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SECTION WORK INSTRUCTIONS

Q/P PROTECTIVE COATING ON STEEL


MANUAL SPACE FRAME REF QWI -10A
REV 0 DATE 20-02- 16
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1. SCOPE

This document outlines the method of zinc coating and subsequent organic thermoset polyester powder
coating as well as epoxy/polyurethane liquid paint coating on steel space frame components.
1.1 SPACE FRAME & STEEL ITEMS IN THE SCOPE OF POWDER COATING PROCESS

1.1.1 All space frame member pipes diameter up to 8 inch, thickness up to 16mm, length not over
6 meter.

1.1.2 All purlin tubes and purlin accessories size up to 250 x 250 mm, thickness up to 16mm, and
length not exceeding 6 meter.

1.1.3 All steel work up to 6 meter long, width up to 0.6m, height up to 1.2m and thickness up to
16mm.

1.2 SPACE FRAME & STEEL ITEMS IN THE SCOPE OF LIQUID PAINT COATING
PROCESS,

1.2.1 Structural steel sections exceeding diameter 219 mm, all long products of length over 6
m, width above 0.6 m and depth higher than 1.2 m.

1.2.2 Machined spherical Steel nodes, threaded adaptors of diameter 50 mm and over.

1.2.3 Machined and fabricated fixed support nodes of diameter 50 mm and over

1.2.4 Machined and fabricated movable support nodes of diameter 50 mm and over
2. ZINC COATING
2.1 After fabrication all items as in 1.1.2, 1.1.3 and 1.2.1 shall be hot dip galvanized to ASTM
A 123 or equivalent.
2.2 Space frame pipe member as in 1.1.1 are fabricated from pre galvanized components.

2.3 Hot dip galvanizing shall be performed in an approved galvanizing company

2.4 All spherical nodes, fixed support assemblies and any other fabricated threaded parts are
electro galvanized to minimum coating thickness 12 micron to ASTM B 633 to meet the
requirements of corrosion class SC 3, Type 2 coating.

2.5 Movable support node as in item 1.2.4 shall also be electro galvanized leaving the bottom
plate welding.

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2.6 After zinc plating, the Teflon twin pads (for support moving mechanism,) shall be placed in and the
bottom plate weld assembled in welding jig keeping the spherical node upside down.

2.7 Clean weld spatter, slag by wire brushing, chipping etc and perform a cosmetic grinding using angle
grinders fitted with flap disc. Remove the debris by moderate air blasting, then wipe clean using
solvent.

When the surface is dry, spray Prime Zinc cold galvanizing compound using aerosol can to restore
the damaged zinc coating, on bottom plate weld and weld affected zone. See Table 6.1.

3 SURFACE PREPARATION

3.1 Pre - Galvanizing


.
3.1.1 All hot forged spherical steel balls (nodes) are initially abrasive blast cleaned in forging
Manufacturers facility to ISO 8501 SA 2 or SSPC equivalent.

3.1.2 Any heavy deposits of rust shall also be removed by hand tools.

3.1.3 All weld spatters, slag shall be removed by chipping, wire brushing, abrasive sanding or other
suitable means.

3.1.4 All exposed sharp edges and irregularities shall be ground off by angle grinders fitted with /
grinding disc flap disc of suitable grit size.

3.1. 5 Where required and if specified, all steel work surfaces of items as in 1. 2.1 shall be abrasive
blast clean to ISO 8501, SA 2.1/2 or equivalent by the Galvanizer before proceeding with HDG
process.

3.2 Post Galvanizing

3.2.1 After galvanizing, any runs, streaks, drops, excess zinc deposits shall be ground off by angle
grinders with flap wheels 120 grit size or higher.

3.2.2 Care must be taken to ensure that no excessive grinding off the zinc to a level below
the minimum required coating thickness.

3.2.3 Damaged galvanization and low coating areas shall be repaired/ restored by cold galvanizing
method using approved cold galvanizing compounds before releasing the material to respective
protective coating process. See Table 6.1

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4 Chemical Pre Treatment Calcium Modified Zinc Phosphate

After inspection of zinc coating and required surface preparation, all newly galvanized Items in the scope
of powder coating shall be chemical pretreated to coat zinc phosphate to improve the paint adhesion and
corrosion inhibition in following steps by immersion method.
1 Galvanize Etch cleaner
2 Water rinse
3 Degreasing in alkaline cleaner
4 Water Rinse
5 Zinc Phosphate Calcium Modified Zinc
6 Water Rinse
7 Water Rinse
8 Dry off -
Refer Work Instructions.QWI-08B- Pre-treatment on Galvanized Steel for Paint bonding.
Refer also Pretreatment Instructions, QWI-08 and Trouble Shooting Chart, QWI -08D.
Bath make up and solution control, Refer, Henkel (Ashwa) System Product Data Sheets,

