS 3894.3
Test method B for magnetic Induction and Eddy Current methods. The previously recorded
surface profile must be deducted from all DFT readings when required to test the DFT of
coatings 150 µm and less.
4.7.4 Inspection Location

The dry film thickness inspection of the coating shall include areas of the structure which are
difficult to paint, are masked by structure, or areas where double coating or light coating is
likely due to the shape of the substrate.
4.7.5 Number of DFT Readings

The applicator shall perform a sufficient number of dry film thickness readings in such a
manner as to ensure a representative account for the DFT compliance of the coated area
inspected. The method as described in AS 3894.3 Section 7 “Inspection Plans” shall be used as
a minimum requirement for a thickness testing plan.
4.7.6 Marking Defective Areas

The marking of the defective areas shall be made using a marking method or marking ink
compatible with the coating over which it is applied.
4.7.7 Discrepancies
Inspection by other authorised parties that find discrepancies to the applicators recorded
findings by way of under-film or over-film DFT readings shall be marked up. These marked up
locations will be re-checked by both parties after re-calibrating the test instruments to the
same certified calibration standards. Confirmation of coated areas that fail to meet the
specifications shall be re-worked and the surface preparation and coatings shall be carried out
in the same order as the original work was specified.
4.7.8 Pin Holes

When required by the specification, the coating is to be tested for film continuity and defects
as described in AS 3894 Parts 1 and/or Part 2. All pin holes and holidays shall be re-coated.
The minimum curing period stated by the manufacture or 5 days shall pass before burring or
immersing the surface.
4.7.9 Adherence of Coatings

The adherence of the coating shall be acceptable throughout the whole coating. Coatings with
poor adhesion shall be completely removed and replaced in accordance with the Specification
at the Supplier’s or Contractor’s expense.
4.7.10 Edges
Particular attention shall be paid to the coating thickness at corners and toes of steel sections.
4.8 Multiple Coat Applications

4.8.1 General
Where more than one coating is specified, each coating shall be tinted differently to the
previous coat so that missed areas will be visually apparent during application and after the
paint has dried.
Surfaces which will be inaccessible after erection of other elements of the structures shall be
painted prior to the installation of the obstructing item.

4.8.2 Preparation of Surfaces Between Coats
Immediately before second and subsequent coats (except those prescribed by the
manufacturer as "wet-on-wet"), the surface will be examined to determine its need for
cleaning.
If grease or oil is present, it shall be removed by a suitable solvent. Salt and dirt adhering to
the surface shall be removed by scrubbing with a solution of non-ionic or cationic detergent
and then pressure-hosed. The same treatment shall be given to areas from which grease or oil
has been removed.
If overall washing is not necessary, the surface shall be dusted down by brush to disturb and
remove deposits not apparent on visual inspection.
4.8.3 Timing of Coatings

Except for coatings designated by the manufacturer as wet-on-wet, coatings shall be applied
only under the following conditions:
(a) The surface is clean and dry
(b) The manufacturer's stated minimum time for re-coat has elapsed
(c) The manufacturer's stated maximum time for re-coat has not elapsed. If the
maximum time has elapsed or in the case of re-coating, then pre-treatment shall be in
accordance with the manufacturer's recommendations
(d) Damaged areas in preceding coat have been made good in accordance with Section 8.
4.9 Protection of Surrounding Areas

Surrounding and adjacent areas to the surfaces being painted shall be protected from paint by
all necessary means. Particular attention shall be paid to minimise droplets of paint being
carried by the wind away from the area being painted. Overspray, drips, spills and damage
caused by wind drift of paint droplets shall be removed at the painting Supplier’s or
Contractor’s expense.
4.10 Coating System Selection

The Supplier or Contractor shall not apply any coating systems until approval in writing is
received from the Engineer for the specific system number applicable to the work.
4.11 Reinstatement of Damaged Areas

Prior to completion of the contracted scope of work, the protective coatings shall be inspected
for signs of damage. All damage shall be repaired and protective coatings reinstated to the
satisfaction of the Engineer. Repair methods for each coating system shall be in accordance
with the paint manufacturer’s recommendations.
Damage not only includes mechanical damage sustained in transport, off-loading, storage and
erection, but also damage caused by site welding and bolting.
4.11.1 Painted Surfaces

The treatment shall be:
(a) Pre-clean the damaged and unpainted areas in accordance with Section 3.6.

