nadi and suva roads upgrade project · pdf filebox culvert sewer realignment specification....

NADI AND SUVA ROADS UPGRADE PROJECT

(NASRUP)

CONSTRUCTION OF Nadi N1: SECTIONS 1D Triple

Box Culvert Sewer Realignment Specification

Contents1 General............................................................................................................................................3

1.1 Scope of this Specification ......................................................................................................3

1.2 Applicable Codes and Standards.............................................................................................3

1.3 Definitions...............................................................................................................................3

2 Materials .........................................................................................................................................4

2.1 Steel Pipe ................................................................................................................................4

2.2 Fittings, Joints and Couplings for Principal Mains...................................................................4

2.3 Pressure Classes ......................................................................................................................5

2.4 Concrete..................................................................................................................................5

2.5 Storage of Materials................................................................................................................5

2.6 Defective Materials.................................................................................................................5

3 Execution.........................................................................................................................................5

3.1 Handling and Placing...............................................................................................................5

3.1.1 Laying and Installation of Pipes...........................................................................................5

3.1.2 Cutting of Pipes ...................................................................................................................6

3.1.3 Jointing of Steel Pipes .........................................................................................................6

3.1.4 Thrust Blocks and Anchorage..............................................................................................7

3.2 Tolerances...............................................................................................................................7

3.3 Inspection and Testing ............................................................................................................7

3.3.1 Pressure Testing of Pipelines ..............................................................................................7

3.3.2 Joint Inspection and Testing (Steel Pipes)...........................................................................7

4 Project Specification ...................................................................................................................8

4.1 General....................................................................................................................................8

4.2 Materials .................................................................................................................................8

4.3 Corrosion Protection...............................................................................................................9

4.3.1 General................................................................................................................................9

4.3.2 Qualifications ......................................................................................................................9

4.3.3 Equipment...........................................................................................................................9

4.3.4 Inspections ........................................................................................................................10

4.3.5 Preliminary surface preparation .......................................................................................10

4.3.6 Mixing and Thinning of Products ......................................................................................11

4.3.7 General Coating Application .............................................................................................11

4.3.8 Application of Coating at Pipe Ends ..................................................................................12

4.3.9 Quality Checks...................................................................................................................12

4.3.10 Field touch up painting .....................................................................................................12

ATTACHMENT A - ALTEX SPECIFICATION..............................................................................................14

ATTACHMENT B - PAINT INSPECTION RECORD ....................................................................................15

ATTACHMENT C – RESULTS OF SURFACE PREPARATION PROCEDURES...............................................16

1 General

1.1 Scope of this Specification

a) This specification has been prepared specifically for Nadi S1 Contract 1D and should not berelied upon for any other purpose.

b) This specification covers the supply and installation of pressure pipe.

1.2 Applicable Codes and Standards

a) All work, materials and practices shall comply with the requirements of current NewZealand/Australian standards for that particular class of work. The following standards shallapply specifically:

- AS 1111.(1-2):2000:ISO metric hexagon bolts and screws- AS 1281:2001:Cement mortar lining of steel pipes and fittings- AS 1579:2001: Arc- welded steel pipes and fittings for water and wastewater- AS/NZS 2312:2002:Guide to the protection of structural steel against atmospheric

corrosion by the use of protective coatings- AS/NZS 3992:1998:Pressure equipment - Welding and brazing qualification- NZS 4224:1983:Code of practice for measurement of civil engineering quantities- NZS 4442:1988:Welded steel pipes and fittings for water, sewage and medium pressure gas

b) Compliance with these Codes and with this Specification shall be the minimum requirementnecessary for this Contract.

c) The documents listed above and in the sections that follow refer to their latest issuecomplete with amendments that are current at the date of the issue and are deemed toform part of this Specification.

d) This Specification takes precedence when it is at variance with any of the cited Codes andStandards.

1.3 Definitions

Expansion joint : A pipe joint that allows relative longitudinal movement betweenadjacent pipes without the occurrence of fracture or leakage

Flexible joint : A pipe joint that allows relative angular (radial) and longitudinalmovements between adjacent pipes without the occurrence offracture or leakage

Specification : The technical specification covering the stated discipline

Rigid joint : A pipe joint that allows no relative movement between adjacent pipeswithout the occurrence of fracture or leakage

Specifications : The documents defined as Specifications in the Contract Documents.

Sewage : Waste liquid

Sewerage : A system of sewers

Sewer : Individual pipeline element of a sewage system

2 Materials

2.1 Steel Pipe

Steel pipes shall comply with AS 1579:2009 Arc Welded Steel pipes and fittings for water andwastewater as applicable, and shall be cement mortar lined in accordance with AS 1281 or AS/NZS1516 and comply with AS 3972. Steel pipes shall be externally protected with one of the following:

a) for buried pipes, to be supplied with “Sintakote” coating and be wrapped in a highdensity polyethylene sleeve, “black jacket” complying with AS/NZS 1518:2002External extruded high density polyethylene coating system for pipes, or “PolykenSynergy” wrapping, or “Polyken YG111” wrapping.

b) for pipe bridges and pipes above ground, a coating complying with AS/NZS2312:2014 Guide to the protection of structural steel against atmosphericcorrosion by the use of protective coatings as specified in Section 4 is to be used.

c) Pipe that is procured uncoated is to be supplied with a factory applied primer.

2.2 Fittings, Joints and Couplings for Principal Mains

a) Except as set out in this section, tees, hydrant tees, crosses, tapers, blank caps, and Gibaultsshall be ductile iron complying with AS/NZS 2280, BS EN 545 or BS EN 598.

b) All fittings, except PVC and ABS, shall be protected with a thermal bonded coating complyingwith AS/NZS 4158, or be externally bitumen coated and internally concrete lined to complywith AS/NZS 2280.

c) Bolts, washers and nuts in joints shall be 316 stainless steel. A nickel or molybdenum basedanti-galling lubricant (eg. molybond) shall be used when installing stainless steel nuts andbolts. Where fixings or fastenings in contact with the material being fixed may give rise todetrimental galvanic action/corrosion, suitable isolating washers and sleeves shall be used.

d) Welded joints shall either be spigot and socket welded or butt joint welded with a collar.Welded joints of steel pipe shall be protected with ‘Polyken’ or ‘Denso Petrolatum’ inaccordance with the manufacturer’s recommendations.

e) Gibault joints shall be fitted with grade 316 stainless steel bolts. Buried gibault joints shallbe protected with ‘Polyken’ or ‘Denso Petrolatum’ in accordance with the manufacturer’s

recommendations. Gibaults shall not be used in direct contact with concrete lined steelpipe.

2.3 Pressure Classes

Pipes, valves, hydrants and fittings shall be designed and manufactured for the working pressureshown on the drawings or in Section 4 of this Specification.

2.4 Concrete

Concrete used for thrust blocks, anchor blocks and minor structures shall comply with Section 16 ofthe Contract Specification and shall have a minimum strength of 20MPa at 28 days.

2.5 Storage of Materials

a) Pipes shall be unloaded and handled in accordance with the manufacturer’srecommendations.

b) Pipes shall be stored on level ground.

c) Pipes shall be protected from direct sunlight if stored for more than one month afterdelivery from the supplier.

d) Steel and ductile iron pipes shall be stored in such a way that liners and coatings arenot chipped or damaged or become debonded from the pipe.

e) Steel pipe shall only be permitted to be delivered to site once external protectivecoating systems have been applied.