5 Electro- Galvanizing
After machining, all spherical nodes, fabricated support assemblies are electro- galvanized.
Before liquid painting in following steps.
1- Degrease in alkaline cleaner
2- Water rinse
3- De rust in acidic solution
4- Water rinse
5- Electro galvanize
6- Water rinse
7- Conversion coating
8- Water rinse
9- Water rinse
10- Dry off

For details refer, Work Instruction- QWI-06, Electro galvanizing of Steel, QWI-06A- Electroplating
Process Control. For Bath make up and solution control, Refer Manufacturers Product Data sheet,
Zinthobrite, CLZ 942/950

Hook marks, wire marks, node holes used for hooking and other inaccessible areas of low coating
thickness shall be cold galvanized using approved cold galvanizing products before releasing the material
to respective protective coating process. See Table 6.1.

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6 Cold Galvanizing
Cold galvanizing to repair/ restore zinc coating, Refer, Prime Zinc Application Procedure.

Galvanizing Repair Inspection / Test Coating Thickness- DFT


6.1 Compound Application Plan
Prime Zinc Fairhill USA Aerosol QPM 4.2.1 25- 40 Micron

7. POWDER COATING
7. 1 Material Preparation
On receipt of job card and materials from fabrication shop, coating supervisor shall draw specified RAL
colour polyester powder from store. Identify on the box with job number near to the suppliers batch number
label.
After QC verification of the issued material, powder is filled in coating equipment tank.
Transfer the powder batch # on job travel card.
If required to use reclaim powder max.10% shall be added to virgin powder before fluidizing in powder
tank.
Ensure the compressor drier and air filters are functional
Fluidize with vigorous air flow using compressed air for one minute at 6 bar air pressure & continue
fluidization with moderate air flow.
For auto guns start up, see page, 4-7 of Encore LT Automatic, Part 1107712-01
Load articles on powder coating conveyer with required spacing between them.
Check damages on zinc coating and restore the damages (if any) on galvanizing before pre heating by cold
galvanizing using Prime Zinc Aerosol spray or approved equal product.

7.2 Pre heating

Galvanized steel articles are hooked on conveyer after zinc phosphating /galvanizing repair are on their
way to the coating application are then preheated to dry off any moisture remaining from previous cleaning
or conditioning stages.

Also pre heating is required to degassing galvanized steel to eliminate the entrapped gases in the steel
material during hot dipping and steel making process, which can cause excessive porosity on coating.
Run for pre heating in the oven, at temperature setting 210- 220 deg C for minimum7 minutes and residence
time of articles inside the oven shall not be less than 30 minutes. Refer clause 8.4, of BS 6497.

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7.3 Cleaning

When the pre heated articles are on their way to powder spraying booth, clean the metal surface by

a) Light sanding the steel articles on conveyor by emery 100 grit size or above, while conveyor
running.
b) Wipe clean by clean & dry cloth,
c) Moderate air blast cleaning.

Before the articles entering the spraying booth, plug all threaded parts and properly mask all portions which
are not required to receive coating.

7.4 Powder Application


All auto/ manual powder spray gun applicators shall be suitably trained and certified by coating
equipment supplier.

Start Auto / Manual Spray guns & apply specified RAL /NCS colour Polyester Powder to obtain DFT 60-
90 microns over galvanization,

Refer. Nordson Manuals, Part 237421G04 for manual spray guns & for Auto start up see page, 4-7 of
Encore LT Automatic, Part 1107712-01,
Polyester powder is thus electro statically applied to parts as charged particles.

The articles to be powder coated are grounded and the powder is charged, this attracts the powder to the
part. The charge holds the powder to the part and the part is then cured in the oven.
For trouble shooting manual spray guns see section 6 of Sure Coat Manual, page 6-1 to 6-5, Part
237421G04.

For trouble shooting auto guns, Refer section 5 of Encore LT Automatic manual page 5-1 to 5-4. Part
1107712-01.
7.5 Post heating (Powder Curing)

The metal parts holding powder particles is run in oven for curing powder on substrate at 200 deg C
metal temperature for a minimum period of 10 minutes,.