(b) Remove the damaged coating to reveal a surface free from loose or flaking materials
(c) For small areas, power tool clean or hand tool clean in accordance with AS 1627.2 or
AS 1627.7 to a Class ST3 finish. For large areas, abrasive blast clean the area in
accordance with Section 3.6.
(d) Feather back by sand papering or blasting the coating surrounding the repair site over
a distance of at least 20 mm. When the existing coating is an epoxy or polyurethane,
particular care is to be taken to ensure that a rough surface is obtained
(e) Clean surface to remove all dust
(f) Apply the first layer of coating before contamination occurs or the cleaned metal
surface can discolour and oxidise. Further to this, all surfaces shall be coated within
four hours of cleaning
(g) Apply the coating(s) in accordance with Section 4 of this specification and the
manufacturer’s instructions.
4.11.2 Galvanised Finished Surfaces

For damaged areas larger than 3 mm in diameter, the treatment shall be:
(a) The surface and surrounding area is to be prepared by power tool or hand tool
cleaning in accordance with AS 1627.2 or AS 1627.7 to a surface finish of Class 2. The
area is to be prepared to a minimum of 50 mm back into the sound coating
(b) Apply two coats of organic zinc rich paint conforming to AS 2204 to give a minimum
dry film thickness of 100 microns
(c) The area to be reinstated shall be colour matched to the surrounding surface.
For areas where the damage to the galvanised coating is less than 3 mm in diameter, the
overlayed paint system, where applied, shall be repaired in accordance with section 4.12.1 of
this specification.

5. Galvanising Requirements
5.1 General
All galvanising shall be carried out by the hot dipping process and conform to the
requirements of AS/NZS 4680.
Hot dipped galvanised steel shall not be cold worked or be subjected to hole punching after
galvanising unless otherwise approved by the Company Representative.
5.2 Preparation
The fabricator shall prepare the items for galvanising in accordance with Section 3 of this
Specification.
Vent holes shall be provided in closed sections (RHS and pipe) by the fabricator for safety and
effective galvanising reasons. Where necessary the galvaniser shall, at the fabricator's expense,
drill venting, handling and drainage holes at points agreed by the designer, fabricator and
galvaniser.
The fabricator shall show on his shop drawings all provision for galvanising, including venting,
handling and drain holes. These drawings shall be submitted for approval.
For temporary identification, the fabricator shall use either water soluble marking paints or
detachable metal labels. For permanent identification, figures shall be heavily punched or
embossed by the fabricator.
The fabricator shall not deliver items in an assembled condition requiring breakdown prior to
galvanising.
Items which are to be hot dipped galvanised shall be acid pickled and fluxed before coating in
accordance with the requirements of AS/NZS4680.
After pickling the work shall be inspected, and any defects which will render the work
unsuitable for galvanising shall be repaired.
After such repairs have been executed, the work shall again be cleaned by pickling.
5.3 Dipping Process

The zinc coating mass and adherence shall be in accordance with AS/NZS 4680 and shall be
tested by the methods described in AS 2331.
The material shall be treated at the lowest possible temperature consistent with smoothly
finished work, except where high bath temperatures are required to allow specified surface slip
factors to be met.
After galvanising all material shall be cooled to ambient conditions in such a manner that no
embrittlement occurs.
Excess zinc shall be removed from the threads to facilitate easy running of components when
assembled.

