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SUBJECT: Surface Treatment / Painting Procedure REVIEW DATE: 02/05/2026
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METHOD STATEMENT:
SURFACE TREATMENT & PAINTING PROCEDURE
PROJECT:
KAFUE LOWER GORGE HYDRO PLANT
MS NUMBER: BRP-RI-KGL-U3-V1
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SUBJECT: Surface Treatment / Painting Procedure REVIEW DATE: 02/05/2026
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1. PURPOSE
This Method statement SURFACE TREATMENT AND COATING APPLICATION MS Number:
BRP-RI-KGL-U3-V1, defines the rules for a safe and efficient surface preparation and coating application on
t h e KUAFE LOWER GORGE HYDRO POWER PLANT Project.
2. SCOPE OF WORK
Degrease & Wash / Abrasive Blasting – Paint Application by: brush/roller /airless & conventional.
3. DEFINITIONS AND ABBREVIATIONS
a. DEFINITIONS
Approved:
Refers to written approval from the client's relevant person.
Coating System:
Refers to the required surface preparation, paint product to be used, number of coats to be applied,
thickness of each coat, as well as overall thickness of complete system.
Coat:
Individual layer of paint applied. A coating system consists of one or numerous coats.
Contractor:
Appointed company with contractual obligations towards CUSTOMER.
Manufacturer:
The manufacturer of the coating/paint material and associated products such as thinners, etc.
Supervisor:
Refers to a responsible person with a minimum of 3 years of relevant experience as a paint supervisor.
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Product Data Sheet:
Technical documents provided by the paint/material supplier for their products, detailing characteristics of the
product along with limitations for application and surface preparation and safe handling of the
product.
Application guide:
Detailed document provided by the material/paint supplier on how to apply/use the product correctly.
Product Safety Data Sheet:
Detailed document describing the risks, hazards, and recommendation of PPE for using the product to ensure
users' safety.
b. ABBREVIATIONS
DFT Dry Film Thickness
WFT Wet Film Thickness
HP Washing High-Pressure Washing
ASTM The American Society for Testing and Materials
ISO International Organization for Standardization
ITP Inspection Test Plan
RH Relative Humidity
QA/QC Quality Assurance/Quality Control
HSE Health, Safety and Environment
PPE Personal Protective Equipment
PDS Product DATA Sheet
CASDS Chemical Safety Data Sheet
CPT Coating Procedure Test
PQT Pre-Qualification Test
4. REFERENCES DOCUMENTS
The following specifications, guidelines, standards, methods, and codes shall be read and followed in conjunction
with this document.
Coating Manufacturer Specification: PPG 18-NOV-2024
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Latest revisions of the following standards apply.
ASTM D4285 Standard test method for indicating oil or water in compressed air.
ASTM D4541 Standard test method for pull-off strength of coatings using portable adhesion testers.
ASTM D5162 Standard practice for discontinuity (holiday) testing of nonconductive protective coating on
metallic substrates.
ASTM D7393 Standard Practice for indicating oil in abrasives.
ISO 4624 Paints and varnishes - Pull-off test for adhesion.
ISO 8501-1 Preparation of steel substrates before application of paints and related products – Visual
assessment of surface cleanliness – Part 1: Rust grades and preparation grades of uncoated steel
substrates and of steel substrates after overall removal of previous coatings.
ISO 8501-3 Preparation of steel substrates before application of paints and related products – Visual
assessment of surface cleanliness - Part 3: Preparation grades of welds, edges, and other areas
with surface imperfections.
ISO 8503 Preparation of steel substrates before application of paints and related products – Surface
roughness characteristics of blast-cleaned steel substrates.
ISO 8502-9 Preparation of steel substrates before application of paints and related products - Tests for the
assessment of surface cleanliness - Part 6: Extraction of soluble contaminants for
analysis – The Bresle method.
ISO 11124 Preparation of steel substrates before application of paints and related products.
Specifications for metallic blast-cleaning abrasives - Part 1 to Part 4.
ISO 12944-4 Paints and varnishes - Corrosion protection of steel structures by protective paint systems Part 4:
Types of surfaces and surface preparation.
NACE SP0188 Discontinuity (holiday) testing of new protective coatings on conductive substrates.
NORSOK M-501 Surface preparation and protective coating.
NS 476 Paints and coatings - approval and certification of surface treatment inspectors.
SSPC-PA 2 Procedure for determining conformance to dry coating thickness requirements.
5. IDENTIFICATION OF CORROSION PROTECTION APPLICATION SYSTEM
FOR FLOATING DOCK
Coat: Description: Wet Film (WFT): Dry Film (DFT): Shade:
Primer SIGMAPRIME 200 132µm 75µm TBA
Final SIGMASHIELD 588µm 500µm TBA
880 GF
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6. MATERIAL SUPPLY
a. All coating materials and solvent thinners will be supplied by PPG.
b. All products will be delivered in sealed, durable packaging along with all relevant documentation,
including Product Data Sheets (PDS), Safety Data Sheets (SDS), and Batch Certificates.
c. The Material Safety Data Sheet (MSDS) must be transferred with each batch of product and maintained -
site throughout the duration of the work.
d. The supplier will retain one sample from each batch for quality verification and reference purposes.
