Corrosion Protection for SERC Project

Project Name: SERC
Title: TII 16.04 Corrosion Protection

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Hitachi Zosen Inova AG
Table of contents
1
General .................................................................................................................... 4
1.1
1.2
1.3
1.4
1.5
Aims and objectives .................................................................................................. 4

Applicability ............................................................................................................... 4
Abbreviations used ................................................................................................... 5
Basic Policy............................................................................................................... 5
Cited and further applicable standards and regulations ............................................ 5
1.5.1
1.5.2
HZI documents ................................................................................................................................. 5

Regulations, Standards and Guidelines .......................................................................................... 5
Planning of corrosion protection .......................................................................... 7
2.1
2.2
Construction .............................................................................................................. 7
Classification according to corrosion loads ............................................................... 7
2.2.1
2.2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.4
2.5
2.5.1
Corrosivity according to EN ISO 12944-2: 1998 .............................................................................. 7

Assignment of the corrosivity categories for the system parts in EfW plants .................................. 8
Selection of corrosion protection measures ............................................................ 10

Coatings ......................................................................................................................................... 10
Galvanising .................................................................................................................................... 11
Aluminium and high-alloy steel ...................................................................................................... 11
Standard components .................................................................................................................... 11
Corrosion protection below insulation ..................................................................... 12

Temporary corrosion protection .............................................................................. 12
Definition of temporary corrosion protection .................................................................................. 12
2.6
Work and environmental protection ........................................................................ 12
Execution of corrosion protection ...................................................................... 13
3.1
Preparation and cleaning of surfaces...................................................................... 13
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
3.4
3.5
3.5.1
3.5.2
3.6
3.6.1
3.6.2
3.7
3.7.1
Object preparation ......................................................................................................................... 13

Pre-cleaning of surfaces ................................................................................................................ 13
De-rusting using a blasting method ............................................................................................... 13
De-rusting of untreated, built-in steel parts .................................................................................... 14
Preparation of mounting weld seams ............................................................................................ 14
Cleaning of primer and intermediate coatings ............................................................................... 14
Processing and application of the coating materials ............................................... 14

Requirements for coating materials ............................................................................................... 14
Preparation and application of the coating materials ..................................................................... 14
Workshop application ..................................................................................................................... 15
Construction site application .......................................................................................................... 15
Determination of the coat thickness according to EN ISO 12944-5: 2008-01 ......... 15

Transport, storage and assembly of coated steel components ............................... 16
Repair of transport and assembly damages ........................................................... 16
Surface preparation of assembly damages ................................................................................... 16
Coating on site ............................................................................................................................... 16
Repair of coating of welding zones ......................................................................... 17

Surface preparation of welding zones ........................................................................................... 17
Coating on site ............................................................................................................................... 17
Repair of damaged areas on hot dipped galvanised steel components .................. 17

Surface preparation of damaged areas ......................................................................................... 17
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Improvement of damaged areas in the zinc coating up to 10 cm2 in size ..................................... 18

Repair of damaged areas with zinc coating over 10 cm2 in size................................................... 18
Monitoring, acceptance and documentation ...................................................... 19
4.1
4.2
4.3
4.4
In-house monitoring by the contractor ..................................................................... 19

Outside monitoring by HZI or external entities ........................................................ 19
Control areas .......................................................................................................... 19
Acceptance ............................................................................................................. 19
Annex A ................................................................................................................. 20
5.1
Terms and definitions used ..................................................................................... 20
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
Milling skin / Cinder ........................................................................................................................ 20

White rust ....................................................................................................................................... 20
Surface preparation degree ........................................................................................................... 20
Preparation grades according EN ISO 8501-3: 2007 .................................................................... 20
Dew point ....................................................................................................................................... 21
Coating thickness ........................................................................................................................... 21
Protection period ............................................................................................................................ 21
Maintenance................................................................................................................................... 21
"Bundesbahn"- Colour code ........................................................................................................... 21
Annex B ................................................................................................................. 22
6.1
6.2
6.3
Table 7: Selection of the coating system structures ................................................ 22

Table 8: Coating material suppliers......................................................................... 27
Supplier names of the coating materials ................................................................. 28
6.3.1
6.3.2
6.3.3
6.3.4
Table 9: Coating supplier 1: Sika ................................................................................................... 28

Table 10 : Coating supplier 2: International Farbenwerke ............................................................. 30
Table 11: Coating supplier 3: Geholit + Wiemer ............................................................................ 32
Table 12: Coating supplier 4: Jotun ............................................................................................... 34
Annex C ................................................................................................................. 36
7.1
Temporary Corrosion Protection ............................................................................. 36
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General
1.1
Aims and objectives
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The purpose of this Technical Implementation Instruction (TII) is to define a uniform

standard for atmospheric corrosion protection so that corrosion protection is guaranteed
corresponding to the operating requirements and future maintenance work can be simplified.
This TII prescribes the type and manner of the implementation of corrosion protection work
and the criteria to secure the quality of the implementation.
1.2
Applicability
This TII applies to the atmospheric corrosion protection of steel structures, mechanical
equipment, apparatuses, containers and pipe lines from non-alloyed and low-alloy steel in
all rooms or system sections of waste combustion plants.
It does not apply to non-insulated steel components, silos, containers, apparatuses, pipe
lines etc. of operational systems for the initial protection and for the repair of local damages
in the period up to the complete transfer of corrosion protection services to the customer.
Excluded from TII corrosion protection are standard elements such as e-motors/drives,
measurement devices, transmitters, adjustment and regulating values and the
corresponding drives. The listed standard elements can be implemented with the
manufacture-standardised corrosion protection.
The TII applies for the planning and implementation of corrosion protection work in the
workshop and at the construction site.
The TII is the basis for the tendering and ordering of corrosion protection work. It is a
component of the offer of the contractor and must be taken into account by all
subcontractors of the company Hitachi Zosen Inova AG (in short: HZI) in their scope of
supply and services.
The responsibility of the supplier is not restricted to its services by the TII.
Exceptions to this TII must be approved in writing by the company Hitachi Zosen Inova AG.
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Abbreviations used
The following abbreviations are used in this TII:
Table 1: Abbreviations
1.4
Short term
Long term
EfW
Energy-from-Waste plant
HZI
Company Hitachi Zosen Inova AG
Supplier
HZI's sub-contractor
Sub-contractor
Supplier of works and plant sections who is not a sub-supplier of HZI.
SPS
Coating material supplier
TII
HZI Technical Implementation Instruction
CP
Corrosion protection
DIN EN ISO
European standard with the status of a German standard
AGI
Working Group Industrial Facility e.V. Worksheet
Basic Policy
Corrosion protection occurs according to EN ISO 12944 part 1 to 8 if no deviating or
supplemental provisions are included. Deviations from the regulations of EN ISO 12944
and/or the requirements of this TII must be coordinated with HZI before the conclusion of
the agreement.
The specifications are minimum requirements. Proof must be provided that the
requirements of the standard, the TII and any additional agreements are met or exceeded.
The supplier must prove that it is qualified for proper implementation of the work. It is liable
for the professional processing of the corrosion protection materials and has the obligation
to review the prescribed corrosion protection systems and their application processes for
their suitability for the specific application.
If the determinations of this guideline are in conflict with current technical rules or official
regulations, HZI must be notified of this in writing and appropriate alternatives are to be
proposed.
The painting system and finish used for both internal and external surfaces shall be suitable
for the particular conditions to be experienced in shipping, storing, erection, commissioning
and operation. Where the surfaces to be painted are subject to heat or attack by chemicals,
oil, acid, fumes etc. special paints having the appropriate resistant qualities shall be used.
1.5
Cited and further applicable standards and regulations
1.5.1
HZI documents
TII Colour scheme 16.10
1.5.2
Regulations, Standards and Guidelines

The Supplier must comply with the requirements of relevant regulations (laws, ordinances,
standards, official and professional association regulations, recommendations, guidelines
etc.) in the version applicable at the time of implementation of the deliveries and services at
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the site where the supply item is used in accordance with the terms of the agreement. It
must take the state of the art in the area of corrosion protection into account.
All regulations, rulings of permit and other official authorities in conjunction with deliveries
and services are to be followed.
In particular, the following standards must be followed:
Table 2: Regulations
Regulation Code
Description
EN ISO 12944, part 1 8
Coating materials Corrosion protection of steel components

through coating systems
Zinc coatings (batch galvanizing) applied by hot dip galvanising
onto steel requirements and tests
Instructions on the application of the standard
EN ISO 1461
with annex 1
EN ISO 8501
Part 1
Part 3
EN ISO 8503, part 2
AGI Q 151 Work Sheet
Preparation of steel surfaces before applying coating materials visual assessment of surface purity
- Rust grades and preparation grades
- Preparation grades of welds, edges and other areas with
surface imperfections
Preparation of steel surfaces before the application of coating
materials rawness parameters of blasted steel surfaces;
process for testing the rawness of blasted steel; comparative
pattern process
Insulation works - Corrosion protection under thermal and cold
insulations at industrial installations
All listed standards are applicable throughout the European Union.