5.4 Appearance
The zinc coating shall be free from lumps, blisters, gritty areas, uncoated spots, acid and black
spots, dross, flux and other surface imperfections. The dry film thickness of the zinc coating
shall be checked in accordance with AS 3894.3.
Any galvanizing shown to be defective by inspection or by any other tests carried out in
accordance with the relevant Australian standards will be cause for rejection. Where the
substrate material is damaged during galvanizing, the damaged section shall be replaced or
made good. localised damage to galvanized steel shall be mechanically prepared to AS 1627.2
St 3 and repaired by coating with a two component zinc rich epoxy coating conforming to
AS/NZS 3750.9 Type 2.
The achieved dry film thickness of the zinc film shall be tested in accordance with AS 3894.3;
test method B for magnetic induction and eddy current methods.
5.4.1 Number of DFT Readings

The Galvanizing applicator shall perform a sufficient number of dry film thickness readings in
such a manner as to ensure a representative account for the DFT compliance of the coated area
inspected. The method as described in AS 3894.3 section 7 “Inspection Plans” shall be used as
a minimum requirement for a thickness testing plan.
5.4.2 Marking Defective Areas

Marking of defective areas shall be made using a marking method or marker ink compatible
with the coating over which it is applied.
5.5 Threaded Fasteners

All nuts, bolts, and washers shall be hot dipped galvanised in accordance with AS 1214 unless
otherwise specified.
All nut threads shall be re-tapped after galvanising and a lubricant applied.
5.6 Inspection
The Company’s representative reserves the right to inspect the works in the galvanising shop
and test it in accordance with AS/NZS 4680 and AS 3894
Any galvanising shown to be defective by inspection or by the tests will be rejected. Any work
so rejected shall be rectified by the Supplier or Contractor, at his own
expense and to the approval of the Engineer. Any component distorted, cracked or otherwise
structurally damaged during galvanising shall be replaced.
5.7 Packing, Storage and Transport

Galvanised items shall be prepared for transport in to avoid the possibility of wet-storage stain
occurring. Cardboard, paper and unseasoned timber shall not be used for packing materials.

6. Handling and Transport
Steelwork shall not be handled until the coating has completely cured or dried hard. Final
coats shall be allowed to dry and cure for a minimum of two days before handling and
transport.
Particular care shall be taken to avoid damage to coatings while being handled and during
transport. Rubber coated or softly padded slings shall be used and soft pads placed under and
between members when they are stacked for storage and transport. Similar measures shall be
taken with the ropes and slings used to secure the steelwork during transport.
Steelwork is to be inspected upon arrival at Site. Particular care shall be taken during
unloading and storage. If, in the Engineer’s opinion, damage to the coating on items is
substantial it shall be fully removed and reinstated at the Supplier’s or Contractor’s expense.
Damaged coatings shall be repaired in accordance with Section 4.12.

7. Post-application requirements
7.1 Inspection and Paintings

All work shall be regularly inspected and tested throughout all stages of cleaning, surface
preparation and coating application. This is done to ensure that each step is in accordance
with the specified requirements and that inspection and testing records are being maintained.
Inspection and testing reports shall be submitted in accordance with Appendix A of the Scope
of Work and Technical Specification.
The procedure associated with each coating system shall in the first instance be carried out in
the presence of the Supplier’s or Contractor’s representative, the applicator, the coating
manufacturer’s representative and the Company Representative. Once these procedures have
been approved, they shall apply until varied in writing by the Company Representative. Work
found to be performed by unapproved procedures shall be rejected.
Primary responsibility for quality control of surface preparation and coating application rests
with the applicator. This will be monitored by independent supplementary inspections by the a
Company appointed representative.
Coating thickness, profile heights and coating adhesion will be measured by using the
following methods.
Wet Film Thickness - AS 1580 Method 107.3
Dry Film Thickness - AS 1580 Method 108.1
Profile Height - Use of Replica Tape (Testex or equivalent) and Surface Comparator
(Keane Tator or equivalent)
Adhesion - AS 1580 Methods 408.1 and 408.2
7.2 Application Records