2.6 Defective Materials

Any pipes or other materials that do not comply with this Specification or that have been damagedduring handling and storage shall be removed from site and replaced or repaired by the Contractor.

3 Execution

3.1 Handling and Placing

The plant and rigging equipment used by the Contractor for the handling and placing of pipes shallbe of the type recommended by the pipe manufacturer and such that at no time during handling andplacing is any pipe overstressed or damaged.

3.1.1 Laying and Installation of Pipes

a) In all cases, the pipe manufacturer’s recommendations for storage, handling,protection and laying techniques shall be followed.

b) Preliminary inspection. Each pipe shall be thoroughly cleaned out and carefullyexamined for damage immediately before laying. The Contractor shall be responsiblefor detecting any damage to pipes or fittings, and for any remedial works required.Damage shall be brought to the attention of the Engineer, who may issue furtherinstructions. Any damage arising as a result of procurement, handling or poor

installation during the Contract Works shall be rectified as directed by the Engineerand at the Contractor’s expense.

c) Alignment. Pipes shall be laid on the bedding cradle true to designated line and level,and within the tolerances specified. Designated invert levels shall take precedenceover design depths shown on the drawings. The completed sewer shall have no kinksor undulations except where shown on the drawings or as directed by the Engineer.

d) No protective cap, disc or other appliance on the end of a pipe or fitting shall beremoved permanently until the pipe or fitting which it protects is about to be jointed.Pipes and fittings, including any lining or sheathing, shall be examined for damage andthe joint surfaces and components shall be cleaned immediately before laying.

e) Suitable measures shall be taken to prevent soil or other material from entering pipes,and to anchor each pipe to prevent flotation or other movement until the works arecomplete.

f) All pipe joints, fittings and anchors shall be left exposed for inspection during thecourse of the acceptance test unless otherwise agreed by the Engineer.

3.1.2 Cutting of Pipes

a) Pipes shall be cut by a method which provides a clean square profile; does not split orfracture the pipe wall; leaves no residue; and causes minimal damage to anyprotective coating(s).

b) Where necessary, the cut ends of pipes shall be formed to the tapers and chamferssuitable for the type of joint to be used. Any protective coatings shall be made good.

c) Where pipes are to be cut to form non-standard lengths, the Contractor shall complywith the manufacturer's recommendations in respect of end preparation for furtherjointing.

d) Pipe jointing surfaces and components shall be kept clean and free from extraneousmatter until the joints have been made or assembled.

3.1.3 Jointing of Steel Pipes

a) Steel pipes shall have spigot and socket joints with rubber rings or shall be plain endedand butt welded as appropriate. Steel pipes shall be flanged where shown on thedrawings.

b) Pipes for welding shall be jointed by an automatic arc welding process capable ofconsistently producing welds complying with the requirements of AS1579.

c) Manual arc welding with automatic wire feed and automatic fluxing may only be usedfor the repair of weld defects. Manual welding shall occupy no more than 2 per cent ofthe total weld length in any pipe, and no weld repair shall be longer than 300mm.

d) Full details of the welding procedure and of the edge preparation proposed to be usedshall be supplied to the Engineer prior to welding.

e) Any faulty welds shall be cut out and rewelded. On no account shall leaks be sealed bycaulking.

f) On completion and acceptance of the welding by the Engineer, the external corrosionprotection shall be repaired as specified in Section 4.

g) All welding of steel pipes shall be carried out by a welder-fabricator qualified to ASME,AS2214 or AS1796 Certificate No.10.

3.1.4 Thrust Blocks and Anchorage

a) Cast in-situ concrete thrust blocks shall be provided where shown on the drawings andat all points where the pressure pipeline changes direction or diameter, resulting in anunbalanced thrust.

b) Normal maximum concrete encasement shall be 180 degrees. All thrust blocks shallbe installed so as not to impair access to bolts or fittings.

c) All fittings and anchors shall be left exposed for inspection until after the acceptancetest unless previously inspected by prior arrangement with the Engineer.

3.2 Tolerances

Tolerances will be in accordance with WAF Technical Specification for the Construction of RelocationWorks – NASRUP Projects.

3.3 Inspection and Testing

3.3.1 Pressure Testing of Pipelines

All pipes shall be subjected to a pressure test after laying and jointing and before the bends, teesand anchor blocks are covered with backfill to a maximum of 500kPa using the method specified inthe WAF Technical Specification for the Construction of Relocation Works – NASRUP Projects.

3.3.2 Joint Inspection and Testing (Steel Pipes)

a) All welds shall be 100% visually inspected. For weld defects exceeding the levels listedbelow, the Contractor shall cut out all faulty welds as indicated and shall re-run themin accordance with the Specification.

Imperfection Allowable Level

Cracks

Lack of Penetration

Underfill

Unfilled Craters

Not allowed

Not allowed

Not allowed

Not allowed

Imperfection Allowable Level

Surface Porosity

Arc Strikes

Linear Misalignment

Undercut

Reinforcement of Butt Welds (cap androot)

Reinforcement of Fillet Welds

Convexity

Concavity

Weld Profile (cap and root)

Not allowed

Not allowed

2mm

t/10 but 1mm maximum

4mm

0.9 x leg length

0.7 x leg length

No pronounced humps orcraters

b) If, by this method, it is shown that the welding is unsatisfactory then the Contractorshall cut out all faulty welds as indicated and shall re-run them in accordance with theSpecification.

c) All test certificates shall be submitted to the Engineer upon completion of these tests.

4 Project Specification

This Section contains project specific schedules and specifications, and takes precedence overSections 2 and 3.

4.1 General

The work involves the procurement and installation of approximately 20m of aboveground 400mmnominal diameter steel concrete lined sewer rising main as shown on Drawings Sheets 556, 557 and558.

4.2 Materials

The following project specific information applies:

a) 400mm nominal diameter Mild steel Concrete lined, pipe 6mm wall thickness,pressure rating 6.4MPa supplied by Pentair or Tyco Water.

b) All fittings to be rated to a minimum of PN16, where noted some fittings will besupplied by Water Authority Fiji.

c) The corrosion protection for above ground pipework is to be in accordance with theAltex specification TG-2015-125412 in Attachment A, alternative corrosion protectionsuitable for Category 4 protection in accordance with AS/NZS 2312 may be proposedsubject to the Engineer’s acceptance. The contractor is to confirm the dimensions and

angles required to connect to the existing sewer rising main and the new section ofsewer rising main along the face of the triple box culvert prior to the ordering andfabrication of all pipe and fittings.

4.3 Corrosion Protection

4.3.1 General

It is recommended that prior to the commencement of painting, the Contractor obtain the technicalassistance from the coating manufacturer to ensure that the proposed preparation and paintapplication will be in accordance with the manufacturer's requirements as detailed in Attachment A.

It is the responsibility of the Contractor to supply the total dry film thickness of the material asspecified. If this thickness is not achieved this shall be corrected by application of an additional coatidentical to the specified topcoat, or by a method recommended by the coating manufacturer andapproved by the Engineer. Work that does not conform to this specification and to the painting andcoating system applicable to the project shall be rejected and shall be reapplied to the satisfaction ofthe Engineer or the coating supplier. The cost of such rework shall be borne by the Contractor.

Adequate ventilation is to be maintained at all times at the work area. Ventilation is to be ofsufficient capacity to maintain a clear atmosphere within the work area during both surfacepreparation and coating operations, including initial cure. During coating operations the work areamust be sufficiently ventilated to maintain the atmosphere below one half of the lower explosivelimit.

