6731R RESENE PROTECTIVE COATINGS - STEELWORK Masterspec sections must be customised to suit the project being specified, by removing irrelevant information and adding project-specific information and selections. 1. GENERAL This section deals with the preparation and painting of structural and miscellaneous steelwork items using Resene coating systems. Modify or extend the above description to suit the project being specified. For specific technical information call the Resene Technical Helpline 0800 RESENE (0800 737 363) or at www.resene.co.nz. Galvanising, zinc and aluminium/zinc spray finishes are covered in the STEELWORK CORROSION PROTECTION section. Brushing and power tool cleaning, abrasive blasting, priming and patch priming are covered in this section, but also repeated in STRUCTURAL STEELWORK and STEELWORK CORROSION PROTECTION sections for projects where this is the only steel coating work involved. This painting specification is written based on information available at the time of writing. This painting specification assumes that the applicator has the necessary skill, experience and equipment to undertake the work. The applicator remains responsible for ensuring proper completion of the work. If in the applicator’s own expertise and judgement an amendment to this specification is required, or where a substrate preparation or required painting system is not covered in this specification, this shall be brought to the attention of the principal and any amendment agreed before work proceeds any further. Related work 1.1 RELATED SECTIONS Refer to 6711R RESENE PAINTING for painting. Include cross references to other sections where these contain related work. Documents 1.2 DOCUMENTS REFERRED TO Documents referred to in this section are: AS 1627 Metal finishing - Preparation and pretreatment of surfaces, Parts 1-10 AS/NZS ISO 9002 Quality systems - Model for quality assurance in production, installation and servicing OSH Guidelines for the provision of facilities and general safety in the construction industry MPNZA Painters hazards handbook Documents listed above and cited in the clauses that follow are part of this specification. However, this specification takes precedence in the event of it being at variance with the cited document. Delete from the DOCUMENTS clause any document not cited. List any additional cited documents. RELATED DOCUMENTS Refer to the following related documents when preparing this section: NZBC F5/AS1 Construction and demolition hazards AS/NZS 2312 Guide to the protection of structural steel against exterior atmospheric corrosion by the use of protective coatings AS/NZS 3750 Paints for steel structures, 3750.15: Inorganic zinc silicate paint AS 3894 Site testing of protective coatings BS 5493 Protective coating of iron and steel structures against corrosion NZS 7703 The painting of buildings Health and Safety in Employment Act 1992 Dangerous Goods Regulations, Flammable Liquids 1985 New Zealand Painting Contractors Association (Inc): Specification manual BRANZ Bulletin 332: Claddings in corrosive environments 1.3 MANUFACTURER’S DOCUMENTS Manufacturer’s and supplier’s documents relating to work in this section are: Resene One-Line specifications and product data manual (hard copy or at www.resene.co.nz) Resene Putting your safety first Copies of the above literature are available from Resene Telephone: 0800 RESENE (0800 737 363) It is important to ensure that all personnel on site have access to accurate, up to date technical information on the many products, materials and equipment used on a project. In most cases individual products are not used in isolation, but form part of a building process. Also a particular manufacturer’s and/or supplier’s requirements for handling, storage, preparation, installation, finishing and protection of their product can vary from what might be considered the norm. Access to technical information can help overcome this potential problem. Requirements 1.4 NO SUBSTITUTIONS Substitutions are not permitted to any specified Resene system, or associated components and products. 