SPECIFICATION FOR PAINTING OF STRUCTURAL STEEL

1.0 SURFACE PREPARATION OF STEEL

One or more of the following methods of surface preparation shall be followed,
depending on condition of steel surface. COMPANY reserve the right to instruct
the type of surface preparation depending upon the condition of material.
Recommended methods of surface preparation of steel briefly are as under.
a) Solvent Cleaning.
b) Manual or hand tool cleaning.
c) Mechanical or power tool cleaning.
d) Abrasive Blast cleaning (Shot blasting SA 2.5).
It is necessary that the CONTRACTOR shall have to resort to any one or
combination of the above method of surface preparation to achieve the
required acceptable standard.
1.1 SOLVENT CLEANING
All contaminants like oil, grease removal shall be carried out either by special
solvents or by degreasing agents. Application and cleaning of solvents shall be
as per manufacturer’s instructions and shall be in accordance with SSPC- SP1.
1.2 MANUAL OR HAND TOOL CLEANING
This method of cleaning shall be used to remove all loose mill scale, loose rust,
loose paint and other loose detrimental foreign matter by use of non- powered
hand tools. The minimum acceptable standards in case of manual or hand tool
cleaning shall be in accordance with ISO 8501- St2 / SSPC-SP2.
1.3 MECHANICAL OR POWER TOOL CLEANING
This method of cleaning shall be used to remove all mill scale, rust, paint and
other detrimental foreign matter by use of power assisted hand tools. The
minimum acceptable standards in case of power tool cleaning shall be in
accordance with ISO 8501- St3 / SSPC-SP3.
1.4 ABRASIVE BLAST CLEANING (SHOT BLASTING / GRIT BLASTING)
1.4.1 Shot / Grit blasting shall be resorted to only after removal of grease, oil and
other contaminants as per SP-1. Special care shall be taken on weld areas to
remove flux and spatter. Precautions shall be taken when grit or shot blasting
of light gauge steel surfaces, to ensure that buckling does not occur due to
continuous impingement of grit or steel shots under high velocity. Surface
anchor profiles shall be measured by Testex tape – press-o-film and the
finished surfaces shall conform to the requirements of ISO 8501- Sa 2½ / SSPC-
SP10.
1.4.2 Blast cleaning shall not be performed where dust can contaminate surfaces
undergoing such cleaning or during humid weather conditions having humidity
exceeding 85%.
1.5 TESTS ON SURFACE PREPARATIONS
The following inspection and tests shall be performed on the steel surfaces
subjected to surface preparation. Test / inspection reports shall be submitted
to COMPANY for his approval and acceptance.
a) Visual examination of surface preparation with comparators.
b) Profile check of the prepared surface with suitable “profilometer“ eg.
TESTEX method.
2.0 PAINT MATERIAL
2.1 PROCUREMENT
All types of paints required for the work shall be procured from the reputed
manufacturers. Contractor shall refer the detailed list of approved paint
manufacturers before initiating the procurement action.
2.2 STORAGE
The Paint material shall be stored strictly in accordance with the instructions of
the paint manufacturer. In general painting materials should be stored in dry,
cool, well ventilated and frost free area.
2.3 PACKING
All paints delivered to the fabrication shop / site shall be in original sealed
container, as packed by the manufacturer. Paint containers shall clearly mark
with paint manufacturer’s name, batch number, date of manufacture, shelf life
and a clear indication of the type and colour of the product.
2.4 MIXING
Paint shall be thoroughly mixed prior to application. Mixing shall be done in a
well-ventilated, clean and dust -free area. Paint shall be mixed by rotating
power mixers or rolling rigs, until a uniform consistency is achieved.
Multiple pack paint materials shall be mixed in accordance with and under the
conditions as specified by the paint manufacturer. Pot life as specified by the
paint manufacturer shall be strictly followed.
2.5 THINNER AND SOLVENTS
Only additives, thinners, solvent etc as recommended by the paint
manufacturer shall be used. A possible extension of the “pot life” by addition of
thinners is prohibited.
2.6 TESTS ON PAINT
In order to ensure that the supplied paint meets the stipulations, samples of
paint shall be tested in laboratories to establish quality of paint with respect to
a) Viscosity.
b) Adhesion/ bond of paint in steel surfaces.
c) Adhesion / simulated salt spray test.
d) Chemical analysis (percentage of solids by weight)
e) Normal wear resistance as encountered during handling & erection
f) Resistance against exposure to acid fumes etc.
Alternatively manufacturer’s test certificates shall be furnished by the Painting
CONTRACTOR in respect of above tests for COMPANY’s approval and
acceptance. COMPANY reserves the right to test the paint material either before
the commencement of work or during the progress of work if in his opinion the
paints supplied are of inferior quality and does not meet the ASTM
requirements.
2.7 PAINT SAMPLE
Before buying the paint in bulk, it is recommended to obtain sample of paint
and establish “Control Area of Painting”. On control area surface preparation,
painting shall be carried out in the presence of COMPANY and the Manufacturer
of paint.
2.8 FINISHING PAINT
Colour /Shade of the finishing paint shall be as per the choice of the COMPANY
and Contractor shall obtain prior approval before procurement action is
initiated.