Written records shall be maintained for all work undertaken so that complete traceability of
work and materials is maintained.
Detailed reports shall be maintained in accordance with AS 3894. Each of the reports
AS3894.10, 11 and 12 shall be completed daily.
As a minimum, these reports should include the following information:
(a) Job identification
(b) Surface preparation performed and equipment and materials used
(c) Coating applied and equipment used including configuration
(d) Materials used including batch number, colour and thinner

(e) Application details including which coat was applied, wet film thickness, dry film
thickness
(f) Weather conditions, including temperature of air and surface during application,
relative humidity, wind conditions and general weather conditions
(g) Names of individuals carrying out each task.
7.3 Guards
Guarding on all equipment shall be painted to highlight its function.
The colour applied to the surfaces shall follow painting systems covered in this Specification.
The Colour coat may be applied as a top coat over the existing finish coat of the machine
taking care to ensure that adequate adhesion occurs. Paint that can be pealed, rubbed or
scratched off shall be deemed to be unsatisfactory and the Supplier or Contractor shall repaint
all affected surfaces to his own account.

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Contents page

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 2 of 24

6. Handling and Transport 22

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 3 of 24

It also defines the requirements for galvanising of fabricated steel items.

ITP Inspection and Test Plan

Substrate Base material over which a protective coating is applied

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 4 of 24

• Queensland Coal Mining Safety & Health Regulations

• Queensland Coal Mining Safety & Health Act

• Workplace Health and Safety Regulation

• Environmental Protection Regulation

2.2 Codes and Standards

AS 1214 Hot dip galvanised coating on threaded fasteners

AS 1580 Paints and related materials - Methods of test

AS 1627 Metal finishing - Preparation and pre-treatment of surfaces

AS 1627.1 Metal Finishing – Preparation and pre-treatment of surfaces – Removal of

AS 1627.4 Abrasive Blast cleaning of steel

AS 1627.7 Hand tool cleaning of metal surfaces

AS 2700 Colour standard for general purposes

AS 3750.9 Paints for steel structures - Organic zinc-rich primer

AS 3894.3 Site testing of protective coatings - Method 3 - Determination of dry film

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 5 of 24

AS 3894.12 Site testing of protective coatings - Inspection report - Coating

AS/NZS 4680 Hot-dip galvanised coatings on fabricated ferrous articles

2.3 Referenced Specifications

2.4 Conflicts in standards

• Queensland Coal Mining Safety and Health Act and Regulations

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 6 of 24

3.1 Environmental Conditions

• Working in confined spaces.

• Safe handling and storage of paints and materials.

3.4 Fabrication Defects

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 7 of 24

Any detergents used shall be non-ionic type.

3.6 Surface Preparation

In addition to, or as part of these recommendations, the following minimum surface

(b) All sharp edges and surface irregularities shall be removed.

• Abrasive blasting air pressure 280 kPa (40 psi) maximum

• Abrasive grade 0.2 - 0.6 mm (GMA Premium or speed blast Garnet)

• Angle of blasting to surface 45º

• Distance of blast nozzle from the galvanized surface 300 - 400 mm

• Blasting nozzle type min 10 mm Venturi type

1 Reference: Galvanizers Association of Australia web site.

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 8 of 24

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 9 of 24

4.3 Coating System

Surface Preparation: Abrasive blast clean to AS 1627.4 Class 2½.

Total DFT 300 micrometers

KME-0000-SP-MD-0003_0 Technical Specification for Painting and Protective Coatings Page 10 of 24

Touch Up Damage: Spot coat to achieve a minimum DFT of 300 micrometers.

4.3.2 Coating System 2

Surface Preparation: Abrasive blast clean to AS 1627.4 Class 2½.

Total DFT 300 micrometers

Colour: Cream Y34

Touch Up Damage: Spot coat to achieve a minimum DFT of 300 micrometers.

4.3.3 Coating System 3

Surface Preparation: Abrasive blast clean to AS 1627.4 Class 2½.

Total DFT 200 micrometers

Colour: Instrument Air – LIGHT BLUE

Touch Up Damage: Spot coat to achieve a minimum DFT of 200 micrometers.

4.3.4 Coating System 4