SYDNEY WATER - AWT 103 - Sydney Water - Steel Reservoirs Coatings PDF

DOCUMENT DETAILS
## NOTE: ALWAYS CHECK IF THIS IS THE CURRENT VERSION **
TITLE NAME: COATING NEW STEEL RESERVOIRS
DOCUMENT NO: 01
FILE NAME: PCS_103_01 TOTAL PAGES: 16
REVISION DATE: December 2002
ABSTRACT: This document is to be used for coating of NEW steel reservoirs only.
For RECOATING of existing reservoirs, use PCS_102.
This document and the document PCS_BC, GENERAL AND

ENVIRONMENTAL REQUIREMENTS when combined form a total
specification.
AUTHORISED BY: STRATEGIC ASSET MANAGEMENT, SWC

(JANSSEN CHAN, POLICY, STANDARDS & MATERIALS MANAGER)
CUSTODIAN:
NAME: JERRY SUNARHO
POSITION: STANDARDS ENGINEER
PHONE: 9828 8572
FAX: 9828 8454
LOCATION: LEVEL 2
CNR BIGGE & MOORE STREETS, LIVERPOOL
NOTES:
1. This page is to be deleted it does not form part of the Document.

SYDNEY WATER CORPORATION
PROTECTIVE COATING SPECIFICATION
PCS 103 Part A
Coating New Steel Reservoirs

TABLE OF CONTENTS
PART A TECHNICAL REQUIREMENTS 3
DB-1 SCOPE 3
DB-2 GENERAL 3
DB-3 SURFACE PREPARATION 3
DB-4 COATING SYSTEM 4
DB-5 COATING SYSTEM GUIDE 5
DB-6 RECTIFICATION OF DEFECTS AND DAMAGED COATINGS 5
DB-7 RESERVOIR SIGNAGE 6
TABLES
A-1 - GUIDE TO CHOOSING A COATING SYSTEM 8
A-2 - EXTERNAL SYSTEM ALK-1B 9
A-3 - INTERNAL - SYSTEM EPX-1 10
A-4 - ANTI-GRAFFITI SYSTEM EPU-5 11
A-5 - THERMAL SPRAYED ZINC METAL SYSTEM TSZ-200S 12
A-6 - REPAIR OF GALVANIZING SYSTEM EPX-12 13
A-7 - HOT DIP GALVANIZING SYSTEM GAL-1 14
APPENDICES
A-1 COATINGS APPROVED UNDER THE AUSTRALIAN PAINT APPROVAL

SCHEME [APAS] 15
A-2 AUSTRALIAN STANDARDS REFERRED TO IN THIS SPECIFICATION 16
UNCONTROLLED IF PRINTED OR DOWNLOADED

Doc. Name: PCS_103_01 December 2002
Doc. Controller: Policy, Standards & Materials Manager Issue: 01 Page 2 of 16
PROTECTIVE COATING SPECIFICATION
PCS 103
COATING NEW STEEL RESERVOIRS
PART A TECHNICAL REQUIREMENTS
This specification contains three parts. Part A shall be read in conjunction with Part B
and Part C.
DB-1 SCOPE
This specification covers the protective treatment of the internal and external surfaces of new
mild steel reservoirs including wall and floor plates, ladders, fittings and galvanized surfaces
such as roof members and ancillary fittings.
DB-2 GENERAL
The coatings shall be applied by a pre-qualified painting contractor, herein and hereafter
referred to as "the Applicator", who is certified for the site application of high performance
coatings, under Class 3 of the Painting Contractors Certification Program (PCCP).
Following surface preparation and prior to the application of any paints, the Superintendent
shall be given the opportunity to inspect the condition of the surfaces to which the coatings
are to be applied.
Work considered by the Superintendent to be unsatisfactory shall be reworked in accordance

with Clause DB-3 and the appropriate coating specification referred to in Clause DB-5.
In this specification the following terms are used:
A coat of paint - definition - a continuous layer of dried paint film resulting from a single
application of paint.
A single application - definition - consists of one or multiple brush strokes or passes of

