January 02, 2014

TRANSMISSION CONSTRUCTION STANDARD TCS-P-122.23, Rev. 0

TABLE OF CONTENTS

1.0 SCOPE

2.0 BACKGROUND

3.0 APPLICABLE CODES AND STANDARDS

4.0 COVERED PAINTING YARD

5.0 CLEANING, SURFACE PREPARATION, AND PAINTING

5.1 General

5.2 Communication with the Galvanizer

5.3 Determining Condition of Galvanized Steel Surface

5.4 Cleaning Galvanized Steel Surface

5.5 Profiling Galvanized Steel Surface

5.6 Application of Paint on Galvanized Steel Surface

5.7 Areas Not to be Painted

5.8 Bolts and Nuts

6.0 FIELD TESTS AND TEST INSTRUMENTS

7.0 REPAIRS TO PAINT COATINGS DAMAGED DURING TRANSPORTATION

8.0 QUALITY CONTROL STEPS

9.0 SAFE WORK PRECAUTIONS

APPENDIX I Typical Pro-forma for Keeping Record of Paint Application Process

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TRANSMISSION CONSTRUCTION STANDARD TCS-P-122.23, Rev. 0

1.0 SCOPE

This standard describes the procedures for preparing and painting hot dip galvanized steel
surfaces of transmission line and substation steel structures to be used in the transmission
system of National Grid Saudi Arabia.

2.0 BACKGROUND

Transmission line and substation steel structures are required to perform in desert, marine
and industrial type corrosive environment. This requires a suitable corrosion protection
system, which could last for the life of the transmission network (say about 30-35 years).
Hot-dip galvanizing of steel structures is so far the preferred solution to combat corrosion
problems. In the past, National Grid Saudi Arabia had tried this solution by applying normal
zinc coating thickness (86 µm) as well as heavy zinc coating thickness (130 µm) in the
inland desert and coastal area respectively. The performance of this system has been
acceptable except in the western coast along the red sea where the conditions are much
severe and require the need of painting over hot dip galvanized steel (known as duplex
system) as a standard corrosion protection system. This standard therefore, has been
developed to provide general guidelines related to surface preparation and application of
paint over hot dip galvanized steel structures for transmission line and substation to their
installation at site. The duplex system (galvanizing and paint together) when applied to a
carefully prepared surface will provide long-lasting surface protection; 1.5 to 2.3 times their
individual service-life.

3.0 APPLICABLE CODES AND STANDARDS

The latest revisions of the following Codes and Standards shall apply. The Contractor may
propose equivalent Industry Codes and Standards other than those quoted hereunder without
jeopardizing the requirements of this TCS, in which case he shall submit a copy of the
proposed standards and shall submit a written proof that the proposed standards in all
significant respects are equal to or better than those specified. Acceptability of any alternate
code or standard is at the discretion of National Grid Saudi Arabia.

3.1 ASTM A780M Standard Practice for Repair of Damaged and Uncoated Areas of Hot
Dip Galvanized Coatings

3.2 ASTM D4414 Standard Practice for Measurement of Wet Film Thickness by Notch
Gages

3.3 ASTM D4541 Standard Test Method for Pull-Off Strength of Coatings Using
Portable Adhesion Testers

3.4 ASTM D6386 Standard Practice for Preparation of Zinc (Hot-Dip Galvanized)
Coated Iron and Steel Product and Hardware Surfaces for Painting

3.5 ASTM E376 Standard Practice for Measuring Coating Thickness by Magnetic-
Field or Eddy-Current (Electromagnetic) Testing Methods

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TRANSMISSION CONSTRUCTION STANDARD TCS-P-122.23, Rev. 0

3.6 ISO 2409 Paints and Varnishes-Cross-Cut Test

3.7 ISO 12944-4 Paints and varnishes-Corrosion protection of steel structures by

protective paint systems-Part 4: Types of surface and surface
preparation

4.0 COVERED PAINTING YARD

All processes related to painting of steel structures shall be performed in a covered yard built
at site or at other suitable location. Yard shall have the facilities, but not limited to the
following:

4.1 Yard area shall be sufficient allowing workers and their equipment to move in a
freely manner within the shed area.

4.2 The stands for resting structure members/angle sections shall be of suitable
dimensions.

4.3 Painting area shall be dust free and shall have proper ventilation to avoid suffocation.

4.4 Yard shall have fire extinguishers to avoid any hazards.

5.0 CLEANING, SURFACE PREPARATION, AND PAINTING

5.1 General

5.1.1 Proper surface preparation is the key to creating an effective bond between
the paint and the galvanized surface. Poor surface will make paint failure in a
few months in the field, and results in blistering, peeling, or flaking paint.
Thus, the surface preparation is extremely important because the degree of
paint adhesion may not be apparent immediately after application. Surface
preparation is the most costly portion of a painting project. Nearly all failures
in painting of hot dip galvanized steel occur because of inadequate surface
preparation or recontamination of reactive clean zinc surface before painting.