7. MATERIAL STORAGE
a. The storage conditions of all the products are to conform to the supplier’s specifications. Daily
inspection of the storage unit will be conducted to confirm the temperatures are within the guidelines
of the paint manufacturer’s recommendation. All equipment used will be calibrated and have a valid
calibration certificate.
b. The paint products shall be kept in an air-conditioned storage container that is dry, enclosed, and well-
ventilated. MSDS of material to be available at the storage container.
c. Should the container show traces of leakage or damage prior to use, the content of the container shall
not be used.
d. All Batch numbers will be recorded on arrival on site and recorded daily when booked out of
stores and recorded on data packs.
e. Shelf life to be adhered to as per supplier information and expiry dates. All paints received shall have
a minimum of half the remainder of their shelf life remaining.
8. SURFACE PREPARATION AND CLEANING PROCEDURE
Prior to abrasive blasting, a comprehensive surface inspection shall be conducted to identify any steel surface
imperfections, including burrs, laminations, weld splatter, and rounded edges. The rust grade shall be
documented in accordance with ISO 8501-1 standards.
All surfaces designated for painting shall undergo high-pressure (HP) washing with an appropriate water-soluble
degreaser to eliminate all contaminants.
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The quality of compressed air shall be verified at the start of each shift through a blotter test to ensure the
absence of oil, moisture, and other impurities.
Pre-blasting operations shall involve the complete removal of existing coatings using abrasive blasting to achieve
a surface profile of SP10 (minimum SA2½) as specified by ISO 8501-1, employing glass grit as the abrasive
medium. Following coating removal, media recovery procedures shall be implemented to collect and remove all
spent abrasive media and residues from the surface.
Dehumidification equipment shall be installed in the blasting environment to maintain ambient conditions within
the parameters specified in the PPG data sheets.
The exposed substrate shall be blast-cleaned to a surface cleanliness standard of SA2½, verified by visual
inspection and profile measurement, prior to recoating. Coating application shall then proceed in accordance
with the manufacturer’s recommendations.
Dust Suppression Process:
The penstock conduit will be housed within two enclosures separated by a distance of approximately 40 to
50 meters. Each enclosure will be fitted with a local extraction system comprising a fan mounted on the
manhole side. An auxiliary ducted air supply system will be installed on the opposite side of the enclosure to
enhance airflow management.
Additionally, a supplementary extraction unit (including a drum filter and fan) will be installed at the
manhole within the enclosure to extract dust escaping from the penetration point. Further enclosures will
also be implemented leading down to the fourth floor to contain and control dust emissions along the conduit.
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Blast operations will be confined within a sealed enclosure zone. Dust mitigation will be achieved using two
portable dust collection units operated by trained personnel, capturing airborne particulate matter generated
during abrasive blasting. Collected dust will be stored in 20-liter sealed containers for safe removal from the site
via the manhole. An exhaust fan will be mounted at the manhole to extract residual dust from the penstock
interior.
Sandblasting equipment (abrasive pots) will be housed within enclosures equipped with extraction fans and
blowers. These extraction systems will duct contaminated air to an enclosed collection chamber. Additional dust
suppression measures will include supplementary extraction systems. Filter cleaning on the fourth floor will be
performed every two hours, and continuous dust level monitoring will be conducted at frequent intervals.
The lower deck of Unit No. 3 will be fully enclosed, including the access walkway to the manhole. An additional
extraction fan will be installed at the vessel entry point where new grit is introduced to ensure effective dust
removal during grit loading. Furthermore, temporary tarpaulin enclosures will be positioned at the vessel entry
and exit points on the third floor.
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Additional dust suppression measures include enclosing the fourth floor workspace where sandblasting pot
operators are present, with operators operating in a wet condition at all times to contain dust emissions. The main
exhaust fan at the surge shaft will be deactivated during blasting activities to prevent dust dispersion.
All openings on the side of the head covers will be sealed to minimize dust leakages. Furthermore, the extraction
fan will be repositioned to enhance airflow and effectively extract dust escaping from the enclosure, ensuring
improved containment and dust control.
Grit drying operations will be conducted within a designated enclosed chamber engineered to contain dust
emissions and maintain environmental control throughout the drying process. The penstock conduit will be
housed within two enclosures separated by approximately 40 to 50 meters. Each enclosure will be fitted with a
local extraction system comprising a fan mounted on the manhole side to facilitate dust capture. An auxiliary
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ducted air supply will be installed on the opposite side of each enclosure to support airflow regulation and ensure
effective dust containment.
9. APPLICATION OF PROTECTIVE PAINT SYSTEM
Environmental conditions shall be continuously monitored throughout the coating
application and curing processes to ensure compliance with specified thresholds. Adequate
ventilation and air circulation shall be maintained to facilitate proper application and curing.
The application of the protective coating system shall be carried out in accordance with the
relevant PPG application guidelines. Material mixing shall follow the manufacturer’s
recommendations, utilizing a pneumatic mixer for uniform blending.