a spray gun required to achieve the specified thickness in one dried layer or film of paint.
A coating system - definition - the total number and types of paint coatings, or other
protective or decorative materials, applied separately and in a predetermined order.
Note:Refer to AS/NZS 2310 Glossary of paint and painting terms for all other definitions.
DB-3 SURFACE PREPARATION
DB-3.1 General
Unless otherwise stated, the surface preparation processes apply to all sides of the
members.
To avoid excessive damage and repair to any pre-primed or pre-coated surfaces, wherever
possible rolling, forming and fabrication operations shall be completed prior to the surface
preparation and coating of part or all of the works.
DB-3.2 Metal Preparation
Prior to surface preparation, all metal defects shall be repaired in accordance with Clause
GR-1.1 of Part B.
DB-3.3 Pre-cleaning Internal and External Surfaces
Remove all grease, oil and other contaminants from the surface in accordance with Clause
GR-1.2 of Part B.
DB-3.4 Abrasive Blast Cleaning - External Surfaces
Abrasive blast clean all external bare steel including welds and surface defects to remove
rust and other debris in accordance with Australian Standard AS 1627 - Part 4, so as to
provide a minimum Class 2.5 - near white metal finish with a surface profile of 38-50
microns. [Refer Clause GR-1.3 and GR-1.4 of Part B].
A suitable containment must be used to prevent the spread of emissions.
DB-3.5 Abrasive Blast Cleaning - Internal Surfaces
Abrasive blast clean all internal surfaces in accordance with Australian Standard
AS/NZS 1627 Part 4, so as to provide a Class 3.0 - white metal finish with a surface
profile of 38-50 microns. [Refer Clause GR-1.3 and GR-1.4 of Part B].
DB-3.6 Galvanized Surfaces
Lightly brush blast or hand abrade zinc surfaces to remove all white rust, metal shine and
other debris and to provide a surface profile of not greater than 10 microns. [Refer
AS/NZS 4680, Appendix A-1].
DB-4 COATING SYSTEM
DB-4.1 External Coating System ALK-1B [Refer Table A-2]
Apply Coating System ALK-1B specified in Table A-2 to the external surfaces of the
reservoir. This system consists of a prime coat which has been shop applied [leaving
suitable weld margins]. Weld margins, mechanical damage, etc. shall be spot blast cleaned
and spot primed after erection. A full prime coat plus two [2] coats of micaceous iron oxide
[MIO] alkyd enamel is then applied in-situ.
When a pastel coloured finish is required, the final top coat of micaceous iron oxide (MIO)
alkyd enamel shall be replaced with two coats of alkyd gloss enamel of the required shade.
For external galvanised surfaces, the above coating system shall be applied, substituting one
coat of non-inhibitive epoxy primer for the alkyd primer.