1.5 QUALIFICATIONS Painters to be experienced competent workers, familiar with the materials and the techniques specified. 1.6 CONTROL SAMPLES Prepare samples of the finished work including the preparation as specified in the STRUCTURAL STEELWORK and STEELWORK CORROSION PROTECTION sections. Obtain approval in writing of the appearance before proceeding. Refer to SELECTIONS for requirements. Amend this clause if deleting surface preparation work from this section. Warranties 1.7 WARRANTY Warrant this work under normal conditions of use against failure. Materials: According to 1(v) Resene Promise of quality – expected system life in the Resene One-Line specifications and product data manual Execution: 3 years Refer to the PRELIMINARIES AND GENERAL section for the required form of warranty agreement and details of when completed warranty must be submitted. Check PRELIMINARIES AND GENERAL for the date of commencement of guarantees; which is normally practical completion of the contract. Refer to the chosen conditions of contract as it may also contain information on warranties/guarantees. Performance 1.8 QUALITY ASSURANCE Maintain quality assurance programmes to AS/NZS ISO 9002 for both preparation and painting/coating, as necessary to assure that work is performed in accordance with this specification and the qualifying requirements of the contract documents. 1.9 GENERAL INSPECTIONS Inspection of the work to take place at each of the stages as scheduled. Refer to SELECTIONS. Confirm a written programme to facilitate these inspections, including notification when each stage of the work is ready for inspection. 1.10 MANUFACTURER’S INSPECTIONS Permit the paint manufacturer to inspect the work in progress and to take samples of their products from site as requested. 1.11 HEALTH AND SAFETY Refer to and comply with the requirements of the Health and Safety in Employment Act 1992 including the obligation to: - Eliminate hazards and if hazards cannot be eliminated or isolated, then minimise the hazards in this work by using the proper equipment and techniques as required by the MPNZA Painters hazard handbook and Resene Putting your safety first handbook. - Supply protective clothing and equipment. - Inform the contractor as well as the employees and others on site of those hazards and put in place procedures for dealing with emergencies. Use this clause if the coatings being used have a hazard substance base. 1.12 MATERIAL SAFETY DATA SHEETS Obtain from Resene (phone 0800 RESENE or www.resene.co.nz) the material safety data sheet for each product used and comply with the required safety procedures. Keep sheets on site. Use this clause if specifying coatings with a hazardous substance base. 2. PRODUCTS Materials 2.1 COATING SYSTEMS Refer to SELECTIONS. Use only Resene products which are guaranteed for consistency and performance under ISO 9001 prepared, mixed and applied as directed in the Resene Engineered Coatings Systems Manual. Where additional information on selected materials and finishing products is necessary include it here. Otherwise include all relevant information under SELECTIONS. 2.2 PRIMER Refer to SELECTIONS for type. Check compatibility with top coating systems. 2.3 THINNERS/ADDITIVES Use only if and when expressly directed by Resene for their particular product in a particular application. Accessories 2.4 ACCESSORIES Contact your local Resene ColorShop, if required, for a full range of accessories and usage advice. 