Refer. Powder Paint data sheet Alwan PR 29. And for conveyor setting. Refer QWI 9A.

The typical cure cycle for thermosetting polyester is 10 minutes at 200 degree Celsius metal temperature
irrespective of the size and shape of the parts in coating.

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Cure cycles always refer to the amount of time the part is at the temperature specified, not how long it is
in the oven. Therefore the hot air circulation inside the oven is carefully controlled by temperature setting
210 220 degree Celsius for the polyester.

The heat input in oven transferred to metal are consumed by polyester to gel , melt, flow and cure the
powder to form the firm, durable coating film on metal surface.

The curing oven shall be validated at least once in a month and the temperature time curve of oven for
various thicknesses shall be understood. .

After completion of curing and the articles reach the unloading area, the coated articles shall be carefully
unloaded to delivery pallet/box suitably protected to minimize scratches.

Check & if required, touch up hook marks, damaged spots/abraded portions using same RAL color
compatible paint.

On completion of unloading of full quantities in designated pallets as in Job card, protect the coated
articles using plastic sheet or other suitable means.

Identify the pallet using label indicating Waiting for Inspection.

Fill in job card, laminate & attach the job card copy to respective pallet / box.

Excess Powder (if any) shall be transferred to same batch number box of the supplier.

Tape the box cover and identify on Box Issued Material or Excess and return to store .

Add prefix OS to the same part number and re book the excess powder in stock computer records.

Do not reclaim powder from manual booth when different colours are sprayed in a week.

Reclaim shall be collected from automatic booth reclaim tanks and stored in the same batch number box,
duly identified as Reclaim, date of reclaim etc.

Reclaim powder & Excess powder shall be stored in the same condition as recommended by the powder
manufacturer.

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7.6 Powder Coating Inspection

7.6.1 In Process Inspection

In process Inspection shall be performed on representative panel/ pipe processed along with each job &
at any change of setup. Color, Impacts, coating thickness, cure and adhesion, porosity shall be tested.
Ref .QPM 4.2.1, QPM 4.10.1, M/S Jotun Corro-coat Powder Coating Manual & BS 6497.

7.6.2 Final Inspection

All final inspections shall be performed inside the coating shop drawing random samples of each
item/type from the delivery pallet/ box, Ref QPM 4.2.1, QPM 4.10.2, BS 6497.

7.7 Non Conforming Parts

Non conforming products during coating inspection shall be moved to non conforming parts area duly
identified. NCN shall be raised for correction & subsequent corrective action. Refer - QPM 4.13
7.8 Powder Coating Repair

If not possible to correct the defects noted , then the coating shall be stripped using powder coating
stripping compounds and the entire surface cleaned from the stripping chemicals , washed , emery sanded
and wipe clean by cloth and reprocess according to clause 4 , 6 & 7.1, 7.2 & 7.3 as applicable.
If found that the powder is under baked, the article shall be re hang on conveyer, after sanding off few
microns of the under baked coating and run for preheat.
Turn the gun voltage down; re spray a thin coat of fresh powder while hot and re run in the oven for
needed curing at a conveyor speed setting indicated for the next bigger/thicker size article.
The articles thus coated shall be inspected and accepted based on passing coating tests done on good
number of samples drawn from the reworked lot.

For powder coat repair guidance Refer- QUALICOAT Guide to the Repair of Powder coated
Architectural Products

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7. 9 Packaging & Delivery: Refer, QPM 4.15.2

7.10 General Powder Coatings Health and Safety Points:

Operators of manual electrostatic guns must be grounded.

If powder does get on the skin, it should be washed off at the earliest convenient time and at least
by the end of the day.

Some workers may show skin reactions to powder. These individuals must be especially careful
to wash frequently.

7.10.1 Extinguishing Media:

Use carbon dioxide, dry chemical or foam,

Ensure sufficient cylinders are available inside the coating shop.

7.10.2 Skin and Eye Contact

Potential skin irritant may dry out skin.

Sensitive individuals should use a barrier lotion and avoid prolonged skin contact.

Eye contact may be abrasive; therefore contact lens use is not recommended or use of safety goggles.

7.10.3 Steps to be taken in case material is spilled

Wear appropriate protective clothing and respirator to prevent over exposure.

Sweep up material taking care not to generate airborne dust.

Collect into closable containers for proper disposal.

7.10.4 Precautions to be taken in Handling and Storage:

Protect containers from physical damage.