3.0 PAINT APPLICATION

Painting shall be carried out by any one or the combination of the following
method of application to suit the site condition and the type of paint being
used. Manufacturer’s recommended method of application shall be strictly
followed.
a) Brush Application.
b) Roller Application.
c) Spray Application.
3.1 BRUSH APPLICATION
Brush application of paint shall be in accordance with the following.
 a) Brushes shall be of a style and quality that will enable proper application of
paint
b) Round, Oval or Wide flat brushes shall be used depending upon the surface
irregularity, rough or pitted steel, large flat painting areas etc
c) There shall be a minimum of brush marks left in the applied paint.
d) Surfaces not accessible to brushes shall be painted by spray.
3.2 ROLLER APPLICATION
Suitable rollers of different nap length to suit varying surface roughness shall
be used. Rollers are not generally recommended for application of primers.
Roller application shall only be used if the first or priming coat of paint has
been applied by brush or other means. Manufacturer’s recommendation shall
be strictly followed for roller applied paints.
3.3 SPRAY APPLICATION
3.3.1 Airless or pneumatic spray application shall be in accordance with the
following
a) Airless spray application shall be as per steel structure paint Manual Vol 1 &
Vol 2 SSPC, USA.
b) Spraying shall be carried out keeping the spray gun at the minimum suitable
distance from the work piece and consistently at 90 0 to the surface being
painted.
c) Correct spray tips, air pressures etc as recommended by the equipment
supplier shall be adopted.
3.3.2 Air spray application shall be in accordance with the following:
a) The equipment used shall be suitable for the intended purpose, shall be
capable of properly atomizing the paint to be applied, and shall be equipped
with suitable pressure regulators and gauges.
b) Appropriate pressure and nozzles shall be those recommended by the
manufacturer of the equipment for the material being sprayed. The
equipment shall be kept in satisfactory condition to permit proper paint
application.
c) Correct combination of air volume, air pressure and fluid flow to give good
atomization shall be ensured to get a defect free painted surface.
d) Traps or separators shall be provided to remove oil and condensed water
from the air. These traps or separators must be of adequate size and
must be drained periodically during operations. The air from the spray gun
impinging against the surface shall show no condensed water or oil.
e) Ingredients shall be kept properly mixed in the spray pots or containers
during application by continuous mechanical agitation.
 f) Spray equipment shall be kept sufficiently clean so that dirt, dried paint
and other foreign materials are not deposited in the paint film. Any solvents
left in the equipment shall be completely removed before applying paint to
the surface being painted.
g) Selection of type of spray application shall depend upon the type of paint
coating being used. At all the time paint manufacturer’s recommendation
shall be strictly followed.
4.0 COATING PROCEDURE
4.1 COMPATIBILITY
General Compatibility between primer, intermediate and top coats, as
applicable for individual painting system shall be established through the paint
manufacturer supplying the paints. Primer and finishing paint for the entire
project shall preferably be procured from the same manufacturer. Mixing of
material from different manufacturers is strictly prohibited
4.2 Surface shall not be coated in rain, wind, when steel surface temperature is less
than 50 C, or when the relative humidity is greater than 85%.
4.3 Applied paint system shall be allowed to cure at ambient and surface
temperatures between 10 ° C and 60 ° C with relative humidity below 85%. All
paint shall be air curing.
4.4 A suitable test area (approx 0.5 m2) shall be painted with agreed paint system.
The test area shall be fully coated with all coats of the agreed coating system
using the tools and equipment to be used for the actual coating work.
The painted test area shall be maintained for the duration of the project.
Painting on test piece shall be carried out such that all the coats shall be made
visible for reference at all time.
4.5 Structural steel shall be preferably prime coated at shop and subsequent finish
coats shall be carried out at site after the alignment and erection is complete.
Portions of structural steel members to be embedded into the concrete shall