3. EXECUTION Conditions 3.1 CONDITIONS FOR PAINTING Coat steelwork in conditions approved for the application of the specified coatings. Carry out off-site preparation and coating application under cover, in a suitable environment, with adequate lighting and with the air temperature between 10°C and 25°C. Ensure prepared and painted surfaces are clean and dry. Do not carry out preparation or painting when the ambient relative humidity exceeds 85%, or when the steel surface temperature is with 3°C of the dew point. 3.2 COATING APPLICATION Apply coatings strictly in accordance with the manufacturer’s stated requirements. Ensure that the manufacturer’s latest product data sheets are available for reference during preparation and painting. 3.3 COMPATIBILITY Ensure that materials are as required by their manufacturers for the particular surface and conditions of exposure, and that materials used within each painting system are compatible with each other and are from the same manufacturer. 3.4 SEQUENCE OF OPERATIONS Complete surface preparation before commencing painting. Apply paint in the specified sequence using the specified paint. Allow full drying time between coats to the manufacturer’s stated requirements. Do not expose primers, undercoats and intermediate coats beyond a few days before applying the next coat. 3.5 DRYING TIME Before handling or applying the next coat of paint, give each coat the required drying time required by the manufacturer. Ensure that surfaces being painted are dry and that ambient conditions are such that condensation does not occur before the paint reaches surface-dry condition. Application - surface preparation 3.6 SURFACE PREPARATION Refer to the Resene One-Line specifications and product data manual for surface preparation sheets (or obtain them by phoning 0800 RESENE or at www.resene.co.nz) listed in the materials systems schedule clauses. Carry out the preparatory work required by them for each of the substrates. 3.7 LEAD-BASED PAINT, ASBESTOS Handle cautiously lead-based paint and asbestos, if present, as outlined in the preamble of the Resene One-Line specifications and product data manual. 3.8 UNPAINTED SURFACES Do not paint: - Faying face of high strength friction grip (HSFG) bolted joints - Areas for site welding keeping 75 mm clear all round - Surfaces for embedding in concrete. Where steel is only partly encased, then extend priming 30 mm maximum into the concrete encasement area. 3.9 BRUSHING AND POWER TOOL CLEANING Remove oil and grease in accordance with AS 1627.1. Water blast to remove salt deposits. Scrape and power wire brush to a minimum class 2 finish to AS 1627.2. Clean to bright metal, but avoid producing a polished surface. Check that no burrs or sharp arrises remain which may prevent full coating thickness being attained. 3.10 ABRASIVE BLASTING Remove oil and grease in accordance with AS 1627.1. Water blast to remove salt deposits. Abrasive blast clean to a class 21/2 finish to AS 1627.4. Clean to bright metal, but avoid producing a polished surface. Select grit type and equipment such that the cleaned surface profile between peaks and valleys does not exceed one third of the dry film thickness. Check that no burrs or sharp arrises remain which may prevent the full coating thickness being attained. 3.11 PREPARING HOT DIP GALVANISED SURFACES Remove grease, oil in accordance with AS 1627.1. Water blast to remove salt deposits. Allow to dry and proceed with the next operation immediately. Carefully whip blast (sweep blast) the surface to provide a slightly roughened surface profile using clean new non-metallic blasting media. Care must be taken to ensure a minimum amount of zinc is removed during this process (no more than 10 microns). Any areas of white corrosion must be totally removed during this process before painting. 