DB-4.2 Internal Coating System EPX-1 [Refer Table A-3]
For all internal steelwork partially or fully immersed in water, the internal coating system shall
be a solventless high build epoxy [coating system EPX-1].
The following additional requirements shall apply:
All steelwork shall be abrasive blast cleaned on site prior to application of any coatings;
where a factory applied primer has been used, that coating shall be removed prior to
application of subsequent coats;
as an alternative coating procedure, an approved epoxy holding primer may be field
applied to prevent deterioration of the blast cleaned surface.
For immersed or partially immersed galvanized surfaces or where the reservoir is within 1 km
of the coastline or subject to salt spray, a coat of a non-inhibitive epoxy primer shall be
applied followed by two [2] coats of high-build, 2-pack solventless epoxy.
Note: Non-immersed galvanized surfaces which are more than 1 km from the coastline
and are not subject to salt spray are not required to be painted.
DB-4.3 External Anti-Graffiti EPU-5 [Refer Table A-4]
Apply Coating System EPU-5 to the bottom strakes of the reservoir to minimise the adhesion
of common graffiti paints and to facilitate easy removal. Care must be taken to prevent
System EPU-5 from overlapping onto other areas. The system consists of two [2] coats of
unmodified polyurethane enamel applied over an epoxy mastic barrier coat. The system
may be applied by brush or roller.
DB-4.4 Metal Sprayed System TSZ-200 [Refer Table A-5]
To protect the base ring of elevated water towers where the base ring is to be in contact with
concrete and cannot be accessed for painting after fabrication and/or erection, 200 microns
of zinc metal shall be hot applied by arc spray to the ring. The thermal sprayed zinc shall
then be seal coated with a non-inhibitive epoxy primer within six hours of application and
before contamination occurs. Finish coats shall then be applied in compliance with the
specification.
DB-4.5 Galvanized Surfaces Roof Members & Ancillary Fittings [Refer Tables A-6
and A-7]
Items specified to be galvanized, including steel roof framing, roof support structures, ladders
and platforms, shall be hot dip galvanized in accordance with AS/NZS 4680 "Hot dip
galvanized (zinc) coatings on fabricated ferrous articles".
DB-5 COATING SYSTEM GUIDE
The Applicator shall select the appropriate coating systems intended for the various parts of
a reservoir in accordance with Table A1 Guide to Choosing a Coating System.
DB-6 RECTIFICATION OF DEFECTS AND DAMAGED COATINGS
To rectify damaged and/or defective areas of coatings and/or to rebuild the dry film
thickness, the Applicator shall adopt the following methodology:
(a) remove all loose and flaking coatings until a sound, tightly adhering edge is achieved;
(b) feather, taper or smooth-off all sharp edges of the remaining sound coating;
(c) grind out pinholes or minor faults sufficiently to ensure the repair coating will penetrate
and eliminate the defect;
(d) ensure the surface is clean and free of oil, grease, dirt and all contaminants in
accordance with Clause GR-1.2, Part B;
(e) abrade the damaged surface with a suitable abrasive tool or emery cloth or by sweep
blasting;
(f) reinstate the surface by applying the coating systems specified in Clause DB-5 and
Tables A-2 to A-6.
Note: The Applicator may adopt an alternative methodology subject to the approval of the
Superintendent.
DB-7 RESERVOIR SIGNAGE
DB-7.1 Interior Signage
Location markings shall be stencilled onto the internal walls and columns as follows to
identify locations within the reservoir:
(i) the wall markings shall be the numerals 1 to 12 inclusive, applied to the wall in a
clockwise configuration;
(ii) the 6 oclock wall position shall be at the base of the internal access ladder and be
represented on the wall by the number 6. The 12 oclock position shall be diametrically
opposite. All other numbers shall be applied progressively according to their positions
on a clock;
(iii) wall and column numbers shall be 200 mm high and positioned 500mm above the
floor;
(iv) columns shall be numbered clockwise with column Number 1 being at the centre and
Number 2 closest to the access point. If the reservoir includes two concentric rings of
columns, the inner ring shall be numbered first and the outer ring second;
(v) wall and column numerals shall be black and stencilled using a 2-pack solventless
epoxy complying with APAS 2974.
The following diagram illustrates the location of the markings.
12
11 1
10 No. 4 2
2
No. 3 No. 1 No. 5 3

9
No. 2
8 4
Access Ladder
7
5
6

DB-7.2 Exterior Signage
The following signage shall be applied to the external wall of the reservoir adjacent to the
external access ladder or stairway:
(a) reservoir identification number e.g. WS123 (as advised by the Superintendent);
(b) date of application of the external and internal coatings by month and year as follows
EXT MM/YY e.g. 08/99
INT MM/YY e.g. 08/99
The colour of the lettering shall be:

Golden Yellow for an environmental green reservoir
OR
Black for a pastel coloured reservoir.
The lettering shall be 100 mm high and applied 1.5 metres above the footpath using an alkyd
gloss enamel complying with APAS-0015/1.