The term "should" and recommendations in EN ISO 12944 are generally to be understood
as a requirement.
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Planning of corrosion protection
2.1
Construction
The supplier must plan its steel structures with compliance of the basic rules on proper anticorrosion design according to EN ISO 12944-3.
In particular, the following rules must be followed:
2.2
Whenever technically feasible, profiles with canted edges should be used.

Sharps edges and corners such as welding plate girders are to be rounded out
(radius over 2 mm) or are to have a chamfer.
Auxiliary devices such as mounting eyes must be planned to avoid transport and
assembly damages.
Classification according to corrosion loads

The major principle for the classification of the plant parts and rooms of the EfW plant in
terms of their corrosive load is EN ISO 12944-2 "Classification of the ambient conditions".
This standard subdivides ambient conditions into six corrosivity categories (C1, C2, C3, C4,
C5-I and C5-M).
Steel parts which are subject to the corrosivity category C1 require corrosion protection only
for aesthetic reasons but not for technical reasons.
2.2.1
Corrosivity according to EN ISO 12944-2: 1998

Table 3 is used to better promote understanding of the classification of local ambient
conditions in terms of their corrosive load. This table is an extract from EN ISO 12944-2. It
includes information and definitions on corrosive load and examples for typical
environments.
Table 3: Corrosivity categories for atmospheric ambient conditions and examples of
typical environments according to EN ISO 12944-2
Corrosivity
category
Examples of typical local ambient conditions (only for information)

External
Internal
C1
insignificant
C2
moderate
Atmospheres with minimal

contamination. Mostly rural areas
C3
moderate
City and industrial atmosphere,

moderate impurities due to
sulphur dioxide. Coastal areas
with minimal salt load.
Industrial areas and coastal areas
with moderate salt load.
Heated building with neutral

atmospheres, e.g. offices, schools,
hotels
Unheated building where
condensation can occur, e.g.
gymnasiums
Production rooms with high moisture
and somewhat air contamination, e.g.
systems for food production,
laundries, breweries, dairies
Chemical systems, swimming pools,
boat sheds over sea water
C4
heavy
C5-I
very heavy
(Industry)
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Industrial areas with high moisture

and aggressive atmosphere
Building or areas with virtually

constant condensation and with
heavy contamination
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C5-M
very heavy
(Sea)
Coast and offshore areas with

heavy contamination.
Building or areas with virtually

constant condensation and with high
salt load
An assignment of the system sections of the EfW plant to the aforementioned corrosivity
categories is described Table 4.
2.2.2
Assignment of the corrosivity categories for the system parts in EfW plants
Table 4 includes an assignment of corrosivity categories on the predominant corrosive
loads in the individual system sections and rooms of waste incineration plants.
The corrosive loads indicated in Table 4are theoretically known in the individual plant
sections. However, reference is made to the fact that, in some plant areas, depending on
unique construction or technological circumstances, special loads can occur due to
increased air humidity over 80% and condensate water formation, chemical loads due to
aggressive media or increased corrosion from combined loads. If loads of this type occur
individually or in combined form, an assignment on the corrosivity C5-I is hereby associated
for this room or this section. Subsequent additional object-related estimates are also
required.
Location-specific corrosion loads are to be taken into account for system components
exposed to external air. This particularly applies to locations in industrial areas.
Table 4: Assignment of the system components and rooms of EfW plants to corrosivity
categories
Corrosivity
categories
according to EN
ISO 12944-2
No classification =>
painting only for
decoration
purposes
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
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Plant section / Room
Complete administration building excluding sanitary rooms

All offices and recreation rooms
Corridors, stairwells in the administration building
The central control room
Mechanical and electrical workshop
The spare part warehouse
The weighing house (inside)
All sanitary rooms (lavatory, showers, etc.)
Crane operators cabin (inside)
All electrical equipment rooms
Transformer rooms
Corridors and stairwells in plant sections
Emission measurement room
Compressed air room /Demineralised treatment room
Ventilation system (HVAC)
Waste bunker
Complete waste receiving hall and residue hall
Baling plant
Battery container (UPS)
Transformer (transformer boxes, outdoor installation)
Emergency diesel build in container or similar (outdoor installation)
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Table 4: Assignment of the system components and rooms of EfW plants to corrosivity
categories
Corrosivity
categories
according to EN
ISO 12944-2
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C3
C4
C4
C4
C4
C4
C4 1)
C5-I
C5-I
C5-I
C5-I
C5-I
C5-I
C5-I
C5-I
C5-I
C5-I
C5-I
C5-M
Plant section / Room
Shredder / crusher room

Turbine table
Turbine cellar
Turbine oil room
Rooms with demineralised / -and feed water pumps
Complete flue gas treatment area
Inside silencer room of induced draft fan
Separate hydraulic rooms
Emission measurement container (outer lateral surface)
Crane operators cabin (outside waste bunker area)
Silo (outer lateral surface) for inside placement area
Silo (outer lateral surface) for outside placement area
Ash loading equipment below Residue Silo
Demineralised water treatment room
Handling and transport of consumables (e.g. HOK, lime etc.)
Feed water pumps
Boiler house
Room of bottom ash water tank
Bottom ash bunker with bottom ash loading
Waste water treatment and flying ash washing
Retention tanks and basins
Chemical storage and handling (e.g. HCl, NaOH, NH4OH etc.)
Equipment exposed to humid area, out from ambient air
Residue handling / - treatment with danger of gaseous chemicals and
salt deposition
Bottom ash extractor area
Belt conveyor, vibration channel, bottom ash expeller etc.
Equipment with partial wetting by liquid chemicals (e.g. HCl, NaOH,
NH4OH etc.)
Stack outside for outdoor installation (outside of the building)
Plant section in unprotected position which are in sphere of influence of
seashore (outside installation)
HV Transformer
ACC consisting of steel construction, uninsulated piping and wind
partition walls (exclusive heat exchanger elements)

CCW cooler
NH4OH tank (external)
Fuel Oil Tank (external)
External steel structure
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Explanations of Table 4:
Footnote
1) Only valid for the warm and dry area of boiler house. Otherwise see
equipment for bottom ash treatment.
2.3
Selection of corrosion protection measures
2.3.1
Coatings
The supplier, is required to acquaint itself fully with the prevailing environmental conditions
at site to ensure he is capable in every respect of carrying out the protective coating works.
The protection systems are to be selected according to the components or equipment and
these corrosive loads and the operating temperatures.
The use of coating systems with a higher corrosion protection value for lower loads is
permitted.
The Supplier will list in a schedule the painting system and finish proposed for the different
items of equipment indicating the stage of work/completion at which the protective costs will
be applied.
In the event of a simultaneous temperature load and chemical loads by aggressive media,
the corrosion protection should be selected according to the temperature load. In these
cases, a limited protection period should be expected.
The protection period is defined according to EN ISO 12944-5 as the expected exposure
time of a protection system depending on the corrosion load until the initial service (also
see Annex A).
2.3.1.1 Coatings on non-alloyed and low-alloyed steel