All paints, coating materials, and thinners shall be delivered to the site in the manufacturer's originalsealed containers with labels intact and seals unbroken.

Paint in storage shall be in a well-ventilated weather protected area and shall be protected againstdeterioration. Manufacturer's specific storage requirements prior to preparation shall be compliedwith. Paint or coatings that have exceeded their marked shelf life, or have livered, gelled, orotherwise deteriorated shall not be used.

4.3.2 Qualifications

The application of the coating should be carried out by a suitably experienced contractor who hasbeen approved by the Engineer 14 days prior to works commencing on site.

4.3.3 Equipment

All equipment for application of paint shall be furnished by the Contractor and shall comply with therecommendations of the coatings manufacturer. The Contractor shall supply all appropriate safetyequipment and shall ensure that the applicator is trained in the use of the equipment.

All coating containers and products shall be correctly and sensibly handled to minimise skin contactor lung exposure to paint or solvent or fumes. It is recommended that gloves, overalls, masks, andshields should be worn at all times while mixing or applying coatings.

After the finish coat has been applied, only nylon ropes or rubber covered slings may be used forhandling steel either in the shop during loading or shipment or during unloading or erection. TheContractor shall rectify any damaged coating.

Where applicable, wooden softeners shall be used to avoid metal-to-metal contact during handlingor shipping to minimise coating damage. Wooden softeners shall also be used when stacking steelfor storage on site, and wooden dunnage shall be provided to separate the steel from the groundsurface.

4.3.4 Inspections

A programme of work inspections and hold points shall be agreed with the Engineer before surfacepreparation work commences.

The Contractor shall carry out his own quality control checks and documentation, sufficient toestablish conformity with the specification. The Contractor shall provide unhindered access for theinspection of the works and his materials and inspection records, at any stage.

The Contractor shall provide adequate intervals for inspection as agreed. This shall includeinspection prior and after blast cleaning, in between coats and final inspection.

The Contractor shall carry out and document such tests on the Paint Inspection Record Sheets(Attachment B) before and after applying each system coating, in order to establish conformity withthe manufacturer’s specification.

The Contractor shall furnish the Inspector with full facilities and correctly calibrated equipment toverify conformity. This shall include, but is not limited to, wet thickness gauges, dry film thicknessgauges, surface temperature gauges, humidity measurement devices.

Work that does not comply with the specification, or which shows surface or subsurface defectsshall be rejected and the coatings shall be cut back and recoated in accordance with the relevantrepair specification, to the Engineer's satisfaction.

4.3.5 Preliminary surface preparation

All sawn, sheared, or flame cut edges shall be de-burred and ground to a smooth minimum 3mmradius, and weld slag, spatter, slivers, and surface defects shall be removed before abrasive blastingor mechanical surface preparation.

Heavy layers of rust not capable of being removed by subsequent cleaning shall be removed bysuitable mechanical preparation to be the equal of the surrounding surfaces.

Deposits of oil and grease shall be removed in accordance with SSPC SP-1 Solvent Cleaning (seeAttachment C) prior to blast cleaning or mechanical surface preparation. Any soluble saltcontamination shall be removed from the surface prior to any surface preparation, and any sourcesor recontamination during and after surface preparation shall be eliminated.

On spiral welded steel pressure pipes all surfaces, except the inside and outside of sockets andspigots, and unconcreted uncoated plain ends shall be prepared for coatings. These excepted

surfaces shall first have grease, dirt and flakes of rust removed and shall then be wire brushed with apower tool so that these surfaces are rust free.

Power tool cleaning shall not be used as an alternative to blast cleaning except for those surfaces,which, because of their location, cannot be open blasted

4.3.6 Mixing and Thinning of Products

The area used for mixing of coatings shall be weatherproof and set up in such a way that nocontamination is introduced to the work area during mixing or coating operations.

All consumables used shall be logged on the relevant Quality Control documentation (productnames, batch numbers, quantities etc.) as used.

Mechanical powered mixers must be used to thoroughly mix two pot products together. This shouldcontinue for at least five minutes or until a full homogeneous consistency is reached.

Catalysts or converters must be added in the correct ratio and thoroughly dispersed. The inductiontime specified on the paint data sheets must be allowed for before any thinning or two pot productsare applied. Thinning ratio and thinner type shall be strictly as recommended and approved by themanufacturer prior to use. No thinner should be added until the induction time has passed.

Power driven stirrers should be fitted to pressure pots used for spraying two pack or heavilypigmented materials, such as zinc primers, that have a tendency to settle or stratify. A uniformconsistency must be maintained.

The maximum pot life of catalysed materials shall be complied with. When the pot life is reached,the spray equipment must be cleaned and flushed with new material catalysed.

Reconstituting paint material that has exceeded its pot life by adding solvent or any other methodshall be prohibited. It is not acceptable to add new catalysed product to existing material that hasexceeded its pot life.

4.3.7 General Coating Application

The specified coating system shall be applied as soon as possible after surface preparation and on noaccount shall the cleaned surface show the slightest evidence of tarnishing, nor be left overnightbefore painting. Surfaces to be painted shall be clean, smooth, dry, and free from dust, and oil, andin a proper condition to receive paint in accordance with the manufacturer’s recommendations.

All paints shall be applied strictly in accordance with the manufacturer's written applicationinstructions in Attachment A and under direction of supervisors experienced in their use.

All coatings shall be uniformly applied free from runs, sags, dry overspray, grit inclusions, or mudcracking and provide a uniform impervious defect free film, to meet the minimum specified dry filmthickness for each coat.

The number of passes and the correct spray technique shall be followed to ensure the minimum dryfilm thickness is achieved on all surfaces. Edges, welds, corners, and discontinuities shall have anextra stripe coat applied with each successive coat to ensure these areas are correctly protected.

Extra coating application by brush may be needed in certain areas to achieve the required dry filmthickness.

The correct intercoat drying and curing times from the Manufacturer’s Specification shall be strictlyobserved. These minimum and maximum times are based on the film thickness applied, the timerequirements for good intercoat adhesion and minimised solvent entrapment and the temperatureand conditions during the full coating cycle time. Recoating shall be carried out as soon as possibleafter the minimum recoat times, so that surface contamination can be minimised.

Painting shall not be carried out when sandblasting of an adjacent area interferes with properapplication or risks contamination or overblast damage of the surface.

Adequate curing time, temperature, and correct humidity shall be provided in shops where work isbeing coated so that a minimum of damage to the coating occurs in handling and shipping.

When unavoidable contamination does occur, it shall be adequately removed to ensure clean,consistent coating and maximum intercoat adhesion.

To minimise coating damage, ensure that adequate cure is achieved before handling coated items.

Adequate care shall be taken to protect surfaces while still wet by the use of screens and ‘wet paint’signs as and where necessary.

4.3.8 Application of Coating at Pipe Ends

The prime coat shall be carried around the ends of the pipe and into the socket, to the edge of theconcrete lining.

4.3.9 Quality Checks

Paint thickness checks shall be carried out after a minimum of 1 day has elapsed since theapplication of the paint. The minimum requirements for paint thickness are as shown in the paintspecification sheets in Attachment A.

Checks of the coating thickness shall be made by the Contractor on a 500mm grid, or as requestedby the Engineer, using a properly calibrated paint thickness gauge accurate to within + or - 3%. Theresults of these tests shall be recorded, and supplied to the Engineer on request.