3.12 PREPARING ZINC AND ALUMINIUM/ZINC COATINGS Remove grease, oil and other solvent-soluble contaminants in accordance with AS 1627.1. Water blast to remove salt deposits. Allow to dry and proceed with the next operation immediately 3.13 SHOP PRIMING Degrease in accordance with AS 1627.1. Water blast to remove salt deposits. Allow to dry and remove all loose corrosion products by any of the following; wire brushing, power tool cleaning, or abrasive blast cleaning. Dust off and apply a coat of primer within 4 hours of completing surface preparation. Ensure primers are applied to the appropriate surface preparation standard and at the specified dry film thickness. Check the manufacturer’s literature. 3.14 PATCH PRIMING Clean areas of damaged priming and areas left clear for site jointing to a standard comparable with the shop cleaning specified. Wash off chemical deposits from welding fumes. Apply priming coats to same standard as shop primers, ensuring thorough coating of bolts, nuts and connection areas. Reprime if the primer fails, or more than 4 weeks elapse before the final coating system is applied. Consult manufacturer if primer has been left exposed for more than 4 weeks before the final coating system is applied. Application - general 3.15 EACH COAT Each coat of paint and the completed paint system to have the following qualities and properties: - Uniform finish, colour, texture, sheen and hiding power. - The proper number of coats applied, specified dry film thicknesses of each coat are achieved. - Free of defects such as pinholing, alligatoring, blistering, staining, overspray, peeling, runs, sags and wrinkling. Completion 3.16 LEAVE Leave the whole of this work uniform in gloss, texture and colour, free from painting defects, clean and unmarked, and to the standard required by following procedures. 4. SELECTIONS 4.1 CONTROL SAMPLES Manufacturer: ~ Coating system: ~ Nature of sample: ~ 4.2 GENERAL INSPECTIONS Coating system: ~ Nature of sample: ~ 4.3 PRIMER Brand/type: ~ 4.4 SHOP PRIMING Dry film build: ~ microns 75 microns dry film thickness however may vary with primer selection. Mild steel primer only systems (including shop priming) 4.5 INORGANIC ZINC SILICATE System: Inorganic zinc silicate Description: Mild steel primer only Surface prep: Refer to Resene Data Sheet Primer coat: Resene Zincilate 10 RA20 @ 75 microns DFT; or Resene Zincilate 11 RA21 @ 75 microns DFT 4.6 INHIBITIVE EPOXY System: Inhibitive epoxy Description: Mild steel primer only Surface prep: Refer to Resene Data Sheet Primer coat: Resene Armourcote 220 RA34 @ 75 microns DFT 4.7 INHIBITIVE ALKYD System: Inhibitive alkyd Description: Mild steel primer only Surface prep: Refer to Resene Data Sheet Primer coat: Resene Armourcote 210 RA35 @ 75 microns DFT Exterior systems Refer to Resene website Refer to http:/www.resene.co.nz/archspec/datashts/spec22_Mild_Steels_Exterior.pdf Refer to http:/www.resene.co.nz/archspec/datashts/spec23_Galvanised_MildSteel.pdf Refer to http:/www.resene.co.nz/archspec/datashts/spec24_New_Metal_Spray_Coat.pdf 4.8 EXTERIOR MILD STEELS, NEW FERROUS METALS MEDIUM TERM PROTECTION System: Resene Spec. No. 22e 2.1UMT Inorganic zinc, epoxy intermediate, acrylic polyurethane Medium term Description: Exterior mild steel, gloss Surface prep: D801.1, D801.8 or D801.7 1st coat: Resene Zincilate 10 RA20 @ 75 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 125 microns DFT 3rd coat: Resene Uracryl 403 RA56 @ 50 microns DFT 4th coat: Resene Uracryl 403 UVS Clear RA56 @ 50 microns DFT (optional) System: Resene Spec. No. 22e 2.2UMT Inorganic zinc, epoxy intermediate, acrylic polyurethane Medium term Description: Exterior mild steel, semi-gloss Surface prep: D801.1, D801.8 or D801.7 1st coat: Resene Zincilate 10 RA20 @ 75 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 125 microns DFT 3rd coat: Resene Uracryl 402 RA55 @ 50 microns DFT 4th coat: Resene Uracryl 402 UVS Clear RA55 @ 50 microns DFT (optional) System: Resene Spec. No. 22e 2.4UMT Inorganic zinc, epoxy intermediate, acrylic polyurethane Medium term Description: Exterior mild steel, low sheen Surface prep: D801.1, D801.8 or D801.7 1st coat: Resene Zincilate 10 RA20 @ 75 