TABLE A-1 - GUIDE TO CHOOSING A COATING SYSTEM
Specification Coating Generic

Table Examples System Classificati
on
A-2 Wall plates, walkways, wind girder, ductile ALK-1B Alkyd
and cast iron fittings.
A-2 Galvanized surfaces such as stair ways, ALK-1B Alkyd
hand rails platforms and galvanized fittings
which require painting e.g. within 1km of the
coastline and subject to salt spray.
A-3 Wall plates, floor plates, columns, iron/steel EPX-1 Solventless
overflow and off-take structures and fittings. Epoxy
A-3 Galvanized surfaces which are immersed or EPX-1 Solventless
in the splash zone such as stairways, hand Epoxy
rails, ladders, platforms.
For non-immersed galvanized surfaces refer
to Note 2 of Table A-3.
A-4 Anti-graffiti treatment. EPU-5 Epoxy
Urethane
A-5 Thermal sprayed zinc for application to the TSZ-200 Thermal arc
base ring of elevated water towers, where spray
the base ring is to be in contact with
concrete and cannot be accessed for
painting after fabrication and erection.
A-6 Repairing and restoring damaged EPX-12 Epoxy Zinc
galvanizing which is not to be painted. Rich
A-7 Hot dip galvanizing GAL-1
Note:
1. The examples given are intended as a guide only and may not be complete.
2. Where the omission of an item gives rise to some doubt concerning which coating system
to be used, the Applicator shall nominate the most appropriate coating system, subject to
the approval of the Superintendent.

PROTECTIVE COATING SPECIFICATION No. PCS 103 PAINTING NEW STEEL RESERVOIRS
TABLE A-2 EXTERNAL System ALK-1B

SURFACE
SCOPE 1st COAT 2nd COAT 3rd COAT 4th COAT
PREPARATION
Zinc Phosphate Primer MIO Alkyd Enamel
Wall plate AS/NZS 1627.4
dft 65-85 microns dft 45-60 microns
Floor plate Class 2.5 Zinc Phosphate Primer MIO Alkyd Enamel
[applied off-site] total dft 220-290 microns
Ductile Iron and Cast Near White dft 65-85 microns dft 45-60 microns
or or
Iron fittings Surface Profile sub. tot. 130-170 microns sub total175-230 microns
[Pre-coated ex BHP works] Alkyd Enamel (2 coats)
[Refer* below] 38-50 microns (Refer Note 2) (Refer Notes 3 and 5)
Epoxy Zinc Phosphate dft 45-60 microns each
(Refer Note 5) (Refer Note 2)
Primer (Refer Note 1) total dft.265-350 microns
Galvanized Degrease Non-inhibitive 2-pack MIO Alkyd Enamel Alkyd Enamel (2 coats)
Hand rails, stair Brush Blast Galvanizing Epoxy Primer dft 45-60 microns dft 45-60 microns each
ways, platform decks Surface Profile Refer DB-4.5 dft 50-75 microns sub total 95-135 microns total dft 185-240 microns
[Refer ** below] <10m [coatings only] [coatings only] [coatings only]
Manufacturers Manufacturers WB Environmental Green
*
colour range colour range tinted for coat WB Environmental Green
COLOUR
identification or
Non-specified colours will be
or AS/NZS 2700 Pastel Colours
selected by the Superintendent Galvanized Surface White or approved colour
** AS/NZS 2700 Pastel (Refer Note 4)
Colours
APAS 2921 APAS 2921 APAS 2910 APAS 2910
*
APAS SPECIFICATION or or
APPROVAL NUMBER for pastel colours for pastel colours
Refer Appendix A-1 APAS 0015/1 APAS 0015/1
** Galvanizing AS/NZS APAS 2971
4680
QUALITY CONTROL TESTS Surface Preparation GR-3.4) Surface Profile (GR-3.6) Dry Film Thickness (GR-3.8) Dew Point (GR-2.3-1)
[minimum] Abrasive Cleaning GR-3.5) Wet Film Thickness (GR-3.7) Surface Temp. (GR-2.3-1) Compressed Air (GR-2.3-2)
Refer PCS Part B
Note 1: For BHP commercially supplied plate, an epoxy zinc phosphate primer may be used as the 1st coat.
Note 2: After construction, brush blast and stripe coat weld margins and spot repair damaged areas before applying the 2nd coat.
The fully primed underside of the floor plates shall be laid directly onto the prepared base of the reservoir.
Note 3: MIO alkyd enamels shall have a Specular Gloss Level of 10 to 15 with a 60 degree geometry head [refer AS/NZS 1580.602.2].
Note 4: Some colours including pastels colours may require an additional (5th) coat for opacity.
Note 5: Do not apply System ALK-1B to strakes and other areas which require anti-graffiti treatment [refer to Table A-4 System EPU-5].