Work that does not comply with the specification, or which shows surface or subsurface defectsshall be rejected and the coatings shall be cut back and recoated in accordance with the relevantrepair specification, to the Engineer's satisfaction.

4.3.10 Field touch up painting

Touch-up painting will be required at field welds, bolt assemblies, primed-only surfaces, and to areasdamaged during transportation, handling, storage, or erection. Refer to the coating repair notes onthe relevant protective coating specification sheet.

Before touch-up paintings;

All damaged paint films shall be removed,

All grease, oil, dirt or other foreign matter shall be removed, All edges of sound paint shall be feathered by sanding or grinding,

Existing gloss paint surfaces shall be sanded or abraded for bond. (An exception can apply to someurethane topcoats)

Bare spots that have exposed the prime coat but not the base material shall have one or two finishcoats applied to regain the specified film thickness.

If the base material or substrate has been exposed the area shall be cleaned down to the base metalin accordance with either SSPC SP-3 or SSPC SP-11 (refer Attachment C), and the area shall betouched up as specified in Attachment A.

Where corrosion has occurred in the base metal due to the damage to the paint system, the areashall be re-cleaned to the original surface preparation requirement and the full specified coatingsystem applied.

ATTACHMENT A - ALTEX SPECIFICATION

NASRUP - Above Ground STCL Pipeline

Job/Project Number : 22998

TG-2015-125412

Spec Type : New

Job Name : 22998 - NASRUP - Above ground STCL pipeline

Description : Exterior coating of a mild steel concrete lined pipe.

Location : Nadi, Fiji, Fiji

Environment : Exterior coastal

Substrate : Mild Steel

Company : MWH Contact : Beth Parkin

Address : Level 13, 80 The Terrace Title :

City : Wellington Postcode :

Region : Wellington Phone : 04 3815703

Country : New Zealand Email : [email protected]

Surface PreparationEnsure all sharp edges are ground to a smooth 2mm radius.Degrease in accordance with SSPC SP1 to remove all soluble contamination.Abrasive blast to AS 1627.4 Class 2½ (SSPC SP10) and achieve a uniform jagged blast profile of between 35 and 50µm.Apply Coat 1 to the prepared Class 2½ substrate.Apply a full coat of Coat 2.Apply full coat of Coat 3.All surfaces must be clean and dry before painting

Coating System

Product Coating Colour TC WFT DFT MR MinRC MaxRC Thin Note1 - Carbozinc 859 EZ2 full prime 9.3 107 75 4:1 90 minutes 90 days #22 - Carboguard 636 full coat 4.6 219 175 4:1 6 hours 5 days #123 - Carbothane 133 LH full coat 8.1 123 75 4:1 8 hours #25

TC = Theoretical coverage m2/litreWFT = Wet Film Thickness um

MinRC = Recoat Minimum@20°C/50% RH

DFT = Dry Film Thickness umMaxRC = Recoat Maximum@20°C/50% RH

MR = Mix ratio by volumeThin = Thinner(Spray)

NotesComplies with AS/NZS 2312.1:2014 system PUR5, 15 to 25 years for an exterior coastal environment category D4: medium (50-80 µm rust/year, ISO 9223 category 4).NB: DO NOT exceed maximum recoat times

Issue Date: Authorised By: Issued By: Written By:Wednesday, 11 March 2015 John Barnes Jaco Herling Jaco Herling

* For specific details referred to in the above specification, please refer to the relevant product or material safety data sheets* Spray application is normally recommended. Suitable equipment may includeairless/air assisted airless /HVLP or conventionalpressure pot equipment* If the specified thickness is not achieved in one coat, additionalcoats must be applied to meet the specified D.F.T. Stripe coats should be brush applied.* Any contamination or moisture which occurs between coats must be removed by suitable means before applying successive coats in the system.* Care must be taken handling and applying all paint coatings. All stated minimumand maximumrecoat times are based on 20°C/50% RH.* Altex Coatings Ltd willaccept no responsibility for performance of the specified product unless the correct thinner is used* This specification has been issued in good faith based on information given by the Client at the time of issue. Altex Coatings Ltd has takenall reasonable steps to ensurethe specification meets the needs of the client but reserves the right to amend or withdraw the specification if ( a changein conditions so dictate)

Protective Coatings Specification

Altex Coatings LimitedPO Box 142TAURANGA

New Zealand

Phone: (64-7) 541-1221Fax: (64-7) 541-1310

Document Summary

PDS attached

Carbozinc 859 EZ2Carboguard 636Carbothane 133 LH

Carboguard® 636*Multi-Purpose Epoxy Coating

Features Very good flexibility – resists chipping andaged embrittlement

Lighter weight – 13% lighter than mostsimilar coatings

Versatile surface tolerant coating Suitable for application over surfaces

prepared by water-jetting Lower viscosity allows application at higher

solids (less thinning) and reduced VOC atapplication

Good thermal qualities by syntactic foammodification; excellent for use underinsulation to 120ºC

Good adhesion to tight rust - especiallywhen used in conjunction with Rustbond®or Altra~Lock 576

Tolerant to surface dampness - particularlywhen brush applied

Self-priming (DTM) for many applications Fast dry to recoat Excellent dry to handling Suitable for fresh and salt water immersion Low temperature cure to below freezing; -

5°C Reduced HAPS and Low VOC

Selection & Specification DataGeneric Type Multi-Purpose Phenalkamine Epoxy High Build.

Description Carboguard® 636 is an advancedtechnology coating suited to marine andindustrial

Selection & Specification Data cont’d

VOC Values 213 grams per litre (mixed)

Induction 15 minutes at 25°C; longer if colder

applications and suitable for atmosphericand many immersion exposures.

The DTM properties makeCarboguard® 636 a versatile coating inmaintenance and new work

Dry Temp.Resistance

121°C dry heat

applications. Syntactic foam modification givesCarboguard® 636 unique thermal shockresistance and flexibility.

Limitations Exterior exposure will cause early loss of sheenand chalking. This will not affect the protectiveproperties of the coating.

Substrates & Surface PreparationGeneral Remove any oil or grease from surface to be

coated with clean rags soaked in Thinner #2,or toluene.

Steel For maximum performance: AS1627.4 Class2½ (SSPC-SP10) with a 30-60 micron jaggedblast profile. Prime as required.For general maintenance power-tool clean toAS 1627.2 or abrasive blast to AS 1627.4Class 2 (SSPC-SP6).For rapid turn-around dockings preparation bywater-jetting to minimum WJ-2 M (NACE No.5/ SSPC-SP 12) is acceptable

GalvanizedSteel

Not recommended for direct application.Sweep abrasive blast to remove allpassivation treatment, white rust etc andrender a profiled surface. Prime withCarboguard® 504 or as recommended.

Gloss Low Sheen

Colour NZ Only: Haze Grey, Off White, MIO, GoldenYellow LF & Aluminium

Primers Carbozinc® 859 EZ2, Carbozinc®

858, Carbozinc® 11, Carboguard®

504.Direct to steel prepared to SP3 or better.Over porous or rusty surfaces correctly sealedand strengthened with Rustbond® orAltra~Lock® 576.

Topcoats Carbothane® 134 HG or 133LH Carboguard® 2929Or self finishing

Concrete Remove all laitance by sweep abrasiveblasting, HP Water-Jetting or acid etching. Formaximum performance and to reduce the riskof pin-holing seal the prepared concrete withCarboguard® 1340.