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 125 microns DFT 3rd coat: Resene Uracryl 404 RA59 @ 50 microns DFT 4th coat: Resene Uracryl 404 UVS Clear RA59 @ 50 microns DFT (optional) System: Resene Spec. No. 22e 2.3MFMT Inorganic zinc, epoxy intermediate, metallic finish Medium term Description: Exterior mild steel, metallics Surface prep: D801.1, D801.8 or D801.7 1st coat: Resene Zincilate 10 RA20 @ 75 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 125 microns DFT 3rd coat: Resene Imperite IF 503 Metallic RA81 @ 75 microns DFT 4.9 EXTERIOR MILD STEELS, NEW FERROUS METALS LONG TERM PROTECTION System: Resene Spec. No. 22e 2.1ULT Inorganic zinc, epoxy intermediate, acrylic polyurethane Long term Description: Exterior mild steel, gloss Surface prep: D801.1, D801.8 or D801.7 1st coat: Resene Zincilate 10 RA20 @ 75 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 200 microns DFT 3rd coat: Resene Uracryl 403 RA56 @ 50 microns DFT 4th coat: Resene Uracryl 403 UVS Clear RA56 @ 50 microns DFT (optional) System: Resene Spec. No. 22e 2.2ULT Inorganic zinc, epoxy intermediate, acrylic polyurethane Long term Description: Exterior mild steel, semi-gloss Surface prep: D801.1, D801.8 or D801.7 1st coat: Resene Zincilate 10 RA20 @ 75 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 200 microns DFT 3rd coat: Resene Uracryl 402 RA55 @ 50 microns DFT 4th coat: Resene Uracryl 402 UVS Clear RA55 @ 50 microns DFT (optional) System: Resene Spec. No. 22e 2.4ULT Inorganic zinc, epoxy intermediate, acrylic polyurethane Long term Description: Exterior mild steel, low sheen Surface prep: D801.1, D801.8 or D801.7 1st coat: Resene Zincilate 10 RA20 @ 75 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 200 microns DFT 3rd coat: Resene Uracryl 404 RA59 @ 50 microns DFT 4th coat: Resene Uracryl 404 UVS Clear RA59 @ 50 microns DFT (optional) System: Resene Spec. No. 22e 2.3MFLT Inorganic zinc, epoxy intermediate, metallic finish Long term Description: Exterior mild steel, metallics Surface prep: D801.1, D801.8 or D801.7 1st coat: Resene Zincilate 10 RA20 @ 75 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 200 microns DFT 3rd coat: Resene Imperite 503 Metallic RA81 @ 75 microns DFT Spray 4.10 EXTERIOR NEW HOT DIPPED GALVANISED MILD STEEL LONG TERM PROTECTION System: Resene Spec. No. 23e 2.1ULT Etch primer, epoxy intermediate, acrylic-urethane finish Long term Description: Exterior new hot dipped galvanised mild steel, gloss Surface prep: D89.1, or D89.2 1st coat: Resene Vinyl Etch RA20 @ 12 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 125 microns DFT 3rd coat: Resene Uracryl 403 RA56 @ 50 microns DFT 4th coat: Resene Uracryl 403 UVS Clear RA56 @ 50 microns DFT (optional) System: Resene Spec. No. 23e 2.2ULT Etch primer, epoxy intermediate, acrylic-urethane finish Long term Description: Exterior new hot dipped galvanised mild steel, semi-gloss Surface prep: D89.1, or D89.2 1st coat: Resene Vinyl Etch RA20 @ 12 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 125 microns DFT 3rd coat: Resene Uracryl 402 RA55 @ 50 microns DFT 4th coat: Resene Uracryl 402 UVS Clear RA55 @ 50 microns DFT (optional) System: Resene Spec. No. 23e 2.4ULT Etch primer, epoxy intermediate, acrylic-urethane finish Long term Description: Exterior new hot dipped galvanised mild steel, low sheen Surface prep: D89.1, or D89.2 1st coat: Resene Vinyl Etch RA20 @ 12 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 125 microns DFT 3rd coat: Resene Uracryl 404 RA55 @ 50 microns DFT 4th coat: Resene Uracryl 404 UVS Clear RA55 @ 50 microns DFT (optional) System: Resene Spec. No. 23e 2.3ULT Etch primer, epoxy intermediate, metallic finish Long term Description: Exterior new hot dipped galvanised mild steel, metallic finish Surface prep: D89.1, or D89.2 1st coat: Resene Vinyl Etch RA20 @ 12 microns DFT 2nd coat: Resene Armourcote 510 RA40 @ 125 microns DFT 3rd coat: Resene Imperite