NETWORK RAIL Specification

New Steelwork XN90/N1

PROTECTIVE SYSTEM XN90/N1-038:
Thermally Sprayed Metal/Epoxy Protective System

FOR THIS ENVIRONMENT:

Thermally Sprayed Metal/Epoxy C2, C3, C4, C5-I, C5-M

Paint System: (BS EN ISO 12944-2)
Life to First Major Maintenance: Up to 25 years

SPECIFICATION:
Surface Preparation: Blast-clean to Sa3 (BS EN ISO 8501-1). Surface profile
within the range of 70-100m.
Metal Coating: Thermally sprayed aluminium or zinc to give a
minimum dry film thickness of 100m.
Coat Material Mdft Applied
(m)
Sealer Metagard L574 Blast Primer 25 Shop
Intermediate Epigrip C402V2 Zinc 150 Shop
Phosphate Primer/Buildcoat
Finish Resistex C137V2 Special 50 Shop
Finish

PADS Reference: 028/980213

If an alternative anti-graffiti finish coat is specified, please refer to Protective System XN90/N1-073
(PADS Reference 028/980475)

Notes on this Specification:

Grit abrasives to be used unless otherwise specified.

All film thicknesses shown are minimums.

Where a stripe coat is specified apply one coat of Epigrip C402V2 at 75µm mdft by brush between coats
1 and 2.

It may be necessary to apply more than one coat of finish for certain colour shades (e.g. some pastel shades and bright
strong colours).

All materials should be obtained from Sherwin-Williams and must be applied in accordance with the relevant Technical Data
Sheet.
This Specification is specifically subject to the disclaimer which can be found at http://protectiveemea.sherwin-williams.com/Home/Disclaimer

Sherwin-Williams Protective & Marine Coatings, Tower Works, Kestor Street, Bolton, BL2 2AL, England UK
Tel: +44 (0) 1204 521771 Fax: +44 (0) 1204 382115
email: technicale@sherwin.com website: www.sherwin-williams.com/protectiveEMEA SW2 03/2013
 Repair Procedure for Damage Resulting From Transport, Erection, etc

The following guidance notes apply to remedial work of the protective system that has been damaged during
transit or erection and includes that caused by any site welding operations. The damaged area shall receive
remedial preparation and painting equivalent to the specified protective system.
In certain instances it may not be possible or practical to metal spray on site and the following procedure is
offered as an alternative. This is subject to Network Rail’s agreement. Generally, damaged paintwork should
be prepared back to a feathered edge of sound paint. This area, together with a further 50mm into the adjacent
areas of sound paintwork, should be appropriately prepared and cleaned down. All paint coats should be
applied such that the edges of the sound protective system are enveloped.

NATURE OF DAMAGE REMEDIAL TREATMENT

Damage to top coat only
Damage to top coat and
intermediate coat(s)
Damage to top coat,
intermediate coat and sealer
coat
Extensive damage to full
protective system including the
sprayed metal coating and
where any site welding has
been carried out
Lightly abrade and clean down all areas to receive paint. Carefully touch in
with one coat of Resistex C137V2 Special Finish to give a minimum dry film
thickness of 50m.
Prepare as above and carefully touch in with one coat each of Epigrip
C402V2 Zinc Phosphate Primer/Buildcoat and Resistex C137V2 Special
Finish to give minimum dry film thicknesses of 150µm and 50m
respectively.
Prepare as above and carefully touch in with one coat each of Epigrip
C402V2 Zinc Phosphate Primer/Buildcoat and Resistex C137V2 Special
Finish to give minimum dry film thicknesses of 150µm and 50m
respectively.
The full protective system should be reinstated. However, if this is not
practical and subject to the client’s agreement the following option may be
acceptable; Spot abrasive blast-clean the exposed steel area in accordance
with BS EN ISO 8501-1 to give a surface standard of Sa2½. This process
should be limited to minimise damage to sound adjacent thermally sprayed
metal. Spot prime the exposed steel with one coat of Epigrip M902
Winterfast Hi-Build Brushing Aluminium to give a minimum dry film thickness
of 100m. Touch in with one coat of Epigrip C402V2 Zinc Phosphate
Primer/Buildcoat to give a minimum dry film thickness of 150m and one
coat of Resistex C137V2 Special Finish to give a minimum dry film thickness
of 50m.

Product Information:
The following products are components of Network Rail Protective System XN90, and are relevant to
Sherwin-Williams Registration Certificate Reference XN90/N1-038. These should be used in accordance with
the appropriate Product Data Sheets and Network Rail Guidance Note NR/GN/CIV/002: The Use of Protective
Coatings and Sealants.

Item Product Volume WFT DFT Theoretical Minimum

No. Solids (microns) (microns) Coverage Overcoating
(%) (m²/ltr) Time (20°C)
7.1.2 Metagard L574 Blast Primer 29 86 25 11.6 3½ hrs
7.2.2 Epigrip C402V2 Zinc 75 200 150 5.0 5 hrs
Phosphate Primer/ Buildcoat
7.3.1 Resistex C137V2 Special 54 93 50 10.8 7 hrs
Finish
7.1.5 Epigrip M902 Winterfast Hi- 75 133 100 7.5 4½ hrs
Build Brushing Aluminium

N.B. The above table is for guidance only. Refer to the appropriate product data sheet for more
details
This Specification is specifically subject to the disclaimer which can be found at http://protectiveemea.sherwin-williams.com/Home/Disclaimer

Sherwin-Williams Protective & Marine Coatings, Tower Works, Kestor Street, Bolton, BL2 2AL, England UK
Tel: +44 (0) 1204 521771 Fax: +44 (0) 1204 382115
email: technicale@sherwin.com website: www.sherwin-williams.com/protectiveEMEA SW2 03/2013