Corrosion Protection - Pylons

ERICO.
ERIC O. ALERS
ALERS - Training
- Course for Course
Training the Corrosionfor
protection
the of High Voltage Pylons
Corrosion protection of High Voltage Pylon
S.R.N. Business Consulting CC - CENTRAL ELECTRICITY BOARD - Mauritius
S.R.N. Business Consulting CC - CENTRAL ELECTRICITY BOARD Mauritius
Page 1
ERIC O. ALERS - Training Course for the Corrosion protection of High Voltage Pylons
Size of team
Experience has shown us to use 5 people per tower

4 painters, one per tower-leg
1 assistant on the ground
to mix paint, supply water, clean bases etc.
We do 4 adjacent towers at a time using 20 people in a team.

By doing this 1 overseer can have visual contact using
binoculars over the entire team.
Page 2
Personal Attributes Required

for Staff to Work on Towers
Can be Male or Female

(bear in mind doubling of ablution facilities)
Preferable age 20 to 45 years

(old enough to be mature, young enough to be agile)
Must be literate enough to understand safety instructions and

acknowledge same by signature at daily tool-box talk
(see form 001 page 1 and 2)
Page 3
Personal Attributes Required of Staff to

Work on Towers
Experience of brush painting is highly desirable but not

compulsory
Must be medically fit and not overweight

(to ensure agility)
Must have good hearing ability and understand all

commands in the language of the Supervisor
Page 4
Personal Attributes Required of Staff to

Work on Towers
Must have good eyesight and not require prescription spectacles

(safety goggles must be worn)
Must be comfortable wearing all personal protective equipment

required
Must not have any fear of working in an elevated position
Must not abuse Alcohol or drugs before or during working in

elevated position.
Page 5
Personal Protective Equipment
Long sleeves and long

legged overalls
(to prevent sunburn)
Page 6
Reflective Vest
(for high visibility)
Page 7
Hard hat complete

with chin strap
(to prevent loss of
hat)
Page 8
Firm soled footwear

(to support
persons weight on
narrow steel)
Page 9
Full body harness with a

minimum of two
attachment lanyards (to
be permanently secured
to steel tower structure)
(see Form 002 page 1 to 4)
Page 10
Soft protective hand gloves

(to allow sense of feel)
Dust fume mask

(to prevent inhalation of paint
fumes)
Page 11
Soft type eye protection (to

protect from paint
splashes and dust)
Page 12
All hand tools used must be

secured by lanyards to
the body harness
Page 13
Equipment required at each Pylon
Single light rope tackle to feed

equipment and material to
painters
Water for drinking
Adequate supply of potable water

with booster pump to wash
down the steelwork
Page 14
Equipment required at each worksite
Full first aid kit

Rescue kit
Fire Extinguisher
Page 15
Safety requirements at the beginning of

each shift
Supervisor will ensure that electrical To be

staff has isolated and earthed done by
all conductors before anyone is Electrical
allowed to ascent the tower Engineer
(to be confirmed in writing)
(see Form 003 page 1 and 2)
Page 16
Safety requirements at the

beginning of each shift
Supervisor will lead a tool-box

safety talk and invite
questions from workers
(see attached Form 001)
Each worker will sign that he is

familiar with the safety
requirements
Page 17
Safety requirements at the

beginning of each shift
Each worker will inspect

and ensure that all
P.P.E. is in good
condition and
working correctly
Page 18
Form 001 Page 1 Tool Box Talk
Page 19
Form 001 Page 2 Tool Box Talk
Page 20
Form 002 WORKING ELEVATED

AREAS Safe working procedures
Page 21
Form 003 Risk Assessment
Page 22
Form 004 010

Appointment Forms
Form 004 Appointment of Supervisor

Form 005 Appointment of First Aid Co-Ordinator
Form 006 Appointment of First Aider
Form 007 Appointment of Health and Safety Representative
Form 008 Appointment of Safety Harness Survey Officer
Form 009 Appointment of Pollution Survey Officer
Form 010 Appointment of Fire Fighting Co-Ordinator
Page 23
Scope of work to be done
The scope of work shall be the painting and

refurbishment of galvanized steel and
previously painted overhead transmission line
towers, plus the replacement of a number of
the structural steel supports that are too badly
rusted to repaint and the replacement of bolts
and nuts where necessary
Page 24
Scope of work to be done
Pre-inspection team to specify the number of

steel supports as well as bolts and nuts
necessary
The scope of work covers the requirements for the

furnishing of materials, labor, tools,
equipment and all other services necessary to
provide for the requirements of this
maintenance work
Page 25
Site Access and Delivery Details
Site : HV overhead lines as indicated