5.1.2 Galvanized steel requires slightly different preparation steps according to the
surface condition. Thus, proper preparation relies on correctly identifying the
galvanized surface condition, and then follows the appropriate cleaning and
profiling steps to achieve optimum bonding of the paint to the hot dip
galvanized steel. For detailed instructions on preparing the surface, refer to
ASTM D6386

5.1.3 The hot dip galvanized coating forms when the iron in the steel reacts with
zinc in the galvanizing kettle. Zinc like all metals, is chemically active and
when exposed to the atmosphere will attract oxygen and water vapors to its
surface to form zinc compounds. The rate of zinc compound formation
depends on number of variables, including the amount of time the steel
withdrawn from the zinc kettle, the temperature of the steel and the humidity

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TRANSMISSION CONSTRUCTION STANDARD TCS-P-122.23, Rev. 0

in the atmosphere. Following five steps shall create a successful duplex

system.

- Communication with the Galvanizer

- Determining Condition of Galvanized Steel Surface

- Cleaning Galvanized Steel Surface

- Profiling Galvanized Steel Surface

- Application of Paint on Galvanized Steel Surface

5.2 Communication with the Galvanizer

Communication between the fabricator (steel manufacturer), specifier (National Grid

Saudi Arabia), painter (contractor/paint applicator/paint manufacturer), and
galvanizer (steel manufacturer) is vital before galvanizing. The various parties may
desire special handling or require alterations to the design to facilitate the
galvanizing process and/or the application of paint. If the galvanizer is aware of that
the steel will be painted after galvanizing, precautions can be taken to avoid any
processes that may interfere with the adhesion of the paint system.

Many galvanizing facilities either immerse the steel in a water-quench or passivation

bath to cool the steel to facilitate quick handling as well as prevent the formation of
wet storage stain. The passivation prevents the formation of excessive zinc
compounds, but also interferes with the paint adhesion and can lead to peeling of the
paint.

5.3 Determining Condition of Galvanized Steel Surface

Knowledge of the condition of the galvanized steel surface layer before paint
application is critical to producing an effective paint coating system. There are three
(3) general conditions experienced on the galvanized steel surface layer. These are
classified as; newly/freshly galvanized steel, partially weathered/aged galvanized
steel, and fully weathered/aged galvanized steel. It is important to identify the
condition of the galvanized steel surface to be painted, as each condition requires a
different amount of cleaning and/or profiling.

5.3.1 Newly/Freshly Galvanized Steel

This condition prevails only within first 48 hours after galvanizing. In this
condition, only zinc oxides are present on the surface with little or no zinc
hydroxides or carbonates. The coating will be bright and shiny, indicating a
totally zinc outer layer, or dull gray, indicating a zinc-iron inter-metallic outer
layer, or a combination of both. Regardless of the surface of the galvanized
steel whether smooth or rough, sweep blasting is necessary to ensure
adherence of the paint system.

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5.3.2 Partially Weathered/Aged Galvanized Steel

The partially weathered galvanized surface condition is present from 48 hours

to 12 months of outdoor exposure after the galvanizing, depending upon
temperature and humidity factors. The partially weathered galvanized
surfaces have a build-up of zinc compounds (zinc hydroxides and/or
carbonates-patina) and, possibly, organic compounds such as dirt, dust, oil, or
grease. These compounds are not well adhered to the substrate and attach to
the zinc coating by electrostatic forces. The zinc compounds, mostly zinc
oxide and zinc hydroxide, should be removed before painting. Partially
weathered galvanized steel may have wet storage stains that should also be
removed before painting.

Partially weathered galvanized steel is the most common galvanized surface

condition when painting, and most difficult to prepare. Painting requirements
for National Gird Saudi Arabia transmission and substation hot dip
galvanized steel structures generally fall under the category of partially
weathered galvanized steel. Therefore, the guidelines presented in this
standard specifically address the partially weathered condition of the
galvanized surfaces.