TABLE A-3 - INTERNAL - System EPX-1

SURFACE
PREPARATION
High Build, 2-pack Solventless
Walls, Floor, AS/NZS 1627.4 Optional High Build, 2-pack Solventless
Epoxy
Columns, Mild Steel Class 3.0 2-pack Epoxy site applied Epoxy
dft 250-350 microns
Overflow and Off-take White Metal Holding Primer dft 250-350 microns
tot.dft 500-700 microns
Structures, Fittings Surface Profile dft <25 microns [Thinning not permitted]
[Thinning not permitted]
[Refer* below] 38-50 microns (Refer Note 1) (Refer Note 4)
Immersed galvanized.
Surfaces, Hand rails, High Build, 2-pack Solventless High Build, 2-pack Solventless
Degrease
Ladders, Platforms Non-inhibitive 2-pack Epoxy Epoxy
Brush Blast
Stair ways, Galvanizing Epoxy Primer dft 250-350 microns dft 250-350 microns
Surface Profile
(For non-immersed [Refer Table A-7] dft 50-75 microns sub total 300-425 microns total dft 550-775 microns
<10m
galvanizing, refer [coatings only] [Coatings only] [Coatings only]
Note 2) [Thinning not permitted] [Thinning not permitted]
[Refer ** below]
Manufacturers B-45 Sky Blue or
White or AS/NZS 2700
* colour range AS/NZS 2700
COLOUR approved pastel colour
approved pastel colour
Non-specified colours will be selected
by the Superintendent B-45 Sky Blue or
White or AS/NZS 2700
** Galvanized Surface White or approved colour AS/NZS 2700
APAS 2974
* APAS 2921 AS/NZS 4020 Certified
APAS SPECIFICATION APAS 2974 APAS 2974
(Refer Note 3)
APPROVAL NUMBER AS/NZS 4020 Certified AS/NZS 4020 Certified
Refer Appendix A-1 APAS 2971 (Refer Note 3) (Refer Note 3)
** AS/NZS 4020 Certified
Galvanizing AS/NZS 4680
(Refer Note 3)
QUALITY CONTROL TESTS Surface Preparation (GR-3.4) Wet Film Thickness (GR-3.7) Surface Temp. (GR-2.3-1) Degree of Cure (GR-3.9)
[minimum] Abrasive Cleaning (GR-3.5) Dry Film Thickness (GR-3.8) Dew Point (GR-2.3-1) Film Continuity 6,000 volts DC
Refer PCS Part B Surface Profile (GR-3.6) Compressed Air (GR-2.3-2) (GR-3.10)
Note 1: A 2-pack Epoxy Holding Primer may be applied on site to avoid deterioration of freshly blast cleaned surfaces prior to the application of the Solventless Epoxy lining .
Note 2 Non-immersed galvanized surfaces are not required to be coated unless the reservoir is within 1 km of a coast line or is subject to salt spray.
Note 3: Coatings to be immersed in potable water shall be certified by a NATA approved laboratory for compliance with AS/NZS 4020.
nd
Note 4: "Stripe coat" weld margins and plate edges before applying 2 coat.

TABLE A-4 - ANTI-GRAFFITI System EPU-5

SURFACE
PREPARATION
AS/NZS 1627.4 2-pack Unmodified
2-pack Epoxy Mastic 2-pack Epoxy Mastic 2-pack Unmodified
Anti-graffiti treatment Class 2.5 Polyurethane
dft 75-100 microns dft 100-150 microns Polyurethane
for application to the "Near White" dft 50-75 microns
Apply by brush or roller to Apply by brush or roller to dft 50-75 microns
two bottom strakes of Surface Profile total dft 275-400 microns
prepared surface existing paint Apply by brush or roller
reservoirs 38-50 microns Apply by brush or roller
(Refer Note 1) (Refer Note 2) (Refer Note 2)
(Refer Note 1) (Refer Note 2)
COLOUR Environmental Green