IF 503 Metallic RA 81 @ 75 microns DFT 4.11 EXTERIOR NEW METAL SPRAY COATINGS: METAL ARC OR ZINC SPRAY LONG TERM PROTECTION System: Resene Spec. No. 24e 2.1ULT Epoxy primer acrylic urethane Long term Description: Exterior new metal spray coatings, gloss Surface prep: Refer to Resene 24e 1st coat: Resene Armourcote 220 RA34 @ 75 microns DFT 2nd coat: Resene Uracryl 403 RA56 @ 50 microns DFT 3rd coat: Resene Uracryl 403 RA56 @ 50 microns DFT 4th coat: Resene Uracryl 403 UVS Clear RA56 @ 50 microns DFT (optional) System: Resene Spec. No. 24e 2.2ULT Epoxy primer acrylic urethane Long term Description: Exterior new metal spray coatings, semi-gloss Surface prep: Refer to Resene 24e 1st coat: Resene Armourcote 220 RA34 @ 75 microns DFT 2nd coat: Resene Uracryl 402 RA55 @ 50 microns DFT 3rd coat: Resene Uracryl 402 RA55 @ 50 microns DFT 4th coat: Resene Uracryl 402 UVS Clear RA55 @ 50 microns DFT (optional) Interior systems 4.12 INTERIOR MILD STEELS, NEW FERROUS METALS System: Resene Spec. No. 22i 2.1AF Description: Mild steel, interior non-encased, alkyd primer, alkyd gloss Surface prep: D801.1, D801.8, D801.5 or D801.7 1st coat: Resene Armourcote 210 RA35 @ 75 microns DFT 2nd coat: Resene Armourcote 608 RA72 @ 50 microns DFT System: Resene Spec. No. 22i 2.1UF Description: Mild steel, interior non-encased, epoxy primer, acrylic urethane gloss Surface prep: D801.1, D801.8, D801.5 or D801.7 1st coat: Resene Armourcote 220 RA34 @ 50 microns DFT 2nd coat: Resene Uracryl 403 RA56 @ 50 microns DFT 3rd coat: Resene Uracryl 403 RA56 @ 50 microns DFT System: Resene Spec. No. 22i 2.2UF Description: Mild steel, interior non-encased, epoxy primer, acrylic urethane, semi-gloss Surface prep: D801.1, D801.8, D801.5 or D801.7 1st coat: Resene Armourcote 220 RA34 @ 50 microns DFT 2nd coat: Resene Uracryl 402 RA55 @ 50 microns DFT 3rd coat: Resene Uracryl 402 RA55 @ 50 microns DFT System: Resene Spec. No. 22i 2.3AEMF Description: Mild steel, interior non-encased, epoxy primer, acrylic epoxy, satin metallic Surface prep: D801.1, D801.8, D801.5 or D801.7 1st coat: Resene Armourcote 220 RA34 @ 50 microns DFT 2nd coat: Resene Imperite IF 503-Metallic RA81 @ 75 microns DFT 3rd coat: Resene Imperite IF 502 Clear-RA82 @ 50 microns DFT System: Resene Spec. No. 22i 2.4UF Description: Mild steel, interior non-encased, epoxy primer, acrylic urethane, low sheen Surface prep: D801.1, D801.8, D801.5 or D801.7 1st coat: Resene Armourcote 220 RA34 @ 50 microns DFT 2nd coat: Resene Uracryl 404 RA59 @ 50 microns DFT 3rd coat: Resene Uracryl 404 RA59 @ 50 microns DFT System: Resene Spec. No. 22i 2.5AMF Description: Mild steel, interior non-encased, alkyd primer, alkyd MIOX metallic Surface prep: D801.1, D801.8, D801.5 or D801.7 1st coat: Resene Armourcote 210 RA35 @ 75 microns DFT 2nd coat: Resene Mica-Bond RA71 @ 50 microns DFT 3rd coat: Resene Mica-Bond RA71 @ 50 microns DFT Topcoats can be deleted from each system if steel component is fully encased. Specified film builds are best achieved by spray application. Brush/roller application will require additional coats to achieve specified DFT’s. Substitute Imperite IF 503 (see Data Sheet RA81) for Uracryl 403 if an iso-cyanate free gloss topcoat is required. Substitute Super Gloss Enamel (see Data Sheet D32) for Armourcote 608 if brush applied topcoats are required. C:\Documents and Settings\Jed Glasgow\Local Settings\Temporary Internet Files\OLKAE\6731R_masterspec_coatings.doc © CIL MasterSpec® STANDARD 2006 6711R RESENE PROTECTIVE COATINGS - STEELWORK Page Branded specification review for 6731R_MASTERSPEC_COATINGS.DOC Version date 31/08/2007 I have checked this specification thoroughly and have verified its content and technical accuracy. ? It is approved for issue ? It is approved for issue with changes as marked ? Signed:................................................................Date:.......................................