ApprovalsFood ProcessingNZ AsureQuality assessed & passed for food/beverage includingdairy farm & factory non-incidental contact. Ref: H3107

Dry FilmThickness

125-200 microns DFT per coat

SolidsContent

80% by volume

TheoreticalCoverageRate

5.33 square metres per litre at 150 microns DFT

Mix Ratio 4:1 by volume (Part A : Part B)

Issued October 2014 - Updating Aug. 2013 - Users should check they are referencing the latest product and safety data by checking for updates or amendments at www.altexcoatings.comManufactured and / or distributed in Australia & New Zealand by Altex Coatings under license to Carboline Company. To the best of our knowledge the technical data contained herein is true andaccurate on the date of publication and is subject to change without prior notice. User must contact Altex Coatings to verify correctness before specifying or ordering. No guarantee of accuracy isgiven or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for coverage, performance or injuries resulting from use. Liability, if any, is limited

Carboguard® 636

to replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY ALTEX COATINGS OR CARBOLINE EXPRESS OR IMPLIED, STATUTORY, BY OPERATIONOF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline and Carboguard are registered trademarks of Carboline Company.

Carboguard® 636*Multi-Purpose Epoxy Coating

Carboline Company.

Condition Material Surface Ambient HumidityOptimum 16° - 24°C 16° - 24°C 16° - 24°C 30 – 70%Minimum 10°C -7°C -7°C 0%Maximum 32°C 50°C 35°C 85%

SurfaceTemp. & 50%

RelativeHumidity

Dry toRecoat

Dry to Topcoatw/ OtherFinishes

MaximumTopcoatTime**

-5C 18 hours 36 hours 1 month16C 5 hours 12 hours 2 weeks24C 3 hours 6 hours 5 days32C 2½ hours 4 hours 2 days

Storage Store indoors. KEEP DRYRatio Kit Size 5 litre 10 litre Temperature 4° to 38°C

Application EquipmentListed below are general equipment guidelines for the application of thisproduct. Job site conditions may require modifications to these guidelines toachieve the desired results. General Guidelines:

Application Conditions

ConventionalSpray

Pressure pot equipped with dual regulators, 9.5mm (3/8”) I.D. minimum material hose, 1.8 mm(.070”) I.D. fluid tip and appropriate air cap.Hold gun 300-350 mm from the surface and at aright angle to the surface.

Industry standards are for substrate temperatures to be above thedew point. For immersion conditions it is recommended to followthis procedure. For non-immersion conditions This product cantolerate damp substrates. See Brush or Roller above. Specialthinning and application techniques may be required above or

Airless Spray Pump Ratio: 45:1Volume Output: 11.5 l/minute min.Material Hose: 12.5mm min. (½” I.D.)

recommendedTip Size: 0.53-0.78mm (.021-.031”)Output Press.: 140-175kg/cm² (2000-2500

psi)The following spray equipment has been foundsuitable; or equivalent.Mfr. & Gun: Graco 207-300Pump*: Bulldog 45:1*Teflon packings are recommended andavailable from pump manufacturer.

below normal conditions.

Curing Schedule

Brush &Roller(General)

Manual application is not recommended for tanklining applications except when stripingwelds. For non-immersion applications overdamp surfaces, brush and roller is thepreferred method. Multiple coats may berequired to obtain desired appearance,recommended dry film thickness andadequate hiding. Avoid excessive re-brushing or re-rolling. For best results, tie-inwithin 10 minutes at 24°C. Thin up to 12.5% byvolume with Thinner #12. Use a short-napsynthetic roller cover with phenolic core.

The above data is indicative for finished DFT’s of 150-200 microns.Drying and curing rates are influenced by ventilation, film thickness,humidity, thinning and other factors.**Antifouling Topcoat – optimum time to topcoat Carboguard® 636with anitfouling coatings is when the film is just tack-free, firmtothumb pressure but ‘thumbnail soft’; typically 2-3 hours at 24°C. Donot overcure.

Packaging, Handling & StoragePack Sizes NZ Only: 5 litre & 10 litre kits

Mixing & ThinningMixing Mix separately, then combine and mix in the

following proportions (4:1 ratio):

Flash Point(Setaflash)

Mix: 38°C Setaflash

Part A 4 litre 8 litrePart B 1 litre 2 litre

& Humidity 0 to 95%

Thinning For spray application thin up to 12.5%by volume with Thinner #12.For brush application thin as requiredwithThinner #25.

Induction 15 minutes at 25°C

Pot Life 4 hours at 25°C

Cleanup & SafetyCleanup Use Thinner #2, Altex 1/2 or Acetone. In case of

spillage, absorb and dispose of inaccordance with local applicable regulations.

Safety Read and follow all caution statements on thisproduct data sheet and on the MSDS for thisproduct. Employ normal workmanlike safetyprecautions. Hypersensitive persons shouldwear protective clothing, gloves anduse protective cream on face, hands andall exposed areas.

Ventilation When used as a tank lining or in enclosedareas, thorough air circulation must be usedduring and after application until the coatingiscured. The ventilation system should becapable of preventing the solvent vapourconcentration from reaching the lower explosionlimit for the solvents used.

Caution This product contains flammable solvents. Keepaway from sparks and open flames.

Shelf Life Part A: 24 months minimum at 24°CPart B: 24 months minimum at 24°C

*Shelf Life: (actual stated shelf life) when kept at recommendedstorage conditions and in original unopened containers.

Manufactured / supplied by:-Altex Coatings Ltd, 91-111 Oropi Road,Tauranga 3112New ZealandPhone: +64 7 5411221Resene Paints Australia Ltd.T/A Altex Coatings7 Production AvenueQueensland 4214AustraliaPhone: +61 7 55949522

Issued October 2014 - Updating Aug. 2013 - Users should check they are referencing the latest product and safety data by checking for updates or amendments at www.altexcoatings.comManufactured and / or distributed in Australia & New Zealand by Altex Coatings under license to Carboline Company. To the best of our knowledge the technical data contained herein is true andaccurate on the date of publication and is subject to change without prior notice. User must contact Altex Coatings to verify correctness before specifying or ordering. No guarantee of accuracy is

Carboguard® 636

Carboline Company.

given or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for coverage, performance or injuries resulting from use. Liability, if any, is limitedto replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY ALTEX COATINGS OR CARBOLINE, EXPRESS OR IMPLIED,STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline and Carboguard areregistered trademarks of

Carbothane® 133 LHHigh Build Polyurethane

Satin Finish

Test Method System Results Report #ASTM D4213

ScrubResistance

1 ct 133 LH0.0027 µm erosion rate

after 100 cycles withabrasive scrub medium

03403

ASTM G26Weatherometer

Blasted steel1 ct IOZ

1 ct 133 LH

No blistering, rusting orcracking after 3500 hours 01982

ASTM G53QUV

2500 hours withUVA 340 bulb

Blasted steel1 ct Epoxy1 ct 133 LH

Colour change less than2 McAdam Units; no

blistering, rusting,cracking or chalking

03394

ASTM B117Salt Fog

Blasted steel1 ct Epoxy Zn1 ct 133 LH

No rusting or blisteringon plane or scribe.