Edge coating, including all edges, corners, welds, rat holes, nuts, and other detailed areas,
shall be performed using brush application to ensure complete coverage. The primary coating
application methods shall include airless spray and conventional spray techniques, as
specified in the project specifications.
Detailed Pre-Painting Surface Preparation:
Surface preparation shall consist of removing all debris, dirt, and loose coating from the
substrate. The existing coating will be cleaned to a height of 200mm above the
designated blast profile line. Enclosures shall be erected at 100-meter intervals,
beginning from the cofferdam, to contain the blasting area. Dehumidification units (two
in total) shall be installed within the enclosures to control humidity levels.
An air supply hose shall be installed at the far end of the penstock within the enclosure to
deliver cool, dry air, facilitating proper airflow and environmental conditions inside the
containment zone.
Initial flash blasting will be performed using 24-mesh glass grit. Upon completion of the
flash blast, cleaning shall be executed using brooms, compressed air, and two vacuum
collection units to remove residual dust and debris. Following cleaning, atmospheric
testing will be conducted to verify that environmental parameters meet specified safety
and quality standards.Surface preparation shall consist of removing all debris, dirt, and
loose coating from the substrate. The existing coating will be cleaned to a height of
200mm above the designated blast profile line. Enclosures shall be erected at 100-meter
intervals, beginning from the cofferdam, to contain the blasting area. Dehumidification
units (two in total) shall be installed within the enclosures to control humidity levels.
An air supply hose shall be installed at the far end of the penstock within the enclosure to
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deliver cool, dry air, facilitating proper airflow and environmental conditions inside the
containment zone.
Initial flash blasting will be performed using 24-mesh glass grit. Upon completion of the
flash blast, cleaning shall be executed using brooms, compressed air, and two vacuum
collection units to remove residual dust and debris. Following cleaning, atmospheric
testing will be conducted to verify that environmental parameters meet specified safety
and quality standards.
Detailed Painting Procedure:
Once atmospheric conditions have been verified to meet project specifications and
the surface has been properly cleaned, a dust and debris test will be conducted to
confirm that the surface is free of contaminants and suitable for coating application.
Surface profile measurements will be obtained using Testex replica tape to verify
that the surface profile adheres to the specified parameters. Upon completion of all
preparatory tests and confirmation that the surface is ready for priming or coating,
the paint materials will be thoroughly mixed according to manufacturer’s
instructions prior to application.
An airless spray system will be employed for coating application, with the paint
filtered to prevent nozzle blockages during spraying. The applicator shall utilize a
Wet Film Thickness (WFT) gauge during application to ensure the desired film
thickness is achieved in real time. After each coat has cured, the Dry Film Thickness
(DFT) will be measured and recorded using a dry film gauge, ensuring that the
coating thickness complies with project specifications and verifying proper
application quality.
10. SUPERVISION AND INSPECTION PERSONNEL
All operations shall be conducted under the direct supervision of a qualified supervisor with a minimum of
three (3) years of relevant industry experience.
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Daily site inspections may be performed by certified inspection personnel holding qualifications such as
NACE CIP Level I, FROSIO Level I, or ICorr Level I, possessing the necessary technical competence and
experience to verify compliance with project standards and specifications.
11. INSPECTION EQUIPMENT AND REQUIREMENTS
All inspection equipment utilized shall be calibrated regularly and accompanied by current calibration
certificates. These certificates shall be maintained by the Quality Control (QC) department and shall be
available for review upon request.
Surface cleanliness shall conform to ISO 8501-1 standards, specifically a minimum cleanliness grade of SA2½.
During coating operations, ambient relative humidity shall be maintained between 10% and 85%.
Substrate temperature shall be maintained at a minimum of 5°C and at least 3°C above the dew point to
prevent condensation and ensure proper curing.
All coating applications shall adhere strictly to the manufacturer’s recommendations outlined in the Product
Data Sheet (TDS). Atmospheric conditions, including temperature and humidity, shall be recorded prior to
commencement and continuously monitored during application. Drying and curing times, as well as
overcoating intervals, shall be observed strictly in accordance with the manufacturer's TDS.
The initial coat must be applied within 4 hours of completion of blast cleaning. Each subsequent coat shall be
applied only after the previous coat has dried for the minimum duration specified by the paint manufacturer,
considering the ambient temperature. The minimum over-coating interval, specific to prevailing conditions,
shall be verified in the Product Data Sheet.
All pertinent application details, including start time, application duration, and ambient conditions during
coating, shall be documented meticulously for each coat to ensure compliance with project requirements.
12. REPAIR PROCEDURE
Defective coatings shall be repaired in accordance with the guidelines specified in the PPG Product Data Sheet.
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Partial mixing of coating materials shall only be performed following the manufacturer’s instructions.
Partially used coating kits shall be resealed immediately after use to prevent contamination and shall be reused
within their designated shelf life. To ensure proper identification, partially used kits shall be clearly marked
and distinguished from unopened, unused kits.
13. APPROVAL
COMPANY: NAME: DATE: SIGNATURE:
RETRO
INTERNATIONAL