Manufacturers Manufacturer's Ti-Tree
Non-specified colours will be selected by G-66 AS/NZS 2700
colour range colour range G65 AS/NZS 2700
the Superintendent or as selected
APAS SPECIFICATION
APAS 2911 APAS 2911
APPROVAL NUMBER APAS 2977 APAS 2977
Unmodified Unmodified
Refer Appendix A-1
QUALITY CONTROL TESTS Surface Preparation (GR-3.4) Wet Film Thickness (GR-3.7) Surface Temp. (GR-2.3-1) Dew Point (GR-2.3-1)
[minimum] Dry Film Thickness (GR-3.8)
Refer PCS Part B
Note 1: After construction, brush blast and "strip coat" weld margins and spot repair damaged primer with 2-pack Epoxy Mastic, before applying the 2nd coat.
Note 2 Apply the anti-graffiti system to the bottom two strakes or other nominated areas. Avoid overlapping onto other strakes and areas.
.

TABLE A-5 THERMAL SPRAYED ZINC METAL System TSZ-200S

SURFACE
PREPARATION
Non-inhibitive 2-pack Epoxy
Abrasive blast
Apply thermal sprayed zinc Primer
clean to meet
Protection of the metal (99.9%) by arc spray dft 50-75 microns Apply the specified finish
AS/NZS 1627.4
base ring of elevated process. total dft (metal spray + coat(s) in compliance with
Class 3.
water towers. dft = 200 microns sealer) the relevant surface
Surface profile 75
(Refer Note 1) =250-275 microns
microns
(Refer Note 2)
COLOUR
Non-specified colours will be selected by Silver grey White As specified
the Superintendent
APAS SPECIFICATION
APPROVAL NUMBER Not applicable APAS 2971
Refer Appendix A-1
Surface Preparation (GR-3.4) Wet Film Thickness (GR-3.7) Surface Temp. (GR-2.3-1) Degree of Cure (GR-3.9)
QUALITY CONTROL TESTS Compressed Air (GR-2.3-2)
[minimum] Abrasive cleaning (GR-3.5) Dry Film Thickness (GR-3.8) Dew Point (GR-2.3-1)
Refer PCS Part B Surface Profile (GR-3.6)
Note 1: Apply the seal coat as soon as possible after applying the sprayed metal coating. Ensure the sprayed zinc is dry and free of contaminants.
Note 2 Thinning of the seal coat may be necessary to achieve effective penetration of the thermal sprayed zinc.
.

TABLE A-6 REPAIR OF GALVANIZING System EPX-12
SURFACE
PREPARATION
Brush blast to AS/NZS
1627.4 Class 2 with a Aluminium Paint Leafing
To repair
profile 5-12 microns or 2-pack Epoxy Zinc Rich Grade
damaged
abrade by hand using Coating dft = 30-40 microns
galvanizing
emery AS/NZS 1627.2 dft = 75 microns total dft = 105-111 microns
(Refer Note 1)
to remove damaged (Refer Note 2)
galvanizing and rust
COLOUR
Non-specified colours will be selected by Light Grey Silver
the Superintendent
APAS SPECIFICATION
APPROVAL NUMBER APAS 2916 APAS 2910
Refer Appendix A-1
QUALITY CONTROL TESTS Surface Preparation (GR-3.4) Wet Film Thickness (GR-3.7) Surface Temp. (GR-2.3-1) Compressed Air (GR-2.3-2)
[minimum] Abrasive Cleaning (GR-3.5) Dry Film Thickness (GR-3.8) Dew Point (GR-2.3-1) Degree of Cure GR-3.9)
Refer PCS Part B Surface Profile (GR-3.6)
Note 1: Alternative repair methodology may be acceptable subject to the approval of the Superintendent.
Note 2 The optional second coat of leafing aluminium is for use when a close colour match to new galvanizing is required.