Access to site: Surfaced road and off-road sections and
mountainous areas
Site office: The team shall provide their own site office
if required
Offloading: The team is responsible for all offloading
Storage facilities: The team shall provide their own storage
facilities
Electricity: Portable unit if required
Toilet facilities: Team to provide
Page 26
Site Conditions
Altitude: No more than 800m above mean sea

level
Temperature: Ambient temperature between 15C and
35C
Average daily
maximum ambient: 32C
Cyclone: Cyclone Conditions at times
Pollution: The area is located near salt water and
is subject to industrial / agricultural
pollution.
Annual average of 4-6 working days per month is lost due

to inclement weather.
Page 27
Paint Specifications
Scope: This section covers the application of coating to

the structural steelwork and also the concrete
foundations.
Requirement: Surface preparation and application of coatings
Page 28
Corrosion Protection System for

Weathered Galvanised Steel
Remove all oil and grease by

washing with a water
emulsifying solvent
degreaser and rinsing with
potable water to a water
break free surface
Page 29

Remove all loose rust, rust scale and

loose or flaking paint by scraping
with flat scrapers followed by wire
brushing of the rusty areas to St2
of the International Standard ISO
8501-1:1988 followed by
sandpapering the existing paint
with medium *80 grit) sandpaper
to feather edge sharp edges,
remove chalking and provide a key.
Page 30

The use of small power tools fitted with medium to

coarse grinding discs combined with wire
brushing and sanding will speed up surface
cleaning. Thoroughly wash all cleaned steel with
running potable water (use hose pipe) and
scrubbing brushes to remove salts.
PH must be 7. Allow to dry 30 minutes and prime.
Page 31

Coating System
1st coat - (Prime coat)
Material - Sigmacover Aluprimer
Generic type - Aluminium pigmented polymine cured
modified epoxy primer/coating
Application - By brush & roller
Theoretical cover - 7,2m/Lt @ 125(micron)
Film Thickness - Wet = 140, Dry = 125
Minimum time between coats - 24hrs @ 25C
Page 32

Coating System
2nd coat - (Intermediate coat)
Material - Sigma Cover 630 Grey 5177 (multimastic)
Generic type Highbuild polymine cured epoxy coating
Application- By brush & roller
Page 33

Coating System
3rd coat - (Finish coat)
Material - Sigmadur Gloss 550 (colour of choice)
Generic type Aliphatic acrylic polyurethane finish coating
Theoretical cover 6.9m/Lt @ 80 (micron)
Minimum curing time - 24hrs @ 25C
Total Dry Film Thickness ( DFT ) 330
Page 34

NEW Galvanised Steel
Includes:
structural members
bolts and nuts
for the Overhead Power Lines.
Page 35

Remove all traces of protective storage oil by scrubbing

with AEROWASH or equivalent followed by thorough
rinsing with potable running water (use hose pipe) to
obtain a water break-free surface. If necessary,
repeat above until water break free. Follow this by
scrubbing with GALVANISED IRON CLEANER or
equivalent and rinsing with potable running water.
Allow to dry before priming.
Note: Failure to achieve a water break-free surface will
result in determination of the primer. It is essential to
do the surface preparation of a small area (a few m).
Page 36

Coating System
Material - Sigmarite Sealer 522 Red-Brown
Generic type - Epoxy Polymide Primer
Theoretical cover - 8.0m/Lt @ 70 (micron)
Page 37

Coating System
2nd coat - (Intermediate coat)
Material - Sigma Cover 630 Grey 5177 (multimastic)
Generic type Highbuild polymine cured epoxy coating
Application- By brush & roller
Page 38

Coating System
3rd coat - (Finish coat)
Material - Sigmadur Gloss 550 (colour of choice)
Generic type Aliphatic acrylic polyurethane finish coating
Theoretical cover 6.9m/Lt @ 80 (micron)
Page 39

Concrete Bases
Surface Preparation
Clean concrete surfaces with Biocidal Masonery Wall Wash or
equivalent, to remove all Algae.
Rinse with clean potable water and allow to dry for 24hrs.
Page 40

Concrete Bases
Coating System
Material - Sigma cover 300 (Brown)
Generic type High build polyamine adduct cured coaltar
epoxy coating
Theoretical cover - 3.9m/Lt @ 200(micron)
Maximum curing time - 36hrs @ 25C
Before over coating
Page 41

Concrete Bases
Coating System
2nd coat :- (Finish coat)
Material:- Sigma cover 300 (black)
Generic type High build polyamine adduct cured coaltar
epoxy coating
Application:- By brush & roller
Theoretical cover:- 3.9m/Lt @ 200(micron)
Film Thickness:- Wet = 265, Dry = 200
Minimum curing time :- 18hrs @ 25C
Page 42
Quality Assurance provisions