The coating systems are to be selected according to Annex B, Table 6 for "For initial
protection" and "For improvements following assembly". The structure of the protective
systems is also shown in Annex B, Table 6.
In Annex B, Table 7 the permissible coating material supplier's and in Table 8 to 12the
accompanying product names are listed. For the primary, i.e. the constructive steel
structure, stack, the coated tanks or silos as if big pieces (approx. > 20m2) which has to be
coated, it is strictly required to apply the paint systems defined in annex B Table 9 and ff.
2.3.1.2 Coatings in floor zones with special loads
Support parts outdoors or in catch cups must be given an additional coat with an epoxy
resin - tar substitute basis with at least 100 m coat thickness as additional injection
protection to 50 cm above the ground or the foundation upper edge. For support parts
outdoors, the foundation head must be integrated into the coating.
Steel supports are to be sealed on the foot point in the steel/concrete transition area with
permanent elastic sealing masses to protect against the penetration of moisture. Suitable
sealing masses (e.g. Sikaflex 11 FC) are to be coordinated with the coating manufacturer
and the test results are to be communicated to HZI before use.
2.3.1.3 Coatings on contact surfaces of prestressed bearing-type shear connection and bolt
joined
It is to consider that the coating has no negative influence to the prestressed connection.
(See as well EN ISO 12944-3 paragraph 5.6.2 and EN ISO 12944-5 paragraph 5.6).
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All contact surfaces of bolt joined of steelwork parts have to derusted before installation
with a surface cleanness of Sa 2 according EN ISO 12944-4.
Contact surfaces of prestressed bearing-type shear connection have to coated on both side
with epoxy resin coating pigmented with zinc phosphate primer. The coating thickness has
to be 80 m. The coating system should be same as the other layers (intermediate and top
coating) which are use for the coating work. The applied epoxy resin coating pigmented
with zinc phosphate primer has to select from annex B Table 6 for initial protection. It has to
be ob-served that in the edge area is coated with a close and sufficient primer coating.
The contact surface of non prestressed bolt joined have to coat on both side with coating
system according annex B Table 6 for initial protection. The coating system is selected to
the defined atmospheric corrosion load.
2.3.2
Galvanising
Galvanized parts are not permitted.
Excluded are:
hot dipped galvanised grating with the necessary clamps

cable trays and supports for cabling
hangers or supports for piping
sub-construction for insulation
The piece galvanisation must occur as hot-dip galvanising according to EN ISO 1461. The
thickness of the zinc coating must be 85 m for steel components with a wall thickness
greater or equal to 6 mm. Table 2 of EN ISO 1461 applies to the thickness of the zinc
coating of steel components.
The steel components are to be constructed according to EN ISO 14713 with proper hot-dip
galvanisation.
The constructions must be structurally complete so that no changes are required. Assembly
welding is not permitted on galvanised system parts. Exclusively threaded couplings should
be provided.
Hot-dipped galvanised structures have not be used in the C4 corrosivity categories and C5I and at additional loads through acid emissions, chlorides, ammonia and with constant
moisture.
No making good on site will be allowed.
2.3.3
Aluminium and high-alloy steel

Aluminium materials can not be used for supplemental loads due to acid emissions,
chlorides or with constant moisture. Exceptions are aluminium alloys with a resistance
which has been expressly confirmed by the manufacturer under the existing loads.
High-alloy steels remain without corrosion protection.
2.3.4
Standard components
The standard components (motors) shall be painted according to manufacturers
standard.
The EPC Contractor protects the hot surface, built with steel and without thermal insulation,
with a sandblasting at Sa 2, one 40- coat of zinc silicate as rust-repellent and one 25coat of aluminium paint as protective coat for zinc silicate. The total thickness shall be 65
microns at the minimum.
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Corrosion protection below insulation

There is a difference between components that need a permanent corrosion protection
even below insulation and components that have to be protected only until to the start of the
hot commissioning (see also chapter 2.5).
A coating system has to be selected according to annex C for functioning corrosion
protection below isolation. For parts in an operating temperature between 120 and 200 C a
coating system according annex B Table 6 "initial protection" has to be selected. There are
two different systems. The total reference paint thickness for system 1 (preferred system) is
180 m, for system 2 (alternative system) 120 m. A surface preparation is necessary with
surface cleanness of Sa 2 according EN ISO 12944-4.
The definition also applies for parts which have only a temporarily temperature impact, like
reserve or safety pipes, for instance.
There are no durable corrosion protection necessary below insulated parts in power station
which have a permanent operation temperature over 120 C according to the worksheet
AGI - Q 151, section 4.
2.5
Temporary corrosion protection

Parts are protected with a temporary corrosion protection only for the time period until to the
hot commissioning of the plant. In this time period are include the transport, storing and
installation.
Parts which contain no corrosion protection such as steel parts for interior structures for
worm shafts or drive shafts, for example, are to be given temporary corrosion protection at
the manufacturer's plant which is easy to remove.
For high temperature impacted parts is preferred a primer on basis of special syntactic resin
e.g. HEMPATEX E:V: Primer 19151 for temporary corrosion protection. The coating has not
to be removed when the commissioning of the plant starts. The primer contains a special
syntactic resin as an adhesive agent which will be decomposing above 180 C. It produces
a slight gas evolution during the decomposition.
2.5.1
Definition of temporary corrosion protection
2.6
Surface preparation with surface cleanness of Sa 2 according EN ISO 12944-4

Coat of special primer, HEMPATEX E:V: Primer 19151, constant and closed layer,
coating thickness minimum 60 m
Colour: RAL 3009, oxide red
By other coating system it has to be a coating which is accepted as a welding
primer e.g. test certificate according DAST-Guideline 006
Work and environmental protection

All of the work and environmental protection regulations must be complied with at the object
location. The supplier must ensure that CP work and the associated secondary services
must be carried out by qualified personnel and by persons who can be proved to have
received proven training in carrying out the work (e.g. security measures for scaffold work,
blasting work, handling of the coating materials, disposal of residual materials etc.)
Coatings and coating auxiliary materials, blast waste, filter dust and other contaminating or
hazardous materials may not enter the environment or into bodies of water.
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Execution of corrosion protection

The corrosion protection system must always be applied completely at the workshop.
If in the opinion of the supplier, there is a deviation from the workshop coating, it must be
approved by HZI.
3.1
Preparation and cleaning of surfaces
3.1.1
Object preparation
Existing valves, inspection glass, sensitive mechanical areas, electrical machine parts etc.,
can be protected effectively from damage or disassembled if necessary.
3.1.2
Pre-cleaning of surfaces
Oils, greases and adherence retardant auxiliaries must be completely removed before derusting and de-scaling. Cleaning must occur according to EN ISO 12944 Part 4, Annex C
"Method for removing foreign coatings and contaminations" with the highest possible
environmentally compatible cleaning process.
Fixed-adhesive, thick-layered contaminations such as concrete and thicker rust coats must
be removed mechanically in advance.
Visible rolling defects, welding pearls, welding and incinerated bottom ashes, burrs etc.
must be fully removed before blast de-rusting.
See chapter 5.1.4- preparation grades P2 according EN ISO 8501-3
3.1.3
De-rusting using a blasting method

