General Specifications for Civil Works

Dubai Municipality
Drainage and Irrigation Department

7.2.5 Protective Coatings to Concrete Works

7.2.5.1 Protective Coating on Concrete (Internal & External)

a) General Requirements

1. The coating system and the surface preparation shall be to the approved
standard and shall conform to the ‘schedule of surface preparation and protection
systems’ given below for concrete work.

2. The coating system proposed shall be applied by Client approved specialist

applicator.

Table 7-20 Surface Preparation on Concrete

System Description Surface Preparation

a) Sweep blasting The surface shall be sweep blasted with

non-metallic mineral abrasive to achieve
a minimum surface roughness of 100
micron on concrete or as recommended
by the paint manufacturer.

b) Surface Cleaning The concrete surface shall be cleaned to

remove dirt, oil, dust, laitance and all
other surface contaminations.

c) Epoxy binder / One coat 100 micron D.F.T two

sealer component polyamide epoxy based
transparent sealer coat shall be applied
by spray application to seal the porous
concrete substrate if any.

d) Filler One coat of alkali resistant acrylic based

filler 100 micron DFT shall be applied by
steel trowel or hand application to fill the
surface voids or as recommended by the
paint manufacturer.

b) Application of Field Coatings:

1. Coating shall be applied with a spraying equipment recommended by the

Manufacturer.

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Dubai Municipality
Drainage and Irrigation Department

i. Areas inaccessible to spray coating or rolling shall be coated by brushing or

other suitable means.

2. Give special attention to ensure that edges, corners, crevices, welds, bolts, and
other areas, as determined by the Engineer, receive a film thickness at least
equivalent to that of adjacent coated surfaces.

3. Protective coating materials shall be applied in strict accordance with the

manufacturer’s printed instructions.

4. Prime coat shall be applied to clean surfaces:

i. Within a 4-hour period of the cleaning.

ii. Prior to deterioration or oxidation of the surface.

iii. In accordance with the manufacturer’s recommendations.

5. Coatings shall be applied in dry and dust-free environment.

i. No coating shall be applied during following conditions:

– When the surrounding air temperature, measured in the shade, is below 17 C

– To wet or damp surfaces.

– In rain, fog or mist or when the relative humidity exceeds 85%.

– When it is expected that the relative humidity will exceed 85% or that the air
temperature will drop below 5 C within 18 hours after the application of the coating
or paint.

– Dew or moisture condensation shall be anticipated.

– The cement laitance is removed with non-metallic mineral abrasive blasting

– Minimum specified surface roughness is achieved.

– Specified primer /sealer coat is applied.

– Filling the surface voids/cracks/and imperfections with approved epoxy filler.

ii. If the above conditions are prevalent, coating shall be delayed until surfaces are
dry.

iii. The day’s coating shall be completed in advance of the probable time of day
when condensation will occur in order to permit the film a sufficient drying time prior
to the formation of moisture.

6. Care shall be exercised to avoid lapping, coating on adjacent surfaces.

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Dubai Municipality
Drainage and Irrigation Department

i. Coatings shall be sharply cut to lines.

ii. Finished coated surfaces shall be free from defects or blemishes.

iii. Drop cloths shall be used to protect floors, fixtures, and equipment.

iv. Care shall be exercised to prevent paint from being spattered onto surfaces from
which such paint cannot be removed.

v. Surfaces from which paint cannot be removed shall be painted or repainted as

required to produce a finish satisfactory to the Engineer.

vi. Apply second coat at right angles to first coat, ensuring pinholes are covered.

7. Surfaces inaccessible after assembly shall be coated before erection.

8. Touchup of surfaces shall be performed after installation.

9. Surfaces to be coated shall be clean and dry at the time of application.

10. Time of Coating:

i. Manufacturer’s recommended recoat time shall be complied with.

ii. Sufficient time shall be allowed to elapse between successive coats to permit
satisfactory recoating, but once commenced, the entire coating operation shall be
completed without delay.

iii. No additional coating of any structure, equipment, or either item designated to be

painted shall be undertaken without specific permission of the Engineer until the
previous coating has been completed for the entire structure, piece of equipment, or
other item.

11. Thickness of Coating:

i. Dry film thickness specified shall be achieved for each coat.

12. Clean up

– Concrete surfaces shall be visually inspected to ensure proper and complete

coverage has been attained.

– Upon completion of the work, staging, scaffolding, and containers shall be

removed from the site or destroyed in an approved manner.

– Coating spots, oil, or stains upon adjacent surfaces shall be removed.

13. Protective coating properties tests are to be conducted on the final coated
surface and shall comply with the requirements specified in Table 7 –22.

c) Schedule of Concrete Protection System

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

1. For Major Structures Internal:

System - ‘A’ 7mm thick in-situ GRP lamination as specified in CL 7.1.6.

System- A - 1 7 mm thick in-situ GRP lamination with grit bonding on top of final
finish coat as specified in CL.7.1.14.

System - ‘B’ 1mm thick heavy duty glass flake vinylester resin based coating
250 micron each. Total D.F.T 4 x 250 microns + Approved Primer recommended by
the paint manufacturer.