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8. LIQUID PAINT COATING


8.1 PRE COAT INSTRUCTIONS
a) All paint applicators shall be properly trained and certified to the respective coating system by the
.coating material manufacturer or approved authority.

b) Paint shall be applied by means and to the film thickness indicated in the approved painting system.
Schedules and data sheets.

c) The method of application shall be specified in the painting system schedules and data sheets.

d) 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, and sags.

e) All node holes shall be suitably plugged during preparation of materials

f) Margins adjacent to the field welds shall be taped off and left unpainted.

g) All painting materials shall be stored in accordance with the manufacturers recommendations and
shall be brought to the point of application in original sealed cans as delivered in labeled containers.

h) The labels shall be legible at the time of application and may include:

Brand Name/Name of Manufacturer

APCS Number / Saudi Armco Stock number etc

Colour, Manufacturers Application Instruction

Expiry Date

i) Colour for top coat shall be selected as per customer requirement from RAL colour specification or
National Colour Scheme subject to availability.

j) Unless otherwise specified semi-gloss paint shall be applied for top coat.

k) Alkyd based paint products shall not be applied on galvanized steel surfaces.

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8.2 Pre heating of Nodes and Support Nodes

Hang the nodes by hooking on to the conveyor keeping enough spacing between articles and run in
powder curing oven above 200 C.

Conveyor may be run in 2 meter per minute.

Unload the nodes carefully after preheating in steel cages and move to liquid paint coating area.
.
8.3 Material Preparation

Hang the Nodes on the jigs with sufficient spacing between them.

If required emery sanding & wipe clean.

Air blast cleaning.

Plug all threaded holes on Nodes.

Move the prepared jigs to closed paint spraying area.

Identify the prepared Jig by marking or tagging by Job number.

8.4 Conditions of Application

Coating Inspector is responsible for ensuring the correct application conditions prior to
Commencement and during coating.

No application shall be made if one or more of the following conditions are likely to exist at the time
of application.

Rain /Sand Strom, wind borne dusty atmosphere.

Relative humidity above 85% or the surface temperature of the steel surface is less than 5 degree.
Celsius above the dew point

Ambient temperature is outside the range of 10 50 degree Celsius.

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8.5 Paint Application

8.5.1 Paint Mixing

Refer appropriate paint data sheet for mixing information for primer, intermediate coat and top coat
See AS/TSF work instructions QWI 10/PM, QWI -10/MM, QWI -10/TM as applicable.

8.5.2 Conventional Air Spray

The paint shall be sprayed in closed spraying areas suitably ventilated.

The pressure on the material in the pot and of air at the spray gun shall be adjusted for optimum spraying effectiveness.
When spraying first coat/ intermediate coat, apply in multiple cross spray pattern to achieve the maximum film
thickness required. The pressure gauge shall be set in the range specified in the coating material data sheet.

The pressure on the material in the pot shall be adjusted when necessary for changes in elevation of the gun above
pot. The air pressure at the gun shall be high enough to properly atomize the paint but not too high as to cause excessive
fogging of paint, excessive evaporation of solvent or loss of paint by over - spraying

Table 8.6 Paint Schedule

8.6.1 Paint Products and Manufacturer- International Paints REF: SAES 101 V - APCS 26T

Coating Thickness
Application Inspection / Microns
Coating Coating Product
Method Test Plan DFT
WFT range
Min Max
Airless
Interseal 738 Spray/Brush
1 Ist Coat
(See Page 2 of 300- 375 250 300
Colour Aluminium TDS Interseal
738) QPM 4.2.1
Interthane 990
Air less Spray/Air
2 Spray (See Page
Top Coat Colour wide range 88 -132 50 75
2 of TDS
via the Chromascan
Interthane 990)
System.
TOTAL
DFT
300 375

TDS Technical Data Sheet

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8.7 Thicknesses of Coatings

The minimum coating thickness shall be in accordance with each painting system adopted and the
maximum thickness in any one application will not exceed to that recommended by the paint
manufacturer or as specified. Refer Table 8.6.1

8.7.1 Wet Film Thicknesses (WFT)

The wet film thickness of each coat and the amount of thinners used in application shall be in accordance
to manufacturer's specification and recommendation.

Painters are issued with proper wet film thickness gauges and shall be used for frequent checks on applied
wet film.

WFT shall be monitored during application so that the final appropriate DFT is obtained using the
following equations.

DFT = WFT x Volume solids value in fraction.

WFT= DFT/ Volume solids value in fraction.

Example If volume solid in the coating material is 60 percent, and to get the DFT 40 microns the WFT
shall be calculated as 40/0.6 = 66.67 microns.