5.3.3 Fully Weathered/Aged Galvanized Steel

Fully weathered galvanized steel is the condition after 12 months of exposure

of the galvanized surface to atmosphere. Zinc compounds cover the entire
surface and the main compound is the zinc carbonate (patina). Zinc carbonate
is tightly adhered to the zinc surface and is water insoluble, and does not
wash off with water. In this state, zinc compound should not be removed, as
the paint performs better when the compounds are left on the surface. Fully
weathered galvanized surfaces are the simplest surface conditions to paint.

5.4 Cleaning Galvanized Steel Surface

Once the condition of galvanized surface has been identified, the next step is to clean
the surface. There are three steps to clean the surface. At each step, follow the
recommendations of ASTM D6386 or any other equivalent industry code/practice
such as Steel Structure Paint Council, USA (SSPC).

5.4.1 Removal of Bumps, Runs and Drips

Remove any excess zinc produced during withdrawal of the steel from the
zinc bath. Excess zinc is normally deposited on the edges of steel. A run is the
excess zinc that freezes along the surface of steel, and drip is the excess zinc
as it falls off the edge of the steel, creating an icicle-like zinc spike. Another
surface condition is the removal of dross particles. The zinc-iron inter-
metallic dross particles float in the zinc bath and trap in the outer layer of
coating. Dross particles are thicker than the coating and cause bumps and
pimples on the surface. Therefore, all bumps, runs, drips and dross particles
shall be smoothed so they will not protrude through the paint coating. Runs,
drips, or dross particles shall be removed by grinding or filing the surface

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smooth flat. Since pure zinc is a soft metal, care shall be exercised to remove
the excess zinc only and leave a flat surface without damaging or removing
the underlying zinc coating.

5.4.2 Removal of Organic Materials

Once the galvanized surface is smooth, next step is to remove all organic
contaminants from its surface. Cleaning shall be done to remove all foreign
matters such as salt, dust, sand, grease and dirt with an alkaline solution,
acidic solution or solvent cleaning as per ASTM D6386.

5.4.3 Rinsing and Drying

Final step of cleaning galvanized steel surfaces is to use fresh water to rinse
the surface of any cleaning solutions. After the fresh water rinse, the steel
shall be dried before proceeding to the profiling stage. The time after drying
until the steel is painted shall be kept to a minimum (no more than 12 hours)
to avoid any further development of zinc compounds on the zinc surface.

5.5 Profiling Galvanized Steel Surface

5.5.1 Upon completion of cleaning, the galvanized surface shall be profiled to

provide an anchorage for the paint. Profiling the galvanized surface means to
roughen all surfaces to be painted to promote better paint adhesion. Profiling
of galvanized steel surfaces shall be done by using sweep-blasting method
only.

5.5.2 The following specified requirements are recommended for sweep blasting of
hot dip galvanized surfaces prior to painting. Compliance with these
requirements will ensure that not more than 10 microns of zinc will be
removed from the galvanized coating during the blasting process, and that the
coating will not be damaged by fracturing of the alloy layers through
excessive impact energy of the blast media on the galvanized coating. It shall
also be ensured that the air used in the blasting is dried air and not saturated
with water otherwise, moisture added to the zinc patina will form carbon
dioxide and affect adhesive ability of the substrate.

a. Blast nozzle pressure (maximum): 275kPa

b. Abrasive material (type): clean ilmenite, garnet, fine copper slag,

aluminum/magnesium silicate, carborundum powder, and organic
materials such as corncobs, walnut shells, lime stone and mineral
sands with a hardness of 5 or less (do not use angular iron blasting grit
under any circumstances)

c. Abrasive grade: 0.2-0.5mm

d. Distance (nozzle to surface): 400-500mm

e. Nozzle type & diameter: venture, 10mm (minimum)

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f. Blasting angle to surface 30-45 degrees

g. Ambient temperature (minimum) 21oC

h. Relative Humidity (maximum) 50%

5.5.3 The aim of sweep blasting procedure is to remove any oxide films and
contaminants from the surface and not to remove excess zinc more than 10
microns. It is not to produce a profile similar to that required on bare steel. If
the sweep blasting process removes too much zinc, it shall be repaired by
process described in ASTM A780.