The surface preparation degree Sa 2 according to EN ISO 12944-4 must be established
for new systems and coatings or partial coatings in the workshop if other requirements are
not explicitly collected. Comparative images of blasted surfaces are included in EN ISO
8501. Special care must be used to remove any existing roller cinder with no residue.
If not prescribed separately, the supplier is to use the suitable blasting materials and blast
method according to the coating supplier. Steels with a higher stability than non-alloyed
steel (e.g. S235JR) must be blasted with mineral blasting materials.
Blasting work can only be carried out if the surface temperature at least 3 K over the dew
point unless there is post-blasting with ideal climatic conditions. This threshold must be
reached as a minimum between blast de-rusting and the application. Subsequent rusting
(e.g. dripping water through compressed air containing water) must be re-blasted.
After blasting still determinable rolling defects, steel rejects etc. are to be polished clean
before application of the coating according EN ISO 8501-3 preparation grades P2.
The rawness of the steel surface should correspond to the degree of rawness "middle (G)"
if blasting occurs with chamfered blasting materials or a combination of chamfered /
spherical blasting materials or "average (S)" if blasting occurs with metallic spherical
blasting materials, according to EN ISO 8503-1.
The average roughness depth Ry5 (equal Rz-Value) should be approximately 50 m. The
comparative pattern method according to EN ISO 8503-2 applies for testing.
The surface roughness must correspond to the specifications of the coating supplier.
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De-rusting of untreated, built-in steel parts

The installation of untreated steel parts requires approval by HZI and is limited to
exceptional cases (no components of secondary significance such as additional mounting
holders etc.).
If blasting is technically not possible, de-rusting occurs to the surface preparation degree St
2 according to EN ISO 12944-4. A system which matches the coating system used for the
currently prepared surfaces with a surface-tolerant primer must be applied according to
Annex B, Table 6, page 2 "Repair" of the same coating supplier.
3.1.5
Preparation of mounting weld seams

If mounting welds are required at the construction site, the prescribed welding seam zones
are covered according to the surface preparation to 50 mm width from the welding seam
edge with appropriate adhesive tape. The tape has to be easy and residue free removable.
If the welding seam zones cannot be planned, they must be polished to be metallically
polished at least up to the surface preparation degree PMa so that qualitative faults in the
welding seams and in the CP system can be avoided.
3.1.6
Cleaning of primer and intermediate coatings

Soiled and dusty primer and intermediate coatings are to be cleaned residue-free according
to a suitable method listed in EN ISO 12944-4, Annex C before application of the following
coating. No chemicals may be used which are hazardous to the environment.
3.2
Processing and application of the coating materials
3.2.1
Requirements for coating materials

The prescribed colour scheme and, if necessary, the prescribed identification, colours, e.g.
DIN 2403, must be followed. Deviating colours must be approved by HZI.
The colours of the coatings correspond to RAL/SIS colour catalogue according to the colour
scheme TII 16.10.
The colours of the individual layers are to be coordinated by the supplier in such a way that
the colour of the following layer is not affected. In particular, this applies to interim coatings.
When two prescribed intermediate coatings are applied, they acquire different colours.
3.2.2
Preparation and application of the coating materials

The coating materials may not be changed by the processor.
If the substrate is blasted to the surface preparation degree Sa 2 , the primer must be
applied on the same day. If this is not possible, HZI must be informed immediately. If
necessary, the relevant surfaces must be re-blasted in order to restore the prescribed
preparation degree.
The following coating may only be applied if dryness degree 4 (dryness degree for the
determination of over-processing. The drying times included in the technical data sheets of
the coating supplier apply.
Coating may only occur if the required processing requirements in EN ISO 12944 and the
coating manufacturer have been met.
The climactic conditions at the site of the coating work must also be documented at the
beginning and conclusion of the coating work in the construction log. The prerequisite is
that the required measurement devices are certified and calibrated for the determination of
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the climactic conditions (relative humidity, air temperature, surface temperature of the
material and dew point).
Coating materials may not be applied to surfaces of the surface temperature is less than 3
K above the air dew point, determined according to EN ISO 8502-4. Only these coating
materials may be applied onto moist surfaces which are permitted on the Technical Data
Sheet or according to the agreement of the coating supplier.
3.2.3
Workshop application
The following rules must be followed:
3.2.4
The blasted surface must be covered on the date of the blast de-rusting with a
complete top coat of the specified primer coating.
The application of all layers must have priority using the injection method.
If the coatings on structural parts such as angles, counter drafts, screw heads etc.
cannot be applied using injection methods in the required coat thickness, they must
be painted with the brush before injection.
For smaller objects, the coating can also be also be implemented with a brush with
priming and for intermediate and top coats with a brush or roller.
Two coats in succession of the same colour are not permitted. The colour deviation
must be detectable in wet and in a dry state.
The one-step coat thickness depends on the coating method. Thus, except for zinc
dust primers, it is permitted to apply the coating material several times to achieve
the prescribed coat thickness of the individual layer. Here colours which cover
poorly (such as yellow, orange etc.) can be applied with the same colour in
succession.
The regulations of the coating supplier must be followed in terms of maximum coat
thickness per coat application and the required interim drying times.
Construction site application

Coating work at the construction site is only permitted in exceptional cases approved by
HZI except for the repair of welding weld seam zones and damages.
The following regulations apply:
De-rusted surfaces are to be primed using a brush at the construction site.

Intermediate and top coatings are to be applied with a brush or a roller.
In the exceptional case, an injection application is permissible with intermediate and top
coats. However, this requires the approval by HZI. However this requires, that the
environment should be protected in such a way that no contaminations can occur through
coating work.
3.3
Determination of the coat thickness according to EN ISO 12944-5:

2008-01
The specified dry coat thicknesses of the prescribed coating systems are target coat
thicknesses. The coat thickness values refer to the measurements with measurement
devices adjusted on the polished plate.
The determination of the target coat thickness is carried out with magnetic or magnetically
inductive measurement devices. EN ISO 2808 applies for "middle roughness" according to
EN ISO 8503-1 for the measurement of the dry coat thickness.
ISO 19840 does NOT apply here.
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The number of actually required steps to achieve the prescribed total coat thicknesses
depends on the selection of the application method.
The contractor must provide the proof of the required coat thicknesses independent of a
workshop or a construction site coating.
The target coat thickness is considered to be of the correct quality if individual
measurement values are greater or the same as 80% of the prescribed target coat
thicknesses and the average value of all measurement results is greater or equal to the
target coat thickness.
The specifications in the manufacturer's Technical Data Sheets apply to the maximum coat
thickness. If no information is included in the data sheet of the coating manufacturer, the
maximum coat thickness should not be more than triple the total coat thickness.
3.4
Transport, storage and assembly of coated steel components

Coated parts may only be transported if the coating is thoroughly dried enough that
transport capability is achieved. The technical data sheets of the coating supplier are
decisive.
If no mounting eyes are available, only textile or rubberised slings are allowed when
fastening coated parts.
The loading areas of the transport vehicles must have supports made of wood or rubber.
The parts are to be secured against slippage using intermediate plates made of wood or
rubber.
The bearing of coated parts is to occur on even services on which no water can accumulate
using based and intermediate plates made of wood or rubber.
Apparatuses, fittings, fans, electrical cabinets and motors with finished coating are to be
protected against damages with appropriate covers when delivered to the construction site.
3.5
Repair of transport and assembly damages
3.5.1
Surface preparation of assembly damages