4000 hours02585

ASTM D5894QUV A

Prohesion1 ct 133 LH

No effect on plane areaand 78% gloss retention

after 1008 hours wet /dry salt fog cycle

03274

ASTM D4585Humidity

Blasted steel1 ct IOZ

1 ct 133 LH

No rusting or blisteringafter 3000 hours 02585

GraffitiResistance


All markings and stainsremoved by solvent afterexposure to: shoe polish,Sharpie Marker, crayon,

lipstick, spray cans ofacrylic, alkyd and epoxy.

03395

ASTM D1735Water Fog


No rusting or blisteringafter 8600 hours 02061

Selection & Specification DataGeneric Type Aliphatic Acrylic-Polyester Polyurethane Satin

Finish

Description High build, low sheen finish that hasexcellent resistance to corrosion, chemicals andabrasion. Suitable for application over anumber of Carboline primers andintermediates, this material provides

very good weatheringperformance in a broad range of colours.

Features • Outstanding performance properties in bothmild and aggressive environments

• High build; suitable for many two-coatsystems

• Application by spray, brush or roller

Substrates & Surface PreparationGeneral Surfaces must be clean and dry.

Employ adequate methods to remove dirt,dust, oil and all other contaminants that couldinterfere with adhesion of the coating. Referto the specific primer’s Product DataSheet for detailed requirements of thespecified primer.

Steel Abrasive blast to AS 1627.4 Class 2 (SSPC-SP6) with a 35-63 micron surface profile formaximum protection. Power or hand toolclean as minimum requirement. Prime withspecific Carboline primers as recommendedby your Carboline sales representative orCarboline specification.

• Indefinite recoatability• VOC compliant to current AIM regulations• Low HAPs content version of time proven

Carbothane® 133 HB

GalvanizedSteel

Ensure no traces of galvanizing passivationtreatment (quench) are present; degrease andabrade surface. Sweep abrasive blasting ishighly recommended.Prime with specific Carboline primer such as

®

Gloss Satin Carboguard 504 or as recommended by your

Colour* Refer to various colour standards,Carboline Colour Guide and custom tints.Certain colours may require multiple coats tohide.

Primers Refer to Substrates & Surface Preparation

Topcoats Carbothane® Clear Coat where required.

Carboline Sales Representative. Refer to thespecific primer’s Product Data Sheet forsubstrate preparation requirements.

Aluminium Degrease, abrade and prime with appropriateCarboline primer as recommended by yourCarboline sales representative or Carbolinespecification.

Dry FilmThickness

Note: Application of Clear Coat will improve UVresistance of certain colours, raise the gloss leveland further enhances 133’s inherent graffitiresistance - refer Performance Data – GraffitiResistance (without Clear Coat).

75-125 microns per coat.Dry film thickness in excess of 175 microns per

PreviouslyPaintedSurfaces

Lightly sand or abrade to roughen anddegloss the surface. Existing paint must attaina minimum 3B rating in accordance withASTM D3359 “X-Scribe” adhesion test. Primewith specific Carboline primers asrecommended by your Carboline salesrepresentative or Carboline specification.

SolidsContent


coat is not recommended.

By Volume: 61% ± 2%

6.1 square metres per litre at 100 microns DFT

Performance Data


VOC Values As supplied: 324 g/litreThinned 5% w #25: 360 g/litreThinned 15% w #25: 400 g/litre

Dry Temp.Resistance

Continuous: 93°C Non-Continuous: 121°CDiscolouration and loss of gloss is observedabove 93°C.

Limitations * The alignment of aluminium flakesin aluminium-filled finishes is very dependenton application conditions and techniques. Caremust be taken to keep conditions as constantas possible to reduce variations in finalappearance. It is also advisable to work from asingle batch of material since variations canoccur from batch to batch. For moreinformation consult Carboline Technical ServiceDepartment. Test reports and additional data available on written request.

Issued Sept 2010 – EX US March 2010Manufactured and / or distributed in Australia & New Zealand by Altex Coatings under license to Carboline Company. To the best of our knowledge the technical data contained herein is true andaccurate on the date of publication and is subject to change without prior notice. User must contact Altex Coatings to verify correctness before specifying or ordering. No guarantee of accuracy isgiven or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for coverage, performance or injuries resulting from use. Liability, if any, is limited

Carbothane® 133 LH

to replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY ALTEX COATINGS OR CARBOLINE EXPRESS OR IMPLIED, STATUTORY, BY OPERATIONOF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and Carbothane® are registered trademarks of Carboline Company.

Carbozinc® 859 EZ2Epoxy Zinc-Rich Primer

Carboline Company.

Condition Material Surface Ambient HumidityNormal 18° - 29°C 18° - 29°C 18° - 29°C 35-60%

Minimum 4°C 4°C 4°C 0%Maximum 38°C 43°C 43°C 90%

SurfaceTemp. & 50%

RelativeHumidity

Dry toHandle

Minimum Dryto Recoat Final Cure

4°C 24 hours 24 hours 28 days10°C 15 hours 15 hours 14 days24°C 6 hours 6 hours 7 days32°C 3 hours 3 hours 4 days


Cleanup & Safety – continued

Caution This product contains flammable solvents. Keepaway from sparks and open flames. Allelectrical equipment and installations should bemade and grounded in accordance with the

SprayApplication(General)

ConventionalSpray

This is a high solids coating and mayrequireadjustments in spray techniques. Wet filmthickness is easily and quickly achieved.The following spray equipment has been foundsuitable and is available from manufacturerssuch as DeVilbiss and Graco.

Pressure pot equipped with dual regulators,12m (3/8”) I.D. minimum material hose, 1.8mm(.070”) I.D. fluid tip and appropriate air cap.

local electricity code. In areas where explosionhazards exist, workmen should be required touse non-ferrous tools and wear conductive andnon-sparking shoes.

Application Conditions

Airless Spray Pump Ratio: 30:1 (min.)* Output:10 lt/minute (min.)

Material Hose: 12mm (3/8”) I.D. (min.)Tip Size: .013-.015”Output PSI: 2100-2300Filter Size: 60 mesh*Teflon packings are recommended andavailable from the pump manufacturer.

Industry standards are for substrate temperatures to be 3°C abovethe dew point. This product simply requires the substratetemperature to be above the dew point.Caution: This Product is moisture sensitive in the liquid stage anduntil cured. Protect from high humidity, dew and direct moisturecontact until cured. Application and/or curing in humidities abovemaximum, or exposure to moisture from rain or dew may result in aloss of gloss and/or microbubbling of the product.

Brush &Roller(General)

Multiple coats may be required to obtain desiredappearance, recommended dry film thicknessand adequate hiding. Avoid excessive re-brushing or re-rolling. For best results, tie-inwithin 10 minutes at 24°C.

Curing Schedule

Brush Recommended for touch-up only. Use amedium natural bristle brush.

Roller Use a medium nap synthetic roller cover withphenolic core.

Mixing & ThinningMixing Power mix Part A separately, then combine and

power mix.DO NOT MIX PARTIAL KITS.

Ratio 4:1 by volume (Part A : Part B)

Thinning Not normally required for airless spray.Use minimum quantity of Thinner #25 requiredfor good spray atomisation; typically 0-20%depending upon gear and conditions.For brush / roller application use Thinner #22.

Pot Life 4 Hours at 24°C and less at highertemperatures. Pot life ends when coatingbecomes too viscous to use.

These times are based on a 75-125 micron dry film thickness.Higher film thickness, insufficient ventilation or cooler temperatureswill require longer cure times and could result in solvent entrapmentand premature failure.*Maximum recoat times are indefinite. Surface must be cleanand dry.