System - ‘C’ 1mm thick Polysulphide modified Epoxy resin coating system
designed for superior adhesion, corrosion Protection, Chemical resistance &
waterproof coating 250 micron for each coat. Total D.F.T (4 x 250 micron) = 1 mm +
approved primer recommended by the paint manufacturer.

System - ‘D’ 0.5 mm thick solvent free 100% solid content polyamine based
Epoxy + Polyurethane resin coating.

Epoxy = 300 microns thick

Polyurethane = 200 microns thick

Total DFT = 500 microns + Approved Primer recommended by the paint

manufacturer.

System - ‘E’ Aggregate dressed (3 component) heavy duty, hard wearing,

solvent less Epoxy, anti slip deck coating minimum D.F.T = 3 mm. +75 micron high
build epoxy finish top coat with anti-fungi and antibacterial agents.

System - ‘F’ Fibre reinforced acid resistant, mineral based alkaline silicate
mortar minimum 6 mm thick with finish top coat for hard floor coating.

System - ‘G’ Double sided PVC lined membrane as specified in section

mechanical specification.

2. For Major Structures External Surfaces above Ground Exposed to Sunlight

System - ‘H’ Alkali Resistant Acrylic based anticarbonation coating + Sealer

coat + filler Coat

Epoxy binder / Sealer Coat – 100 microns thick.

Alkali Resistant Acrylic based filler 100 microns thick.

Alkali Resistant acrylic based anticarbonation coating – 100 x 3 coats = 300

microns thick.

d) For minor Structures (Internal Surfaces)

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Dubai Municipality
Drainage and Irrigation Department

System - ‘I’ 7mm thick in-situ GRP lamination over grano benching for sewer
MH’s as specified in CL 7.1.6.

System - ‘J’ 7mm thick Prefabricated GRP liner as specified in CL 7.1.5 for
sewer manholes.

System - ‘K’ Two component Epoxy mortar 10mm thick over grano benching of
storm water MH’s as specified in CL 7.1.7

System - ‘L’ Solvent free 100% solid content Polyamine based pure Epoxy 300
micron thick + primer, for storm water MH’s and Inspection chambers (sewer) etc.

e) For Minor Structures (External surfaces)

System - ‘M’ Rubberised bitumen emulsion + P.E sheet on top as specified in

7.1.8.

System - ‘N’ 5 mm thick GRP pre fabricated benching or in-situ lamination over
benching of inspection chambers (sewer) as specified in Clause 7.2.3.

Table: 7. 21 Schedules of Concrete Protection Details

Sr. Particular Protection Protection details

System

EXTERNAL PROTECTION FOR ALL MAJOR STRUCTURES

1 Below Ground Level

a. Below Blinding P.E 1000 gauge PE Sheet (250 micron thick)

b. Above Blinding (raft) System Approved bituminous primer + 2 layers

T1,T2,T3 & bituminous membrane 1.5 mm and 2mm
T4 thick each & 6 mm thick protection board as
specified.

c. Walls outer surface System Approved bituminous primer + 2 layers

T1,T2,T3 & bituminous membrane 1.5 mm and 2mm
T5 thick each with 3 mm thick protection board
on top as specified.

2 Above Ground Level System ‘H’ Approved sealer coat and filler coat and
Alkali resistant acrylic based anticarbonation
coating (300 micron) thick

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

INTERNAL PROTECTION AND ROOFING DETAILS –

1 Stilling Tank, Pump Station,

Discharge chamber, Outfall

Floor, Wall, Roof System ‘D’ Approved primer recommended by the paint
manufacturer + 300 micron pure epoxy paint
+ 200 micron polyurethane Paint

2 Chemical Storage Area Bund System ‘A’ GRP Liner (7mm thick)

3 Potable Water Tank

Concrete Base floor and support System ‘D’ Approved primer recommended by the paint
wall manufacturer + 300 micron pure epoxy paint
+ 200 micron polyurethane Paint

4 Aeration Tanks

Floors, Walls & Ceiling, inlet/ System ‘B’ Approved primer recommended by the paint
Outlet channels manufacturer + 1 mm thick heavy duty glass
flake vinyl ester resin based coating.

Top Walkways System ‘E’ 3 mm thick heavy duty (3 component) non-

slip epoxy abrasion resistant deck coating +
high build 75 micron finish coat on top with
anti-fungi and anti-bacterial agents.

Valve chamber ( Waste activated System ‘L’ 300 micron pure epoxy paint ( Polyamine
Sludge) based) ( Solvent free 100% solid content)

5 FST Distribution / RAS Bellmouth

Chamber

All chambers walls / floors System ‘C’ Approved primer recommended by the paint
manufacturer + Polysulphide modified epoxy
resin coating 1mm thick

6 Gas Holders

Gas holders System ‘G’ Double sided PVC membrane as specified

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Table 7. 22 Test on Protective Coating of Concrete

Sr. Properties Test Method Minimum Requirements

1 Dry film thickness BS 3900 Specified thickness for each

coat

2 Discontinuity (holiday) National Association of 100% pin hole free

detection Corrosion Engineer’s
standard recommended
practice

3 Pull of adhesion strength ASTM D4541/ISO 4624 3.00 N/mm2 for epoxy coating

2.00 N/mm2 for anti

carbonation coating

Notes: (1) Freedom from pinhole shall be established by the use of a spark tester.