The surfaces should be prepared with preparation degree PMa according to EN ISO 129444.
All damaged or loose layers have to be removed. It is necessary by the preparation of
damaged rim zones to the intact coating are blurred transition.
3.5.2
Coating on site
Damages to the metallic substrate must be prepared to the surface preparation degree
according chapter 3.5.1 and primed with a surface-tolerant primer which matches the
coating system used according to Annex B, Table 6 , second part of the table for "Repair" of
the same coating supplier.
The remnants of damaged coatings must be removed and the missing coating must be
enhanced in the system for damages not extending to the substrate.
Damages within the primer and intermediate coatings must be serviced before other
coatings can be applied.
Any existing adhering paint or beads must be completely removed before the application of
the repair coating on areas where the parts have laid on supports during workshop coating
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3.6
Repair of coating of welding zones
3.6.1
Surface preparation of welding zones
The surfaces should be prepared with preparation degree PMa according to EN ISO 129444.
The preparation grade for welding zones before application of the coating is P2 according
EN ISO 8501-3.
3.6.2
Coating on site
Welding zones must be primed with a surface-tolerant primer which matches the coating
system used according to Annex B, Table 6 1 and second part of the table for "Repair" of
the same coating supplier.
The remnants of damaged coatings must be removed and the missing coating must be
enhanced in the system for damages not extending to the substrate.
Damages within the primer and intermediate coatings must be serviced before other
coatings can be applied.
Any existing adhering paint or beads must be completely removed before the application of
the repair coating on areas where the parts have laid on supports during workshop coating.
3.7
Repair of damaged areas on hot dipped galvanised steel

components
The galvanised structures must be delivered clean to the construction site. Primarily not
permitted are missed areas in the coating, hard zinc inclusions, slag inclusions and other
foreign bodies and fluid residues.
By extension, also standard EN ISO 1461 is agreed upon for the repair of damaged areas
on the zinc covering on site at the construction site.
The interior surfaces are excluded from the missed area regulation on hollow constructions
that cannot be walked on. A check is hardly possible or not possible. No specialised repair
is possible given a lack of accessibility.
Repairs occur according to EN ISO 1461 depending on the size of missed areas. Areas
without zinc coating (missed areas) may not constitute more than 0.5 % of the component
surface in their totality. The size of an individual missed area may be a maximum of 10 cm2
and must be repaired properly.
3.7.1
Surface preparation of damaged areas

The surfaces should preferably be prepared with blast de-rusting up the surface preparation
degree of Sa 2 according to EN ISO 12944-4 but at least through machine polishing up
to a service preparation degree PMa according to EN ISO 12944-4.
The edges to the intact zinc coating are to be evened out cleanly and may not be hollow.
Steel blasting materials can result in quickly rusting deposits on the intact zinc coating. For
this reason, iron-free blasting materials should preferably be used. Deposits from blasting
are to be removed.
It is recommended that coverage masks be used in order to prevent increasing the missed
area unnecessarily.
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Improvement of damaged areas in the zinc coating up to 10 cm2 in size

Improvement of the damaged areas using special, suitable coating materials:
The coating materials must have at least 90 mass-% zinc in dry film. The 2K epoxy resin
zinc dust coating materials are suggested. The following applies:
3.7.3
The missing areas must be repaired even and clean with a sufficient overlap into
the intact area.
A coat thickness of at least 100 m to the primer material must be maintained for
damaged areas.
The repair must be performed exclusively by a specialised company.
Repair with "zinc spray" or other sprays with aluminium powder is not permitted.
Repair of damaged areas with zinc coating over 10 cm2 in size

Improvement of the damaged areas using of new zinc coating
Thermal injection of zinc according to EN ISO 2063

Target layer thickness: 100 m to 120 m
This method is time-consuming, the protection period of the repaired missed area generally
corresponds to the intact zinc covering. The accessibility of the areas in question must be
reviewed before use.
It is to be decided if and when the thermal injection of zinc to repair damaged areas is used
on site on the object in coordination with HZI, taking the interests of both parties into
account.
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Monitoring, acceptance and documentation
4.1
In-house monitoring by the contractor
The supplier or subcontractor of the corrosion protection is to maintain a construction log

throughout the entire execution period of the corrosion protection work in which in particular
the existing conditions (air and surface temperature, humidity, dew point, name and batch
of the coating material) are documented when applying the coatings. This construction log
must be submitted to HZI for a check at regular intervals.
The supplier or subcontractor controls and documents the achieved surface preparation
degree, the coordination of the coating materials used with the specifications, the layer
thicknesses of the primer, intermediate and top coatings and the improvement of damages
and welding seam areas. A log must be transferred to HZI with the results.
4.2
Outside monitoring by HZI or external entities

HZI reserves the right to all monitor compliance with the specifications in addition to its own
checks. Here HZI must be notified of the dates for the implementation of the work in a
timely manner but at least 5 working days in advance.
The responsibility of the supplier for the quality of corrosion protection is not restricted by
the outside checks.
4.3
Control areas
Control areas are suitable areas on the structure, component or similar items which are
designed to:
present an acceptable execution standard for the work;

confirm that the information of a coating supplier or a Contractor is correct;
assess the coating at a later time.
The decision to create control surfaces and on their number is made by HZI according to
the type and size of the objects before the corrosion protection work begins.
Control areas are to be created and logged according to EN ISO 12944-7 and -8.
The control areas are to be created in the presence of the HZI representative, the supplier
and the coating supplier. It is the responsibility of the supplier to invite the representatives.
The date is to be announced to HZI in a timely manner.
4.4
Acceptance
Acceptance of corrosion protection occurs between HZI and the supplier following
conclusion of all corrosion protection work including repair work and a final inspection.
During inspection, the construction logs and the logs for in-house and outside monitoring
must be provided.
Partial acceptances of construction phases are possible by agreement with HZI.
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Annex A
5.1
Terms and definitions used
5.1.1
Milling skin / Cinder
Thick oxide layer which occurs on steel during processing in heat or in heat treatment
5.1.2
White rust
White to dark grey corrosion products on galvanised surfaces
5.1.3
Surface preparation degree

Preparation degree for the initial protection and maintenance according to EN ISO 12944-4
Table 5: Surface preparation degrees
Preparation
degree 1)
Blasting
Major characteristics of the prepared surfaces 2)
Sa 2
Milling skin / cinder, rust, coatings and foreign contaminations are removed.
Remaining traces are only detectable as lightly spotty or stripped shaded
areas.
Local blasting
PSa 2
Solid-adhesive coatings must be intact. Loose coatings, milling skin / cinder,

rust and foreign contaminations are removed. Remaining traces are only
detectable as lightly spotty or stripped shaded areas.
Machine polishing on partial areas

PMa
Solid-adhesive coatings must be intact. Loose coatings, milling skin / cinder,

rust and foreign contaminations are removed. Remaining traces are only
detectable as lightly spotty or stripped shaded areas.
Manual preparation
St 2
Loose milling skin / cinder, loose rust, loose coatings and loose foreign
contaminations are removed. Loose milling skin / cinder is considered loose if it
can be lifted with a stiff putty knife.
Explanations on the foot notes:

1) All of the abbreviations used correspond to the abbreviations of EN ISO 8501-2.
2) Representative photographic comparative samples include EN ISO 8501-1 and -2.
5.1.4
Preparation grades according EN ISO 8501-3: 2007

The preparation grades of welding, edges and other faces with surface un-steadiness are
defined in part 3 of EN ISO 8501. The different types of un-steadiness are illustrated and
described in table 1 of aforementioned standard. The requirements for the preparation
grades are defined also in table 1. There are defined three different preparation grades for
steel surfaces which make the parts ready for an appropriated coating.
P1 Light Preparation
No preparation respective only minimum requirements
P2 Thorough Preparation (HZI Standard)
The most unsteadiness of surface are treated
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P3 Very Thorough Preparation

The surface is free of visible unsteadiness
5.1.5
Dew point
Dew point is the temperature at which the moisture from the air condenses from a solid
surface.
The probability of dew formation is estimated based on the relative humidity and the
temperature of the steel surface.
Further details on the dew point and on dew formation are included at EN ISO 8502-4.
5.1.6
Coating thickness
In accordance with EN ISO 12944-5:2008-01, the prescribed coat thickness for individual
coatings or the entire coating system in order to achieve the requested protection period.
The target coat thickness of the coating is determined according to chapter 3.3
5.1.7
Protection period
The protection period shall be guaranteed and will not be less than 7 years for mechanical,
parts and 15 years for civil works (according to EN 12944 or latest equivalent applicable EN
norm(s) if existing).
5.1.8
Maintenance
All measures adopted in EN ISO 12944 which aim toward the function of corrosion
protection being maintained. Maintenance includes coating work among other things. This
can include repairs, partial renovations or complete renovations.
5.1.9
"Bundesbahn"- Colour code