5.5.4 The sweep blasting procedure is the most difficult part of the process of
painting hot dip galvanized steels, as it is prone to several potential operator
errors, which include:

- Removal of too much zinc, wasting zinc from the galvanized surface

- No profile, leaving residual contaminants and lack of adhesion of the

paint coating

- Cracking of the galvanized layer, leading to blistering and peeling of

paint coating later or in the service conditions

5.5.5 Three primary causes of failures of painted galvanized steels that result from
improper surface preparation of the galvanized surface prior to coating are;
over-blasting, under-blasting, and residual surface contamination. Over-
blasting will remove too much zinc during the blast procedure resulting in
delamination. Under-blasting removes too little of zinc patina leaving
contaminants on the surface, which later on will lead to premature failure of
paint coating. Residual surface contamination, picked up even after successful
blasting operation, will result in poor paint adhesion and premature paint
coating failure.

Suitable measures shall be adopted to avoid and eliminate all such errors.

5.5.6 Qualified and experienced operators shall be employed for sweep-blasting

procedure. The operators shall be evaluated by trying them in a test section
and measuring coating thickness before and after blasting with an approved
type magnetic thickness gauge. A reduction of 5-10 microns in galvanized
coating thickness shall be considered acceptable while over 10 microns of
coating removed shall not be acceptable.

5.6 Application of Paint on Galvanized Steel Surface

5.6.1 After the surface of the galvanized steel has been cleaned and roughened to
provide a profile, the steel is ready for painting. The paint shall be applied by
an airless spray gun on the galvanized steel surface. Application by brushing
may be allowed during touch up paints and if the work involves only few

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structures subject to approval by National Gird Saudi Arabia. Manufacturer’s

recommendations and instructions regarding application method and air
conditions shall be strictly followed.

5.6.2 Under high humidity and/or high temperature atmospheric conditions, the
formation of zinc oxide on the blasted surface will begin very quickly, so
under such conditions the paint shall be applied immediately, within one hour
after blasting, if practicable. Zinc oxide formation is not visible with naked
eye, therefore in any atmosphere; painting shall begin as soon as possible
after surface preparation. The paint shall be compatible with the zinc coating
and the manufacturer shall be consulted for information on paint
compatibility.

5.6.3 The type of paint, number of coats i.e. primer coat, intermediate coat (s), top
coat(s) and dry film thickness (each coat and total excluding zinc coating)
shall be as specified in 78-TMSS-13 and in accordance with the paint
manufacturer’s recommendations.

5.6.4 All paint materials in successive coats shall be from the same manufacturer
unless otherwise agreed with National Gird Saudi Arabia. Successive coats
shall be of different color shades.

5.6.5 Strictly follow the recommendations, instructions on pot life and other
specific provisions for application as submitted by the paint manufacturers.

5.6.6 Check Wet and Dry Film Thickness using instruments stated above.

5.6.7 Surfaces completed but not meeting the standards set forth in this
specification shall be re-coated.

5.6.8 Use of thinners shall be strictly restricted to the cleaning of tools. Paint shall
always be applied on clean and dry surfaces. Paint shall be applied in an
evenly manner to be free from runs, sags, taps, skips, holidays or other
defects.

5.7 Areas Not bo be Painted

Grounding point of lattice towers and tubular poles above the concrete level

Insulator string attachment pins and their contact surfaces

Ground Wires/OPGW attachment pins and their contact surfaces

5.8 Bolts and Nuts

Clean bolts, nuts, washers etc. by washing in fresh warm water containing wax-free
detergent and about 0.5% ammonium hydroxide.

The heads of bolts, nuts/locknuts, washers etc. shall be painted by brush after
erection of structures, providing a touch up coat.

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6.0 FIELD TESTS AND TEST INSTRUMNTS

6.1 During application of paint, the wet film thickness shall be continuously checked by
means of approved type wet film thickness gauge in accordance with ASTM D 4414
or any other equivalent industry code. Dew point shall be controlled by means of an
approved type instrument.

6.2 Dry film thickness on the steel shall be measured by means of an electromagnetic
and magnetic gauge in accordance ASTM E376 or any other equivalent industry
code.

6.3 Adhesion tests shall be performed by means of an approved type of multi-cross cutter
in accordance with ASTM D 4541 or any other equivalent industry code.

6.4 All instruments for application of paint and measurement of paint coating thickness
shall be subject to approval by National Gird Saudi Arabia.