not be painted.
4.6 Surfaces inaccessible after assembly shall receive two coats of primer prior to
assembly.
4.7 Surfaces inaccessible after erection, including top surfaces of floor beams
supporting grating / chequered plate /RC Slabs shall receive one additional
coat of finish paint over and above the number of coats specified prior to
erection.
4.8 Each coat of paint material shall be applied as continuous film uniform
thickness free of pores. Any spot or areas missed in application shall be
recoated and permitted to dry before the next coat is applied. Applied paint
should have the desired wet film thickness.
4.9 Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an
additional coat can be applied without development of any detrimental film
irregularities, such as lifting or loss of adhesion of the under coat.
Manufacturer’s instruction shall be strictly followed for inter coat intervals.
4.10 No paint shall be force dried under conditions which will cause checking,
wrinkling, blistering formation of pores or detrimentally affect the condition of
the paint.
4.11 No drier shall be added to paint on the job unless specifically called for in the
manufacturer's specification for the paint.
4.12 Paint shall be protected from rain, condensation, contamination, snow and
freezing until dried to the fullest extent practicable.
4.13 Blast cleaned surface shall be coated with one coat of primer before surface
degradation occurs but in no case later than 3hrs. Irrespective of the method of
surface preparation, the first coat of primer shall be applied not later than 2-3
hours after preparation and on dry surface.
4.14 When the successive coat of the same colour is specified, alternate coat shall be
tinted as far as practicable; sufficient to produce enough contrast to indicate
complete coverage of the surface. The tinting material shall be compatible with
the material and not detrimental to its service life.
4.15 All field welded areas on shop painted item shall be mechanically cleaned
(including the weld area proper, adjacent areas contaminated by weld spatter
or fumes and areas where existing primer, intermediate / finishing paint is
burnt). Subsequently, new primer and finishing coats of paint shall be applied
as per painting specification.
4.16 Care shall be taken to protect adjacent equipment, piping, structures etc., from
spillage and spatter during field painting by use of adequate temporary covers.
If surfaces are accidentally spattered or sprayed, the paint shall be immediately
and thoroughly removed. For cleaning of spillages an inert absorbent material
shall be used
5.0 PAINTING SYSTEM
5.1 The recommended painting system of all Structural Steel Works covering
surface preparation, application of one coat of epoxy primer of
minimum75micron and two coats of epoxy paint 150microns each after
fabrication and touch-up if required after erection.
6.0 REPAIR OF COATED SURFACE
6.1 Wherever shop primer painting is scratched, abraded or damaged, the surfaces
shall be thoroughly cleaned using emery paper and power driven wire brush
 wherever warranted, and touched up with corresponding primer. Touching up
paint shall be matched and blended to eliminate conspicuous marks.
6.2 If more than 30% area of the painted surface of an item requires repair, the
entire surface shall be repainted. In such an event no extra payment will be
permitted.
7.0 TEST ON PAINTING SYSTEM
Following inspection and tests shall be performed during and after the
application of paint system.
a) Wet film thickness (WFT) spot checks shall be carried out during painting
operation to ensure that film thickness is being maintained.
b) Dry film thickness (DFT) check of intermediate and final coating layers in
accordance with the specification and /or paint manufacturer’s
recommendation.
c) Quality of adhesion between the coating system and the steel substrate and
of the adhesion between the coatings layers shall not be less than those
specified in the Codes / Standards.
d) Porosity Check: Holiday detection test shall be carried out and all
indications shall be repaired as per approved repair procedures.
8.0 FINAL INSPECTION
8.1 As part of the Quality Assurance, a final inspection in the presence of the
representatives of COMPANY and CONTRACTOR shall be conducted prior to the
final acceptance of the paintwork. Part of this final inspection checks shall be
a. Visual check of the appearance
b. Checks on DFT’s of the total applied coating system