TABLE A-7 HOT DIP GALVANIZING System GAL-1

AVERAGE GALVANIZING THICKNESS
THICKNESS OF STEEL GALVANIZING MASS (Refer Notes 3 and 4)
SCOPE (Refer Note 1) (Refer Note 2) m
mm g/sq.m Minimum Average
Galvanized steel surfaces such as roof members 1.5 320 35 45
and ancillary fittings. >1.5 3.0 390 45 55
(Refer Note 5) >3.0 6.0 500 55 70
>6.0 600 70 85
QUALITY CONTROL TEST
Dry Film Thickness (GR-3.8)
[minimum]
Note 1: Reference: Table 1, Page 8 of Australian Standard AS/NZS 4680.
Note 2: 100 g/sq.m 14 m thickness of galvanizing.
Note 3: Refer AS/NZS 3894.3.
Note 4: Fasteners 50 m thickness of galvanizing.
Note 5: Steel items to be galvanized shall be prepared and processed in compliance with Australian Standard AS/NZS 4680 "Hot dip galvanized (zinc)
coatings on fabricated ferrous articles"

APPENDIX A-1
(Informative)
COATINGS APPROVED
UNDER THE
AUSTRALIAN PAINT APPROVAL SCHEME [APAS]
SPECIFICATION
STANDARDS
COATING DESCRIPTION
APAS Previously AUSTRALIA
(Note 1) GPC
Aluminium paint Leafing grade alkyd APAS 2910 AS/NZS 3750.7
enamel
Aluminium paint Leafing grade alkyd APAS 2910 AS/NZS 3750.7
enamel
Alkyd Enamel Full gloss exterior APAS 0015/1 GPC-E-15/3 AS/NZ 3750.15
enamel or GPC-E- Type 4
240
MIO Alkyd MIO pigmented APAS 2910 GPC-C- AS/NZS
Enamel alkyd enamel Gloss 29/10A 3750.15
10-15 60 deg.
Head
Zinc Phosphate Anti-corrosive zinc APAS 2921 GPC-C- AS/NZS 4025
Primer phosphate 29/2A
pigmented primer
Epoxy Mastic 2-pack Epoxy Mastic APAS 2977 GPC-C-29/7 AS/NZS 3750.1
Type 2
Epoxy Zinc 2-pack, Epoxy APAS-2971 GPC-C- AS/NZS 2674
Phosphate Primer 29/7E Type 1
Non-inhibitive 2-pack, Non- APAS-2971 GPC-C-29/7 AS/NZS 2674
Epoxy Primer inhibitive Epoxy Non-inhibitive
Primer
Organic Zinc 2-pack epoxy zinc APAS 2916 AS/NZS 3750.9
Rich rich coating
Solventless High-build, 2-pack, APAS 2974 GPC-C-29/7 AS/NZS 3750
Epoxy Solventless Epoxy Type 4
(Note 2)
Polyurethane 2-pack, APAS 2911 AS/NZS 3750.6
Finish Polyurethane Full
Gloss Unmodified
Note 1: A Certificate of Supply from the paint manufacturer must be provided by the
Applicator, confirming the currency of the APAS approval.
Note 2: Coatings required for immersion in drinking water shall be certified by a NATA
approved laboratory for compliance with AS/NZS 4020.

APPENDIX A-2
(Informative)
AUSTRALIAN STANDARDS
REFERRED TO IN THIS SPECIFICATION
AS/NZS 1580.602.2 Methods of test Measurement of specular gloss of non-

metallic coatings
AS/NZS 1627 Surface Preparation, Parts 1-9
AS/NZS 2310 Glossary of paint and painting terms
AS/NZS 2673 Alkyd enamel/Micaceous iron oxide alkyd
AS/NZS 2674 Type 1 Epoxy zinc phosphate/non-inhibitive epoxy primers
AS/NZS 2700 Australian standard colours
AS/NZS 3750.1 Epoxy mastic
AS/NZS 3750.2 UHB epoxy
AS/NZS 3750.6 Polyurethane high solids
AS/NZS 3750.7 Paints for steel structures aluminium
AS/NZS 3750.9 Organic zinc rich primer
AS/NZS 3750.10 Epoxy enamel, 2-pack
AS/NZS 3570.15 Type Full gloss/MIO pigmented alkyd
4
AS/NZS 3894.1 Site testing of protective coatings Continuity testing - High
voltage (brush) method
AS/NZS 3894.3 Site testing of protective coatings Determination of film
thickness
AS/NZS 3894.4 Site testing of protective coatings Degree of cure
AS/NZS 3894.5 Site testing of protective coatings Determination of surface
profile
AS/NZS 3894.6 Site testing of protective coatings Contamination
AS/NZS 3894.10 Inspection report Daily
AS/NZS 3894.11 Inspection report Equipment
AS/NZS 3894.12 Inspection report Coating
AS/NZS 4020 Products for use in contact with drinking water
AS/NZS 4025 Zinc phosphate, anti-corrosive primer
AS/NZS 4680 Hot dip galvanized (Zinc) coatings on fabricated ferrous
articles