Colour codes of "Bundesfarbton" contain a high amount of iron mica. A "Bundesbahn"
colour code is defined for the intermediate coating. The definition of the colour for the
intermediate coating is based on the colour of the primer according to chapter 3.2.1
All "Bundesbahn" colour codes:
DB 301, DB 310, DB 501; DB 502, DB 503, DB 510, DB 601, DB 603, DB 610, DB 701, DB
702, DB 703
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Annex B
6.1
Table 6: Selection of the coating system structures
Expected protection period of the coating systems taken as a basis according to EN ISO 12944-5:2008-01 protection period "high"
Component
equipment
Working
tempera
For initial protection
Steel frames, steel
components such as
stairs, stairwells etc.
Apparatuses
Containers
Pipe lines
/
1)
Working
temp.
120C
not insulated
Corrosion load as a basis
Coating system structure
Reference
paint thickness 4) [m]
Corrosivity category C2
Offices and product rooms, dry, warm,
minimal contaminations, no deposits of
corrosive salts
PC
TC
80
60
Product rooms with moderate
contamination, minimal deposits of
corrosive salts
PC
Relative humidity > 80%, short-term wet
and weak alkaline to weak acid load,
deposits of corrosive salts
PC
IC
2K-ER-zinc phosphate rapid

2K-PUR
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Sa 2
Total: 140
TC
TC
2K-ER-zinc phosphate / iron

mica rapid
2K-PUR
100-120

2K-ER- iron mica rapid
"Bundesbahn" colour
2K-PUR
100
100-120
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Sa 2
80-100
Total: 200
60-80
Total: 280
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Level
of
surface
preparation
Sa 2
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Component
equipment
Working
tempera
Steel frames, steel
components such as
Apparatuses
Containers
Pipe lines
Apparatuses,
containers, pipe lines

and and repair of
Not insulated steel
components,
Apparatuses,
Containers, Pipes,
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/
1)
Working
temp.
120C
not insulated
Reference
Level
of
surface
preparation
Corrosivity category C5-I

Relative humidity > 80%, Continuous
wet effect and frequently high chemical
loads, resulting in heavy condensation
moisture and heavy deposits of corrosive
salts
PC
IC
80-120
120-140
Sa 2
TC

"Bundesbahn" colour
2K-PUR
60-100
Total: 320
Corrosivity category C5-M

Plant section in unprotected position
which are in sphere of influence of
seashore (outside installation)
121 200C
Insulate
d and
not
insulated
PC
IC
TC

"Bundesbahn" colour
2K-PUR
Recommendation: System 1
ER-phenol resin (2-fach)
80-120
120-140
Sa 2
60-100
Total: 320
Sa 2
2 x 100
Total: 200
Alternative: System 2
PC
TC
200 C400C
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Ethyl silicate-zinc dust

Acrylic silicone resin/silicone
70
50
Total: 120
International
Intertherm 751 CSA
2 x 100
Total: 200
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Sa 2
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Component
equipment
Working
tempera
Ducts
For reparation after

erection
Steel frames, steel
components such as
Apparatuses
Containers
Pipe lines
erection
Steel frames, steel
components such as
Apparatuses
Containers
Pipe lines
erection
Steel frames, steel
components such as
Apparatuses
Containers
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/
1)
Working
temp.
400550C
Not
insulated
120C
not
insulated
PC
TC
PC
IC
TC
PC
IC
TC
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Reference
Level
of
surface
preparation
International
Intertherm 898 CSA
1 x 175
Total: 175
Sa 2
2K-ER-combination-zinc
phosphate, surface tolerant
2K-PUR-rapid
80
PMa 2)
PSt 2 3)
2K-ER-combination-zinc
2K-ER-iron mica rapid
"Bundesbahn" colour 5)
2K-PUR
60
2K-ER-combination zinc
2K-PUR
100
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60
Total: 140
PMa 2)
PSt 2 3)
80
60
Total: 200
100-120
60-80
Total: 280
PMa 2)
PSt 2 3)
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Component
equipment
Working
tempera
Pipe lines
/
1)

erection
Steel frames, steel
components such as
Apparatuses
Containers
Pipe lines
Working
temp.
Reference
Level
of
surface
preparation
Corrosivity category C5-I / C5-M
PC
100-120
PMa 2)
PSt 2 3)
IC
TC
2K-ER-combination zinc
2K-PUR
120-140
60-80
Total: 320
Explanations on Table 6:
1) Table 6 applies exclusively to components and equipment made of unalloyed or low-alloy steel
2) PMa = Surface treatment using machine polishing in partial areas according to EN ISO 12944-4 (Machine polishing for the surface preparation is
only permitted if blast de-rusting is not feasible)
3) Item 2 = Surface preparation using manual de-rusting, only applies to de-rusting of untreated built-in steel components (see chapter 3.1.4)
4) The number of steps required to achieve the individual target coating thicknesses indicated in this regard depends on the selection of the
application process. The number of steps listed in Table 6can be reached with an application of coatings through airless injections.
5)less VOC and minimum 50% content of iron mica .
Abbreviations used:
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PC:
Primer coating
IC:
Intermediate coating
TC:
Top coating
ER:
Epoxy resin
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ER - zinc phosphate:
Epoxy resin coating pigmented with zinc phosphate
ER - surface tolerant:
Epoxy resin coating, suitable for steel substrates with minimal residual rust
ER-EG:
Epoxy resin coating pigmented with iron mica
PUR:
Polyurethane
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Table 7: Coating material suppliers

Overview of the company names and the exact addresses of the selected coating supplier:
Table 7: Coating material suppliers
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Short form of the coating supplier
Address
Sika
Sika GmbH
Kornwestheimer Str. 103-107
D-70439 Stuttgart
HEMPEL
HEMPEL GmbH
Hindenburgdamm 60
D-25421 Pinneberg
International Farbenwerke
International Farbenwerke GmbH

Bereich Korrosionsschutz
Lauenburger Landstr. 11
D-21039 Brnsen
Geholit + Wiemer
Geholit + Wiemer Lack- und Kunststoffchemie GmbH

Sofienstr. 36
D-76676 Graben-Neudorf
Jotun
Jotun (Deutschland) GmbH

Winsbergring 25
D-22525 Hamburg
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Supplier names of the coating materials

The names of the coating materials of the coating supplier is assigned to the coating system structures according to Table 6
6.3.1
Table 8: Coating supplier 1: Sika

Initial
protec
tion
X
Repair
Component/Equipment
Working temperature
Corrosivity
category 1) used
as a basis

Name of the coating materials 2)
Reference
paint thickness 3)
(m)
Steel frames,
steel components
such as stairs,
handrails etc.
Apparatuses
Vessels
Piping
C2
PC
TC
SikaCor EG Phosphat Rapid

SikaCor EG 5
PC
TC
SikaPermacor 2305 Rapid

SikaPermacor 2330
PC
IC
TC

SikaPermacor 2315 EG-Rapid
SikaPermacor 2330
80
60
Total 140
100
100
Total 200
100
100
C3
C4
< 120C
not insulated
C5-I / C5-M
PC
IC
TC

SikaPermacor 2315 EG-Rapid
SikaPermacor 2330
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Sa 2
Sa 2
Sa 2
80
Total 280
80
140
Sa 2
100
Total 320
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Preparation
degree
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Initial
protec
tion
Repair
Component/Equipment
Working temperature
Corrosivity
category 1) used
as a basis

Apparatuses, Vessels
Piping not insulated and
insulated
121-200C4)
C2 und C3
System 2
2-K-Ethyl silicate-zinc dust / silicone
resin coating
PC
SikaPermacor 2511
TC
SikaCor Alutherm
Steel frames,
steel components
such as stairs,
handrails etc.
Apparatuses
Vessels
Piping
C2
PC
TC
SikaPermacor 2004
SikaPermacor 2330
C3
PC
IC
TC
SikaPermacor 2004
SikaPermacor 2029
SikaPermacor 2330
C4
120C
not insulated
C5-I / C5-M
PC
IC
TC
PC
IC
TC
SikaPermacor 2004
SikaPermacor 2029
SikaPermacor 2330
SikaPermacor 2004
SikaPermacor 2029
SikaPermacor 2330
Reference
paint thickness 3)
(m)
70
50
Total 120
80
60
Total 140
60
80
60
Total 200
100
100
80
Total 280
120
120
80
Total 320
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Preparation
degree
Sa 2
PMa
PSt 2
PMa
PSt 2
PMa
PSt 2
PMa
PSt 2
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Table 9 : Coating supplier 2: International Farbenwerke