c. Shade verification

d. Holiday Testing.

e. Scratch Test

f. Adhesion test.
8.2 As part of acceptance procedure, a report shall be prepared that shall include:
a) General:
 Names of the Painting Contractor and the responsible personal
 Scope of work
 Dates when the work was carried out.
 Copy of the work and quality plan
 Deviations from this Specification and/or the quality plan.

b) Inspection equipment
  Type and calibration of instruments used.

c) Surface Preparation
 Condition of surface before preparation
 Checks on the requirements as specified for cleaned surface.

d) Coating application
 Information on coating systems being applied (i.e. product names, DFT’s)
 Checks on requirements as specified for coating application
 Check on dry film thicknesses of the total coating system applied

e) Conditions
 Checks on humidity, dew point and substrate temperature.
f) Inspection reports
 Copy of the inspection reports of the Contractor
 Inspection from an independent third party
9.0 DOCUMENTATION
Contractor shall keep records and furnish the following documents to the
COMPANY
a) A written quality plan with procedure for qualification trials and for the
actual work.
b) Daily progress report with details of weather conditions, particular of
applications, number of coats and type of material applied, anomalies,
progress of work versus program.
c) Results of measurement of temperatures, relative humidity, surface profile,
film thickness, holiday detection, adhesion tests with signature of
appropriate authority.
d) Particulars of surface preparation and paint application during trials and
during the work.
e) Details of non-compliance, rejects and repairs.

f) Type of testing equipment and calibration.

g) Code and batch numbers of paint materials used including shelf life.
h) Visual examination of surface preparation compared with the standards.
i) Profile check of the prepared surface with suitable “profilometer.
j) Dry film thickness check of intermediate and final coating layers, in
accordance with the specification and/or paint manufacturer’s
recommendation
k) Checks/ tests carried out as per clauses above.
10.0 GUARANTEE
10.1 The paint system shall provide sufficient protection of the underlying steel
surface against the attack of the environment, other than mechanical damage,
chemical spillage as result of operational activities or other unusual
occurrences from the outside caused by others.
10.2 The CONTRACTOR is fully responsible for the quality of the work and for all
related QA/QC activities as indicated in the specification.
10.3 The CONTRACTOR shall guarantee quality of their coating works for the period
specified in Data Sheet-B and for the coating condition as specified below.
10.3.1 The guarantee period starts from the date of acceptance of CONTRACTOR’s
paint work.
10.3.2 Initial acceptance of any new coating work by COMPANY will not release the
CONTRACTOR of his obligation under this section until final inspection has
been carried out and acceptance of the completed work has been agreed in
writing.
10.3.3 These guarantee clauses regarding coating specifications are prevailing and
supersede the warrantee requirements in General Conditions of Contract.
11.0 EXCLUSIONS
11.1 This specification excludes paintings of the following structures /equipment.
Mechanical & electrical equipment and parts.
a) Buried & Overhead piping works

b) Storage tanks

c) Insulated parts

d) Any other items of work specifically excluded in the scope of works.

END