Storage
The Supervisor shall be responsible for the delivery,
unloading and storage of the necessary materials to
ensure progress of the works in accordance to
the programme.
All materials shall be stored under cover and clear of
the ground.
Every care shall be taken during mixing of materials
to ensure the least possible spillage occurs and
the Supervisor shall take steps to clear up the
spillage immediately.
All materials shall be stored so as to ensure that
materials are used on a first in first out basis.
Page 43
Scaffolding
The Supervisor shall provide and erect his own
scaffolding and rigging as may be required.
All scaffolding and rigging shall meet the
requirements of both the Occupational Health
and Safety Act and Owners Operating
Regulations for High Voltage Systems.
At the end of every shift, the Supervisor shall
ensure that all scaffolding and rigging are
removed to allow for a minimum clearance
from each conductor of 2,5 meters.
Page 44
Coating Application
The following parameters shall be strictly adhered to during
the application of the coatings.
Ensure mixing of multi-pack products in the correct ratio.
Ensure that all induction periods for multi-pack products are
achieved as called for in the manufacturers data sheet.
Page 45
Inspections
The Engineer may check the Dry Thickness of each coat
prior to over coating, If it is found that insufficient coating
thickness has been achieved, the Supervisor will be
instructed to apply further coats to the Engineers
satisfaction.
All testing of Dry Film Thickness will be accordance to SABS
141. In the case of a dispute the permascope MK E 58
fully electronic instrument shall be the unit of final
determination.
Page 46
Inspections
A minimum of 90% of all thickness shall comply with the
requirements of this specification. A maximum tolerance
of 10% will be allowed on the balance of the measured
thickness. Any coatings not complying with these
requirements will be rejected.
Where the coating system is excessively thick, the Engineer
may instruct the Supervisor to remove the coating system
and reapply to the correct thickness
Page 47
Crevices
Crevices in overlapping joints, such as between mating
surfaces of bolted connections and similar narrow gaps,
shall be caulked with material suitable for out door use
and be over coatable such as acrylic silicone sealer.
Page 48
Nuts, Bolts and Washers
All bolts, nuts, studs, pins and washers shall be hot dip
galvanized in accordance with ISO 1461 and painted
according to the system for new galvanized iron.
Page 49
Replacement Structural Steel Members
All replacement members shall be hot dip galvanized in

accordance with ISO 1461 and painted according to paint
specification for new galvanized iron structural members.
Maximum of one member to be replaced at a time to prevent
undue weakening of the tower.
Page 50
Thank You
We hope you have enjoyed this theoretical course.
Now, lets move out into the field and put into practice what
you have learnt.
Page 51

Corrosion Protection - Pylons

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ERICO.

Experience has shown us to use 5 people per tower

We do 4 adjacent towers at a time using 20 people in a team.

Personal Attributes Required

Can be Male or Female

Preferable age 20 to 45 years

Must be literate enough to understand safety instructions and

Personal Attributes Required of Staff to

Experience of brush painting is highly desirable but not

Must be medically fit and not overweight

Must have good hearing ability and understand all

Personal Attributes Required of Staff to

Must have good eyesight and not require prescription spectacles

Must be comfortable wearing all personal protective equipment

Must not have any fear of working in an elevated position

Must not abuse Alcohol or drugs before or during working in

Personal Protective Equipment

Long sleeves and long

Personal Protective Equipment

Personal Protective Equipment

Hard hat complete

Personal Protective Equipment

Firm soled footwear

Personal Protective Equipment

Full body harness with a

Personal Protective Equipment

Soft protective hand gloves

Dust fume mask

Personal Protective Equipment

Soft type eye protection (to

Personal Protective Equipment

All hand tools used must be

Equipment required at each Pylon

Single light rope tackle to feed

Water for drinking

Adequate supply of potable water

Equipment required at each worksite

Full first aid kit

Safety requirements at the beginning of

Supervisor will ensure that electrical To be

Safety requirements at the

Supervisor will lead a tool-box

Each worker will sign that he is

Safety requirements at the

Each worker will inspect

Form 001 Page 1 Tool Box Talk

Form 001 Page 2 Tool Box Talk

Form 002 WORKING ELEVATED

Form 003 Risk Assessment

Form 004 010

Form 004 Appointment of Supervisor

Scope of work to be done

The scope of work shall be the painting and

Scope of work to be done

Pre-inspection team to specify the number of

The scope of work covers the requirements for the

Site Access and Delivery Details

Site : HV overhead lines as indicated

Altitude: No more than 800m above mean sea

Annual average of 4-6 working days per month is lost due

Scope: This section covers the application of coating to

Requirement: Surface preparation and application of coatings

Corrosion Protection System for