Initial
protec
tion
X
Repair
Component/Equipment
Working temperature
Corrosivity
category 1) used
as a basis

Reference
paint thickness 3)
(m)
Steel frames,
steel components
such as stairs,
handrails etc.
Apparatuses
Vessels
Piping
C2
PC
TC
Intercure 200
Interthane 990 s
80
60
Total 140
PC
TC
Intercure 200 HS
Interthane 990 s
140
60
Total 200
120C
not insulated
C4
PC
IC
TC
Intercure 200 HS
Intercure 420
Interthane 990 s
100
120
60
Total 280
Sa 2
PC
IC
TC
Intercure 200 HS
Intercure 420
Interthane 990 s
120
140
60
Total 320
Sa 2
C3
C5-I / C5-M
insulated
121-200C4)
Print date 23.09.13 14:38
C2 und C3
Last saved 23.09.13
System 1
ER-phenol resin
PC
Intertherm 228
TC
Intertherm 228
Page 30 of 40
100
100
Total 200
Preparati
on
degree
Sa 2
Sa 2
Sa 2
Project Name: SERC

AIC:
000000
50021972 - 1.0
Document Nr-Rev:

Initial
protec
tion
Repair
Component/Equipment
Working temperature
Corrosivity
category 1) used
as a basis

Reference
paint thickness 3)
(m)
Preparati
on
degree
Steel frames,
steel components
such as stairs,
handrails etc.
Apparatuses
Vessels
Piping
C2
PC
TC
Interplus 256
Interthane 990 s
80
60
Total 140
PMa
PSt 2
PC
IC
TC
Interplus 256 / Interplus 356

Interplus 770
Interthane 990 s
60
80
60
Total 200
PMa
PSt 2
120C
not insulated
C4
PC
IC
TC

Interplus 770
Interthane 990 s
PC
IC
TC

Interplus 770
Interthane 990 s
100
120
60
Total 280
120
140
60
Total 320
C3
C5-I / C5-M
Print date 23.09.13 14:38
Last saved 23.09.13
Page 31 of 40
PMa
PSt 2
PMa
PSt 2
Project Name: SERC

AIC:
6.3.3
000000
50021972 - 1.0
Document Nr-Rev:
Table 10: Coating supplier 3: Geholit + Wiemer

Initial
protec
tion
X
Repair
Component/Equipment
Working temperature
Corrosivity
category 1) used
as a basis

Reference
paint thickness 3)
(m)
Steel frames,
steel components
such as stairs,
handrails etc.
Apparatuses
Vessels
Piping
C2
PC
TC
GEHOPON-E4R - Metallgrund
WIEREGEN-M16R
80
60
Total 140
PC
TC
GEHOPON-E4R - Metallgrund
WIEREGEN-M87
120
80
Total 200
120C
not insulated
C4
PC
IC
TC
GEHOPHON-E24R - Metallgrund
GEHOPHON-E8R-IC
WIEREGEN-M87
100
100
80
Total 280
Sa 2
PC
1. IC
2. IC
TC
GEHOPHON-E24R - Metallgrund
GEHOPHON-E8R-IC
GEHOPHON-E8R-IC
WIEREGEN-M87
100
80
80
60
Total 320
Sa 2
C3
C5-I / C5-M
C2 und C3
insulated
121-200C4)
Print date 23.09.13 14:38
Last saved 23.09.13
System 2
2-K-Ethyl silicate-zinc dust / silicone resin
coating
GB
GEHODUR-F35-Zink
DB
GEHODUR-S10, alusilber
Page 32 of 40
75
2x25
Total 125
Preparati
on
degree
Sa 2
Sa 2
Sa 2
Project Name: SERC

AIC:
000000
50021972 - 1.0
Document Nr-Rev:

Initial
protec
tion
Repair
Component/Equipment
Working temperature
Corrosivity
category 1) used
as a basis

Reference
paint thickness 3)
(m)
Preparati
on
degree
Steel frames,
steel components
such as stairs,
handrails etc.
Apparatuses
Vessels
Piping
C2
PC
TC
GEHOPHON-E60-Korrogrund
WIEREGEN-M16R
80
60
Total 140
PMa
PSt 3
PC
IC
TC
GEHOPON-E8R-IC
WIEREGEN-M87
60
80
60
Total 200
PMa
PSt 3
120C
not insulated
C4
PC
IC
TC
GEHOPON-E8R-IC
WIEREGEN-M87
PC
1. IC
2. IC
TC
GEHOPON-E8R-IC
GEHOPON-E8R-IC
WIEREGEN-M87
100
100
80
Total 280
100
80
80
60
Total 320
C3
C5-I / C5-M
Print date 23.09.13 14:38
Last saved 23.09.13
Page 33 of 40
PMa
PSt 3
PMa
PSt 3
Project Name: SERC

AIC:
6.3.4
000000
50021972 - 1.0
Document Nr-Rev:
Table 11: Coating supplier 4: Jotun

Initial
protec
tion
X
Repair
Component/Equipment
Working temperature
Corrosivity
category 1) used
as a basis

Reference
paint thickness 3)
(m)
Steel frames,
steel components
such as stairs,
handrails etc.
Apparatuses
Vessels
Piping
C2
PC:
TC:
Penguard Express ZP
Hardtop XP
80
60
Total 140
PC:
TC:
Penguard Express ZP
Hardtop XP
120
80
Total 200
Sa 2
PC: Penguard Express ZP

IC: Penguard Express MIO
TC: Hardtop XP
100
120
60
Total 280
Sa 2
PC:
IC:
TC:
120
120
80
Total 320
Sa 2
C3
C4
120C
not insulated
C5-I / C5-M
C2 und C3
insulated
121-200C4)
Print date 23.09.13 14:38
Last saved 23.09.13
Penguard Express ZP
Penguard Express MIO
Hardtop XP
System 1
PC: Epoxy HR
TC: Epoxy HR
System 2
GB: Resist 78
DB: Solvalitt
Page 34 of 40
125
125
Total 250
75
2x25
Total 125
Preparati
on
degree
Sa 2
Sa 2
Project Name: SERC

AIC:
000000
50021972 - 1.0
Document Nr-Rev:

Initial
protec
tion
Repair
Component/Equipment
Working temperature
Corrosivity
category 1) used
as a basis

Reference
paint thickness 3)
(m)
Steel frames,
steel components
such as stairs,
handrails etc.
Apparatuses
Vessels
Piping
C2
GB:
DB:
C3
GB: Jotamastic 80, aluminium red

ZWB: Jotamastic 80, aluminium
DB: Hardtop XP
80
60
Total 140
75
75
50
Total 200
100
100
80
Total 280
120
120
80
Total 320
C4
120C
not insulated
C5-I / C5-M
Jotamastic 80, aluminium

Hardtop XP

DB: Hardtop XP
DB: Hardtop XP
Preparati
on
degree
PMa
PSt 3
PMa
PSt 3
PMa
PSt 3
PMa
PSt 3
Explanations on Error! Reference source not found.:

1) Corrosive category used as a basis according to EN ISO 12944 - 2, more information on corrosion loads used as basis are included in chapter
6.1 Table 6.
2) The aforementioned coating material names are coordinated with the CS (coating supplier). Intermediate and top coats (known as rapid
systems) were selected
3) The number of steps required to achieve the individual target coating thicknesses indicated in this regard depends on the selection of the
application process. The number of steps listed in Table 8 can be reached with an application of coatings through airless injections.
4) The indicated coating materials can be used for insulated and not insulated apparatuses, containers and pipe lines at operating temperatures of
121-200C.
Print date 23.09.13 14:38
Last saved 23.09.13
Page 35 of 40
Project Name: SERC