Packaging, Handling & StoragePack Sizes 5 litre 10 litre**

Part A: 4 litre 8 litrePart B: 1 litre 2 litre**10 litre kits available on bulk specialorder only.

MOISTURE CONTAMINATION WILLSHORTEN POT LIFE AND CAUSEGELLATION.

Cleanup & SafetyCleanup Use Thinner #2 or Acetone. In case of spillage,

absorb and dispose of in accordance with localapplicable regulations.


StorageTemperature& Humidity

Part A: 20°CPart B: -2°C

Store under cover.4°-43°C0-90% Relative Humidity

Safety Read and follow all caution statements on thisproduct data sheet and on the MSDS for thisproduct. Employ normal workmanlike safetyprecautions. Hypersensitive persons shouldwear protective clothing, gloves anduse protective cream on face, hands andall exposed areas.

Ventilation This product contains iso-cyanate. For sprayapplication users must have air-fed masksas directed in local regulations.Adequate ventialtion must be maintainedthroughout application and cure to avoid buildup of solvent vapours

Shelf Life Part A:Min. 24 months at 24°CPart B:Min. 24 months at 24°C


Manufactured / supplied by:-Altex Coatings Ltd, 91-111 Oropi Road,Tauranga 3112New ZealandPhone: +64 7 5411221Resene Paints Australia Ltd.T/A Altex Coatings7 Production AvenueQueensland 4214AustraliaPhone: +61 7 55949522

Issued Sept 2010 – EX US March 2010Manufactured and / or distributed in Australia & New Zealand by Altex Coatings under license to Carboline Company. To the best of our knowledge the technical data contained herein is true andaccurate on the date of publication and is subject to change without prior notice. User must contact Altex Coatings to verify correctness before specifying or ordering. No guarantee of accuracy isgiven or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for coverage, performance or injuries resulting from use. Liability, if any, is limitedto replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY ALTEX COATINGS OR CARBOLINE, EXPRESS OR IMPLIED,STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and Carbothane® are

Carbothane® 133 LH

Carboline Company.

registered trademarks of

Carbozinc® 859 EZ2Epoxy Zinc-Rich Primer

Test System Results

Q-Fog Prohesion3000 hours CZ 859 EZ2 65-75 µm

Some rust at scribe, 1.5mmscribe-zone pinheadblistering. No corrosion orblistering in the field. Traceof surface salting

Q-Fog Prohesion3000 hours

CZ 859 EZ2 65-75 µmPUR Gloss 50-55 µm

Very slight rust at scribe, noundercut, no blisters.

Q-Fog Prohesion3000 hours

CZ 859 EZ2 65-75 µmCg 690 125-150 µm

Slight rust stain at scribe, nocorrosion or undercut, noblistering

Salt WaterImmersion3000 hours

CZ 859 EZ2 65-75 µmCg 690 125-150 µm

Slight rust and rust stain atscribe, pinhead blistering in3mm scribe-zone, no fieldblistering

Selection & Specification DataGeneric Type Two component zinc-rich epoxy primer

Description A two-component, high solids, zinc richepoxy primer formulated for the protection ofproperly prepared steel substrates. 859 EZ2can be applied by conventional, airless,or plural component spray. Recommendedwhere a high performance, highly corrosionresistant zinc primer is desired. Typicalapplications include structural steel, tanks,piping, equipment and other miscellaneous partsin industrial, offshore

Substrates & Surface PreparationGeneral Surfaces must be clean and dry.

Employ adequate methods to remove dirt,dust, oil and all other contaminants that couldinterfere with adhesion of the coating. UseThinner #2 or Altex 10/90 PreparationSolvent according to SSPC-SP1.

Steel Abrasive blast to a commercial finish inaccordance with AS 1627.4 Class 2 (SSPC-SP6) and obtain a 38-50 micron blast profile.

or architectural projects.

Features • Excellent application properties• Tough abrasion resistant film• Excellent adhesion & undercutting

resistance• Superior corrosion resistance• Meets VOC regulations, <335 gms/litre• Fast drying for recoat• Meets or exceeds SSPC Paint System 20

GalvanizedSteel

PhosphatizedSteel

Touch up welds etc – Abrade adjacent soundgalvanizing and hand tool clean exposed weldto AS 1627.7 (SSPC-SP2)

Apply 859 EZ2 directly to dry, properlyphosphatized substrate. Perform adhesiontests to insure proper, uniform and acceptableadhesion direct to phosphatized metalsubstrate.

Level 3 (2002)• Excellent film-forming properties eliminate

topcoat blistering• Excellent resistance to salting on

weathering exposure

Gloss Matte

Colour Australia: GreyNew Zealand: Green

Grey (10 litre kit only)

Topcoats Epoxies, polyurethanes and others asrecommended by Carboline.

Curing ScheduleSurface

Temp. & 50%RelativeHumidity

Dry toTouch

Dry toHandle orAssemble

Dry toTopcoat

2°C 3 hours 8 hours 6 hours*10°C 1 hour 5 hours 2 hours*24°C 30 min 2 hours 1.5 hours*32°C 15 min 1 hour 1 hour*54°C 10 min 30 min 30 min*

*Consult Carboline Technical Service for specific wet-on-wet recoatrecommendations. Some topcoats are suitable for immediate (30min or less) recoating of 859 EZ2. These times are based on a 50-75

Dry FilmThickness

SolidsContent


50-75 microns per coat. For more severeenvironments 859 EZ2 may be applied at100 microns dry film thickness.Typical priming thickness = 60 microns

By Volume: 70% (ASTM D 2697-7 days)

14.0 m2/l at 50 microns11.6 m2 at 60 microns (optimum systemDFT)9.3 m2/l at 75 microns.Mixing and application losses will vary and mustbe taken into consideration when estimating jobrequirements.

microns dry film thickness. Higher film thickness, insufficientventilation or cooler temperatures will require longer cure times andcould result in solvent entrapment and premature failure.Note: Product may be force cured – see table below.

FORCE CURE INFORMATIONFlash Off Bake Time Cool Down Total

Convection Oven10 min 30 min - 65°C 20 min 60 min

Infra-Red Oven5 min 15 min – 65°C 15 min 35 min

Times and substrate temperatures shown are based on in-housetesting and will vary depending on oven type, as well as substratesize and type.


VOC Values As supplied: 334 g/lThinned 20% with #2: 434 g/lThese are nominal values.

Performance Data

Dry Temp.Resistance

Continuous: 82°CNon-Continuous: 110°CDiscoloration is observed above 82°C

Pot Life 3 Hours at 24°C unthinned. Pot life decreases athigher temperatures. Pot life ends when coatingbecomes too viscous to use. This product ismoisture sensitive. Avoid moisturecontamination.

Issued May 2012 - Ex December 2011Manufactured and / or distributed in Australia & New Zealand by Altex Coatings under license to Carboline Company. To the best of our knowledge the technical data contained herein is true andaccurate on the date of publication and is subject to change without prior notice. User must contact Altex Coatings to verify correctness before specifying or ordering. No guarantee of accuracy isgiven or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for coverage, performance or injuries resulting from use. Liability, if any, is limitedto replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY ALTEX COATINGS OR CARBOLINE EXPRESS OR IMPLIED, STATUTORY, BY OPERATION

Carbothane® 133 LH

OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and Carbozinc® are registered trademarks of Carboline Company.