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TITLE NAME: COATING NEW STEEL RESERVOIRS

FILE NAME: PCS_103_01 TOTAL PAGES: 16

REVISION DATE: December 2002

This document and the document PCS_BC, GENERAL AND

AUTHORISED BY: STRATEGIC ASSET MANAGEMENT, SWC

NAME: JERRY SUNARHO

POSITION: STANDARDS ENGINEER

PHONE: 9828 8572

FAX: 9828 8454

1. This page is to be deleted it does not form part of the Document.

PROTECTIVE COATING SPECIFICATION

PCS 103 Part A

Coating New Steel Reservoirs

PART A TECHNICAL REQUIREMENTS 3

DB-3 SURFACE PREPARATION 3

DB-4 COATING SYSTEM 4

DB-5 COATING SYSTEM GUIDE 5

DB-6 RECTIFICATION OF DEFECTS AND DAMAGED COATINGS 5

DB-7 RESERVOIR SIGNAGE 6

A-1 - GUIDE TO CHOOSING A COATING SYSTEM 8

A-2 - EXTERNAL SYSTEM ALK-1B 9

A-3 - INTERNAL - SYSTEM EPX-1 10

A-4 - ANTI-GRAFFITI SYSTEM EPU-5 11

A-5 - THERMAL SPRAYED ZINC METAL SYSTEM TSZ-200S 12

A-6 - REPAIR OF GALVANIZING SYSTEM EPX-12 13

A-7 - HOT DIP GALVANIZING SYSTEM GAL-1 14

A-1 COATINGS APPROVED UNDER THE AUSTRALIAN PAINT APPROVAL

A-2 AUSTRALIAN STANDARDS REFERRED TO IN THIS SPECIFICATION 16

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PROTECTIVE COATING SPECIFICATION

COATING NEW STEEL RESERVOIRS

PART A TECHNICAL REQUIREMENTS

Work considered by the Superintendent to be unsatisfactory shall be reworked in accordance

In this specification the following terms are used:

A single application - definition - consists of one or multiple brush strokes or passes of

DB-3 SURFACE PREPARATION

DB-3.2 Metal Preparation

DB-3.3 Pre-cleaning Internal and External Surfaces

DB-3.4 Abrasive Blast Cleaning - External Surfaces

A suitable containment must be used to prevent the spread of emissions.

DB-3.5 Abrasive Blast Cleaning - Internal Surfaces

DB-3.6 Galvanized Surfaces

DB-4 COATING SYSTEM

DB-4.1 External Coating System ALK-1B [Refer Table A-2]

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DB-4.2 Internal Coating System EPX-1 [Refer Table A-3]

The following additional requirements shall apply:

DB-4.3 External Anti-Graffiti EPU-5 [Refer Table A-4]

DB-4.4 Metal Sprayed System TSZ-200 [Refer Table A-5]

DB-5 COATING SYSTEM GUIDE

DB-6 RECTIFICATION OF DEFECTS AND DAMAGED COATINGS

DB-7 RESERVOIR SIGNAGE

DB-7.1 Interior Signage

The following diagram illustrates the location of the markings.

No. 3 No. 1 No. 5 3

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DB-7.2 Exterior Signage

The colour of the lettering shall be:

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TABLE A-1 - GUIDE TO CHOOSING A COATING SYSTEM

Specification Coating Generic