(2) Coating system should be resistant to:

(a) Sulphate and chloride ion penetration

(b) CO2 diffusion

(c) Bacterial and fungus growth

(d) Atmospheric temperature resistant

(e) Acids and alkalis of PH2 -14

(f) To accommodate shrinkage cracks appearing on concrete

substrate.

7.2.6 Coating System for Ferrous, Non Ferrous Metals and Plastics

7.2.6.1 GENERAL

a) DESCRIPTION

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Provide all labour, materials, equipment, services and accessories necessary to

furnish and install the coating system work of this Section, complete and functional as
indicated in Contract Documents and as specified herein.

1. Coatings for all ferrous, Non-ferrous surfaces, interior and exterior.

2. Submerged ferrous metal surfaces.

3. Structural and miscellaneous steel including tanks, hoppers and similar

equipment.

4. Equipment furnished without factory finished surfaces.

5. Exposed galvanized metal except handrails, grating, piping and checkered plate.

b) SUBMITTALS.

Manufacturer’s Data

1. Manufacturers current printed product description, materials safety and technical

data sheets for coating systems.

2. Detailed mixing, thinning and application instructions, minimum and maximum

application temperature, curing and drying times between coatings.

3. Instructions for surface preparation requirements, number and types of

Coats required for each surface.

4. Colour charts for each coating system.

5. Certifications from manufacturer verifying factory applied prime coatings are

compatible with the specified finish coatings.

6. Detailed maintenance manual including the following information:

i. Product name and number.

ii. Name, address and telephone number of manufacturer and local distributor.

iii. Detailed procedures for routine maintenance and cleaning.

iv. Detailed procedures for light repairs such as scratches and staining.

7. Abrasive:

i. Certified information of:

– Particle size distribution.

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Dubai Municipality
Drainage and Irrigation Department

– Dust generation at proposed operating pressure and distance.

– pH value.

– Soluble chloride content.

– Analysis for free silica.

– Trace toxic contaminants.

ii. Sample Panels

– Apply a complete coating system to a panel of the same material as that on

which the coating will be applied and submit for approval for each colour specified.

– Approved sample panels will be used for quality control in applying coating
systems.

iii. C. Certificates of Compliance.

iv. E. Inspection Reports.

v. F. Test Reports.

c) DELIVERY, STORAGE AND HANDLING

1. Delivery

i. Deliver materials in original, unopened packages and containers bearing

manufacturer's name and label including the following information:

– Name or title of material.

– Manufacturer's stock number and date of manufacture.

– Manufacturer's name.

– Contents by volume for major pigment and vehicle constituents.

– Thinning instructions where recommended.

– Application instructions.

– Colour code and name.

2. Storage

ii. Store materials on site in a suitable location, protected from exposure to extreme
weather.

iii. Keep area clean and accessible.

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Drainage and Irrigation Department

iv. Restrict storage of coating materials and related equipment.

v. Keep temperature of storage area between 18 C and 32°C.

vi. Comply with Local Laws and Regulations.

vii. Cloth and Cotton wastes that might constitute of fire hazard shall be placed in
closed metal containers or destroyed at the end of each workday.

viii. Provide approved fire extinguishers in material storage area.

d) QUALITY ASSURANCE

1. Applicator Qualifications

i. Submit name and experience record of manufacturers recommended coating

applicator.

ii. Include list of utility or industrial installations painted, responsible officials,

architects, or engineers concerned with the project and the approximate contract
price.

2. Inspect surface and correct defects prior to application of each coat.

3. The protective coating systems specification, report on paint work progress and
the final report on corrosion protection should be provided by the applicator in the
formats (A), (B) and (C) given in this clause.

Form A – Form for a Protective Paint System Specification for New Work

(To be filled in for each constituent element of the structure by the applicator)

Project:

Name of Client:

Project: Protective paint system:

Location: ISO 12944-5 paint system No.

Constituent element: Environment:

Drawing No. / area: Required durability:

Position No.: Sheet No:

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 General Specifications for Civil Works
Dubai Municipality
Drainage and Irrigation Department

Shop Application

Surface Preparation Grade:

Type of Prefabrication Primer (if used):

Paint manufacturer: Area:………..m2

Protective Paint Nominal dry Overcoating interval Drying time

System film at ….qC (h)
thickness μm

Minimum (h) Maximum (h)

1st Coat

2nd Coat

3rd Coat

4th Coat

Total:

Site Application

Surface Preparation Grade:

Touch up:

Complete:

Paint Manufacturer: Area: ………..m2

Protective Paint Nominal dry Overcoating interval Drying time

System film at ….qC (h)
thickness μm

Minimum (h) Maximum (h)

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Dubai Municipality
Drainage and Irrigation Department

1st Coat

2nd Coat

3rd Coat

4th Coat

Total:

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