7.0 REPAIRS TO PAINT COATINGS DAMAGED DURING TRANSPORTATION

Any area/steel damaged during handling, transportation and installation shall be scuffed
with fine/medium grade abrasive paper (grade 320) for 20mm around the damaged area.
Remove all debris and dust. If bare steel is exposed, apply at least two coats of zinc rich
primer from the same manufacturer as of the paint. This is to replace the damaged zinc
coating. If excessive removal or damage to the zinc coating has occurred, it shall be replaced
by hot dipping in a zinc bath.

When the surface becomes dry, apply the same paint system to cover the damaged area and
for 20mm around it after the surface preparation as described before in this standard. If the
zinc layer is not damaged, then apply the paint after the surface preparation as described
before in this standard.

8.0 QUALITY CONTROL STEPS

8.1 Painting shall be carried out in accordance with paint manufacturer’s

recommendation, guidelines, and instructions. Qualified expert appointed by the
paint manufacturer shall supervise the entire paint application process including
initial cleaning and sweep blasting.

8.2 Brush, spray gun and the pot in which paint is transferred, shall be properly cleaned
and free of grease, dust etc. Before use, stir and filter all paints thoroughly.

8.3 Avoid painting during the hottest part of the day, as it will lead to poor and uneven
application.

8.4 Check removal of sharp edges, weld spatter, slivers and similar mechanical
interference with the application of paint. After cleaning, test the surface to ensure
that it is “water break” free.

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8.5 During and after application of each paint coat, ensure that the paint is uniformly
applied to the required wet film or dry film thickness as appropriate in accordance
with manufacturer’s recommendations.

8.6 Check gloss, uniformity and absence of crates, fish eyes, blisters, runs, sags, and
other visible defects.

8.7 Check and record total dry film thickness (DFT) determined by electromagnetic
gauge calibrated on a similar hot dip galvanized surface but unpainted surface.
Alternatively, calibrate the gauge on smooth polished steel plate, and then measure
the thickness of hot dip galvanized surface without paint. Deduct the mean of at least
ten (10) hot dip galvanized thickness readings from the total layer thickness over
steel to obtain the average paint thickness.

8.8 Keep and maintain the record of cleaning, sweep blasting and paint application
process details, which shall form the part of As-Built Data to be submitted to
National Grid Saudi Arabia. Appendix-I shows a typical Pro-forma which shall
include but not limited to the details provided therein.

8.9 Contractor shall provide guarantee to National Grid Saudi Arabia for corrosion
protection of paint for minimum twenty (20) years. The format of guarantee shall be
decided mutually between National Grid Saudi Arabia and the Contractor.

9.0 SAFE WORK PRECAUTIONS

9.1 Take necessary precautions to protect the personnel and property from hazards due to
falls, injuries, toxic fumes, fires, explosion or other harm. Always use masks and
cotton gloves during the work.

9.2 Material Data Sheets of each product (paint, thinners and other chemicals etc.) shall
be available and all workers shall be aware of encountered hazards.

9.3 All paint and thinners shall be stored in a well-ventilated area protected from sparks,
flame, direct rays of the sun and from excessive heat. Painting yard shall have a
ventilation system in proper working conditions.

9.4 All work to be done and all equipment used shall be in accordance with the local
authority regulations.

9.5 Wash primer has an acidic composition, therefore avoid its contact with eyes and
skin. In case of contact, the affected area shall be flushed with plenty of water.

9.6 Do not smoke near the paint and never use any thing that could spark or flame.

9.7 Have Fire Extinguishers nearby.

9.8 Remove debris from the area immediately and dispose it properly.

9.9 Avoid static electricity by bonding/grounding of the containers.

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TRANSMISSION CONSTRUCTION STANDARD TCS-P-122.23, Rev. 0

PPENDIX-1

Typical Pro-forma for keeping record of Paint Application Process

Project:

Contractor:

Temperature: Weather:

Dew point: Date:

Structure Mark Number/Steel Pole Section:

1. Details of chemical cleaning (if performed):

2. Sweep blasting specifications applied as per Clause 5.5 (give details):

3. Pre-primer cleanliness (give details):

4. Zinc coating thickness before painting, µm:

5. Primer coat type & thickness, µm:

6. Intermediate coat(s) type & average dry/wet film thickness, µm:

7. Top coat(s) type & average dry/wet film thickness, µm:

General Remarks

_____________________ _________________________________
Contractor’s Representative National Gird, Saudi Arabia’s Representative

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