AIC:
000000
50021972 - 1.0
Document Nr-Rev:
Annex C
7.1
Temporary Corrosion Protection
In the following table are listed parts and components which should have a functioning coating until to the start of hot commissioning. The
temporary corrosion protections protect parts and component for time period of 8 to 12 month.
Table 12: Example for parts and component which are manly installed in EfW plants with temporary corrosion protection
Legend: X = applicable, = not applicable
Table 12: Coating Systems for temporary corrosion protection
Component/Equipment
ID-Fan
Fan-Frame, not insulated parts
Insulated fan casing outside
Insulated fan casing inside
Fan inside parts with rotor
Primary- and secondary air fan
Recirculation air fan
Print date 23.09.13 14:38
Operation
Temperature
[C]
Surface
preparation
grade
Temporary Coating System

according TII 16.04 Chapter
2.5
Coating System according TII

16.04, Annex B, Table 6, for Initial
protection
40
120 180
120 180
120 - 180
Sa 2
Sa 2
St 2
-
X
Supplier Standard
System C3 - C5-I/M until 120 C

System 121-200 C
-
40
80
80
80
Sa 2
Sa 2
Sa 2
-
X
Supplier Standard

-
40
135 - 230
135 - 230
135 - 230
Sa 2
Sa 2
Sa 2
-
X
X
Supplier Standard
System C3 - C5-I/M until 120

-
Last saved 23.09.13
Page 36 of 40
Project Name: SERC

AIC:
000000
50021972 - 1.0
Document Nr-Rev:

Component/Equipment
Air preheater (LUVO)

Heat exchanger
Casing inside
Insulated Casing outside
LUVO-frame not insulated parts
Boiler
Diaphragm walls outside
Boiler drum outside
Collector
Piping
Insulated blow-down tank (pressurised)
Insulated boiler blow-down tank
(atmospheric)
Combustion section
Insulated air ducts outside
Insulated air ducts inside
Not insulated air ducts outside
Not insulated air ducts inside
Sheet metal construction (FG-Ducts, Filter
casing, catalyst casing, reactor etc.)
Insulated sheet metal construction outside
Sheet metal construction inside
Grate ash removal
Ash hoper inside
Insulated ash hopper outside
Hopper doors an dampers
Print date 23.09.13 14:38
Operation
Temperature
[C]
Surface
preparation
grade

2.5

protection
200
200
200
40
Sa 2
Sa 2
Sa 2
Supplier Standard
X
X
-
System C3 - C5-I/M until 120
260
260
260
up to 400
165
100
Sa 2
Sa 2
Supplier Standard
Supplier Standard
Supplier Standard
Supplier Standard
X
X
up to 200
up to 200
up to 80
up to 80
Sa 2
Sa 2
Sa 2
Sa 2
X
X
X

-
up to 300
up to 300
Sa 2
-
X
-
up to 200
up to 200
up to 80
Sa 2
Sa 2
Sa 2
X
X
-
Last saved 23.09.13
Page 37 of 40
Project Name: SERC

AIC:
000000
50021972 - 1.0
Document Nr-Rev:

Component/Equipment
Bottom ash chute

Bottom ash chute inside
Bottom ash chute outside (is not insulated)
Residue conveying
Residue conveying inside
Not insulated residue conveying outside
Insulated residue conveying outside
Ash conveying
Ash conveying inside
Not insulated ash conveying outside
Insulated ash conveying outside
Grate
Grate construction (grate blocks are
excluded, they are row)
Parts by the grate e.g. oil collecting tray etc.
Ram feeder
Ram feeder outside
Ram feeder inside
Feed hopper
Feed hopper inside with incl. damper
Feed hopper outside
Bottom ash extractor
Bottom ash extractor inside in exhaust
vapour area
Bottom ash extractor inside in water area
Bottom ash extractor inside outside
Print date 23.09.13 14:38
Operation
Temperature
[C]
Surface
preparation
grade

2.5

protection
up to 80
up to 80
Sa 2
Sa 2
X
-
up to 120
up to 50
up to 120
Sa 2
Sa 2
Sa 2
X if holes 500 mm
X

-
up to 120
up to 50
up to 120
Sa 2
Sa 2
Sa 2
X if holes 500 mm
X

-
200
Sa 2
80
Sa 2
80
up to 180
Sa 2
Sa 2

-
up to 80
up to 60
Sa 2
Sa 2
X
-
up to 80
Sa 2
up to 60
up to 80
Sa 2
Sa 2
X
-
Tar coating (Teeranstrich), Hempatur

System C5-I/M until 120 C
Last saved 23.09.13
Page 38 of 40
Project Name: SERC

AIC:
000000
50021972 - 1.0
Document Nr-Rev:

Component/Equipment
Piping
Hydraulic piping
Print date 23.09.13 14:38
Operation
Temperature
[C]
Surface
preparation
grade

2.5

protection
up to 80
chromatized
Last saved 23.09.13
Page 39 of 40
Project Name: SERC

AIC:
000000
Print date 23.09.13 14:38
Document Nr-Rev:
50021972 - 1.0
Last saved 23.09.13
Page 40 of 40

Corrosion Protection for SERC Project

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Project Name: SERC

Title: TII 16.04 Corrosion Protection

Hitachi Zosen Inova AG

Aims and objectives .................................................................................................. 4

HZI documents ................................................................................................................................. 5

Planning of corrosion protection .......................................................................... 7

Corrosivity according to EN ISO 12944-2: 1998 .............................................................................. 7

Selection of corrosion protection measures ............................................................ 10

Corrosion protection below insulation ..................................................................... 12

Work and environmental protection ........................................................................ 12

Execution of corrosion protection ...................................................................... 13

Preparation and cleaning of surfaces...................................................................... 13

Object preparation ......................................................................................................................... 13

Processing and application of the coating materials ............................................... 14

Determination of the coat thickness according to EN ISO 12944-5: 2008-01 ......... 15

Repair of coating of welding zones ......................................................................... 17

Repair of damaged areas on hot dipped galvanised steel components .................. 17

Print date 23.09.13 14:38

Last saved 23.09.13

Project Name: SERC

Title: TII 16.04 Corrosion Protection

Hitachi Zosen Inova AG

Improvement of damaged areas in the zinc coating up to 10 cm2 in size ..................................... 18

Monitoring, acceptance and documentation ...................................................... 19

In-house monitoring by the contractor ..................................................................... 19

Terms and definitions used ..................................................................................... 20

Milling skin / Cinder ........................................................................................................................ 20

Table 7: Selection of the coating system structures ................................................ 22

Table 9: Coating supplier 1: Sika ................................................................................................... 28

Temporary Corrosion Protection ............................................................................. 36

Print date 23.09.13 14:38

Last saved 23.09.13

Project Name: SERC

Title: TII 16.04 Corrosion Protection

Aims and objectives

Hitachi Zosen Inova AG

The purpose of this Technical Implementation Instruction (TII) is to define a uniform

Print date 23.09.13 14:38

Last saved 23.09.13

Project Name: SERC

Title: TII 16.04 Corrosion Protection

Hitachi Zosen Inova AG

Company Hitachi Zosen Inova AG

Supplier of works and plant sections who is not a sub-supplier of HZI.

Coating material supplier

HZI Technical Implementation Instruction

European standard with the status of a German standard

Working Group Industrial Facility e.V. Worksheet

Cited and further applicable standards and regulations

Regulations, Standards and Guidelines

Print date 23.09.13 14:38

Last saved 23.09.13

Project Name: SERC

Title: TII 16.04 Corrosion Protection

Hitachi Zosen Inova AG

EN ISO 12944, part 1 8

Coating materials Corrosion protection of steel components

AGI Q 151 Work Sheet

All listed standards are applicable throughout the European Union.

Print date 23.09.13 14:38

Last saved 23.09.13

Project Name: SERC