Carbozinc® 859 EZ2


Cleanup & Safety continuedVentilation When used in enclosed areas, thorough air

circulation must be used during and afterapplication until the coating is cured. The

SprayApplication(General)

ConventionalSpray

Airless SprayNon-plural

Airless SprayHeated PluralComponent

The following spray equipment has beenfoundsuitable and is available frommanufacturers such as DeVilbiss and Graco.

Pressure pot equipped with dual regulators, 9mm(3/8”) I.D. minimum material hose, 1.8mm (.070”)I.D. fluid tip and appropriate air cap.

Pump Ratio: 30:1 (min.)Output: 12 lt/minMaterial Hose: 9mm (3/8”) I.D. min.Tip Size: .015-.019”Output PSI: 2100-2300Filter Size: 30-60 meshTeflon packings are recommended and availablefrom the pump manufacturer.

Pump Ratio: Graco 35:1 (min)GPM Output: 12 lt/min. (min)Lower Units: Two (2) #0

One (1) #5Heaters: One (1) Graco Viscon (A side)Material Hose: 15 metre x 9mm I.D.Mixer: 250mm staticGun: Graco Silver 205-591Tip Size: .015-.019”Output psi: 2400-2800Filter Size: 30-60 mesh (in-line)Solvent Flush Pump Ratio: 10:1

ventilation system should be capable ofpreventing the solvent vapor concentrationfrom reaching the lower explosion limit for thesolvents used. In addition to ensuring properventilation, appropriate respirators must beused by all application personnel.

Caution This product contains flammable solvents.Keep away from sparks and open flames. Allelectrical equipment and installations shouldbe made and grounded in accordance withthe National Electric Code. In areas whereexplosion hazards exist, workmen should berequired to use non-ferrous tools and wearconductive and non-sparking shoes.

Application ConditionsCondition Material Surface Ambient Humidity

Normal 16° - 29°C 16° - 32°C 16° - 32°C 0 – 90%Minimum 4°C 2°C 2°C 0%Maximum 32°C 49°C 43°C 95%

Packaging, Handling & StoragePack Sizes AU/ NZ: 5 litre kit 10 litre kit

Part A: 4 litre 8 litrePart B: 1 litre 2 litre

Touch-up Respray or brush. Brushing recommended onlyfor touchup of small areas. Use medium, naturalbristle brush applying with full strokes. Avoidexcessive rebrushing.

Mixing & ThinningMixing For plural component application equipment


StorageTemperature& Humidity

Part A 18°CPart B 20°C

Store under cover4° to 35°C0 to 90% RH

follow the equipment manufacturer’s instructions.Power mix each component separately priorto using plural component spray equipmentor batch mixing. THIS PRODUCT ISMOISTURE SENSITIVE. AVOID MOISTURECONTAMINA- TION. DO NOT MIX PARTIALKITS.

Ratio 4:1 by volume (Part A : Part B)

Thinning For normal batch mix applications, it shouldbe thinned 20-25% with Thinner #2. For hotterthan normal application conditions it may bethinned20-25% with Thinner #33. Thinning not normallyrequired for plural heated application. Use ofthinners other than those supplied orrecommended by Carboline may adversely affectproduct performance and void product warranty,whether expressed or implied.

Pot Life 3 hours at 24°C unthinned. Pot life decreases athigher temperatures. Pot life ends when coatingbecomes too viscous to use. This product ismoisture sensitive. Avoid moisturecontamination.

Cleanup & SafetyCleanup Use Thinner #2 or Acetone. In case of spillage,

absorb and dispose of in accordance withlocal applicable regulations.

Safety Read and follow all caution statements onthis product data sheet and on the MSDS forthis product. Employ normal workmanlikesafetyprecautions. Hypersensitive persons should wearprotective clothing, gloves and use protectivecream on face, hands and all exposed areas.

Issued May 2012 – ex December 2011

Shelf Life Part A 12 months at 24°CPart B 12 months minimum at 24°C


Manufactured / distributed by:-Altex Coatings Ltd, 91-111 Oropi Road,Tauranga 3112New ZealandPhone: +64 7 5411221Resene Paints Australia Ltd.T/A Altex Coatings7 Production AvenueQueensland 4214AustraliaPhone: +61 7 55949522

Manufactured and / or distributed in Australia & New Zealand by Altex Coatings under license to Carboline Company. To the best of our knowledge the technical data contained herein is true andaccurate on the date of publication and is subject to change without prior notice. User must contact Altex Coatings to verify correctness before specifying or ordering. No guarantee of accuracy isgiven or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for coverage, performance or injuries resulting from use. Liability, if any, is limited

Carbozinc® 859 EZ2

to replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY ALTEX COATINGS OR CARBOLINE, EXPRESS OR IMPLIED,STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and Carbozinc® are registeredtrademarks of Carboline Company.

ATTACHMENT B - PAINT INSPECTION RECORD

PAINT INSPECTION RECORD

Project:

Client contact:

Contractor:

Inspector:

Reference docs:

Items inspected

Substrate Coat 1 Coat 2 Coat 3 Coat 4

Climate

Data

Date/Time

% RH

Air Temp

Dew Point

Surface Temp

Surface

Preparation

Date/Time

Cleanliness

Profile

Paint/

Application

Type

Date/Time

Batch Number

Mixing

Thinning

Coating

Inspection

Date/Time

W.F.T

Number

Min

D.F.T Max

Average

Std Dev

Holiday

AppearanceComments:

Signature: Date:

ATTACHMENT C – RESULTS OF SURFACE PREPARATION PROCEDURESSSPC SP-1 Solvent cleaning

Removal of all detrimental foreign matter such as oil, grease, dirt, soil, salts, drawing and cuttingcompounds, and other contaminants from steel surfaces by the use of solvents, emulsions, cleaningcompounds, steam or other similar materials and methods which involve a solvent cleaning action.

Surface Preparation - SSPC SP-10 (SA 2 ½) near white blast cleaning

This involves the removal of nearly all mill scale, rust, rust scale, paint, or foreign matter used by theuse of abrasives propelled through nozzles or by centrifugal wheels.

A near white blast cleaned surface finish is defined as one from which all oil, grease, dirt, mill scale,rust, corrosion products, oxides, paint, or other foreign matter have been completely removed fromthe surface except for very light shadows, very slight streaks or slight discolourations caused by ruststain, mill scale oxides, or light, tight residues of paint or coating that may remain. At least 95% ofeach square centimetre of surface area shall be free of visible residues, and the remainder shall belimited to the light discolouration mentioned above.

SSPC SP-3 (St 3) Power tool cleaning

Removal of all rust, scale, mill scale, loose paint and loose rust by power wire brushes, power impacttools, power grinders, power sanders or by a combination of these methods. The substrate shouldhave a pronounced metallic sheen and also be free of oil, grease, dirt, soil, salts, and othercontaminants. The surface should not be buffed or polished smooth.

SSPC SP-11 Power tool cleaning to bare metal

Power tool cleaning shall produce a bare metal surface and retain or produce a surface profile. Thisrepresents a higher level of cleaning than SSPC SP-3.

The surface shall be free of all visible oil, grease, dirt, dust, mill scale, rust, paint, oxide, corrosionproducts, and other foreign matter. Slight residues of rust or paint may be left in the lower portionsof pits. Coated abrasive discs, coated abrasive flap wheels or non-woven abrasive wheels capable ofrunning on power tools are some methods of achieving this standard. The minimum profile requiredis 25 microns.