8.8 Multiple Coat Application

Where more than one coating is specified each coating shall be tinted differently from the others by
coating supplier so that missed areas will be visually apparent.

8.9 Preparation of Surfaces between Coats

Immediately before each coating after the first (except those prescribed by the manufacturer as wet on
wet) the surface shall be examined to determine its need for cleaning to accept subsequent coats.

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8.10 Timing of Coatings

Except for coatings designated by the manufacturers as wet on wet, coatings shall be applied only under
the following conditions:-

The surface has been cleaned and dried

The manufacturer's specified minimum time for recoat has reached.

The manufacturer's specified maximum time for recoat has not been elapsed.

Damaged areas in the previous coat have been made good or repaired.

8.11 Coating Inspections

8.11.1 Coating Inspector Qualifications.

Coating Inspector shall be qualified and certified to NACE CIP Level 2.

8.11.2 Inspection Measuring &Test Equipments (IM & TE)

IM & TE for coating shall be periodically calibrated for accurate measurement and records of calibration
shall be maintained.

The coating inspector shall ensure the availability of following documents before
Commencement of any coating work.

a) Project coating specifications (if any).

b) All applicable codes and standards related to the coating work.

c). Coating Manufacturers Product Data Sheets (PDS) and Material Safety Data Sheets.

d). Manufacturers application guidance

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8.13 Inspection & Test


The coating inspector shall perform the following Inspection and test as required and record as appropriate
in coating inspection report.

a) Surface temperature / dew point, relative humidity etc- Elcometer 319/2 (Hygrometer)
b) Relative Humidity Sling Psychrometer with psychometric table

c) Verification of Wet Film Thickness Using Wet comb Gauges.

d) Dry film thickness DFT are tested by digital Elcometer 456.

e) Adhesion Test by Cross Hatch Tool.

f) Pin Hole Detection by Pin Hole Detector /Holiday Detector.


g) Colour Matching (Top coat) - Visual RAL colour Card/ Approved colour Panel.

9 Packaging & Delivery


On completion of all coating works and related in process inspections,
a) All spherical nodes are individually wrapped and packed in boxes.

b) Support nodes are packed in steel boxes or on pallets as appropriate.

c) Space Frame pipe members, purlin tubes are packed in steel pallets firmly strapped.

d) All coated materials shall be suitably wrapped to protect against dust.

e) The quantity in each box is checked against to match the quantity in job card/ packing list.

f) Laminate the copy of Job card/packing list and attach to the pallet / box.

g) The box/ pallet labeled to indicate status as for Final Inspection.

Applicator then signs the original job card and packing list and pass to Finishing Supervisor.

Supervisor shall enter the used coating materials batch numbers on the job card.

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9.1. Final Quantity Check

All packed materials, boxes and pallets are verified by the Finishing Supervisor against project bill of
materials and sign the original job travel card / packing list for completion and forward to QA/QC to
begin final Inspection.

9.2. Final Inspection

Upon completion of final inspection as in Test / Inspection plans, QA /QC shall prepare Final Inspection
&Test Record (FITR) and record the report (FITR) number and result of inspection on the job card.

The Job travel sheet/ packing list is signed by the concerned Inspector and return to Dispatch via
Finishing Supervisor for delivery of materials to installation site. Refer QPM 4.15.2

After dispatch, dispatch supervisor shall forward all original Job cards, packing lists, shop drawings to
Production Manager for storage and preservation of Records.

Refer - QPM 4.16, Record Control.

10. Non Conformances

Refer, QPM 4.13

11. Bibliography

1- Phosphating and metal pre- treatment - A guide to modern processes and practices - D. B .Freeman
2- Jotun Powder Coating Manual - Jotun Corro- coat Norway

3- The Coating Inspectors Handbook -Tom Swan - M-TEST, East #4 Humble, TX 77 338

4- Painting Over Hot Dip Galvanized Steel Thomas J Langill Phd- Technical Director
American Galvanizers Association,

5- Painting Manual For Refinery & Marketing Terminal Central Electrochemical Research Institute Karaikudi
630006, India (2007)

6- Industrial Painting & Coating Kansas Small Business Environmental Assistance Programme

7- Preparing Hot-Dip Galvanized Steel Surfaces For Painting Or Powder Coating: By Kimberlie J. Dunham, M.S.

8- Electroplating Engineering Hand Book- FOURTH EDITION, EDITED BY Lawrence J Durney.

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