Date: 04-April-2024

COATING NOTES
On the Base of Saudi Aramco Standard’s

Guided By: Mr. Sayed Wajid Mehmood (QC Inspector)

Prepared By: Mr. Mubashir Zaman (Coating QC Inspector)
 ABBREVIATION

ARAMCO Saudi Arabian Oil Company

SAES Saudi Armco Engineering Standards
APCS Approved Protective Coating System
SSPC System Specification for Protective Coating
SATIP Saudi Armco Typical Inspection Plan
SAIC Saudi Armco Inspection Checklist
SAEP Saudi Armco Engineering Procedure
PM Project Manager
PMT Project Management Team
PID Project Inspection Department
INCR Internal Non-Confirmative Report
NCR Non-Confirmative Report
QMS Quality Manger System
SAMSS Saudi Aramco Materials System Specifications
ASTM American Society for Testing & Materials
RFI Request for Inspection
QCP Quality Control Plan
MRI Material Receiving Inspection
MAR Material Approval Required
ITP Inspection and Testing Plan
SAES [SAUDI ARAMCO ENGINEERING STANDARD]
SAES-H-001 Coating Selection & Application for Industrial Plant and Equipments
SAES-H-002 Internal & External Coating for Pipeline and Piping
SAES-H-002-V Approved Saudi Armco Data Sheet for Pipeline and Piping
SAES-H-003 Protective Coating System for Concert Stucture
SAES-H-004 Selection Coating & Application for Off Shore
SAES-H-200 Storage, Handling and Installation of External Coated Pipes
SAES-H-101 Protective Coating System for Industrial paint and Equipments
SAES-H-101-V Approved Aramco Saudi Data Sheet for Paint & Coating System
SAES-H-102 Safety Requirements for Coating
SEAS-H-201 General Specification for over the ditch, Internal & External FBE
Coating of Field Wield Girth
SEAS-B-067 Safety Identification and Safety Colors

APCS [APPROVED PROTECTIVE COAT SYSTEM]

APCS-1A IN ORGANIC ZINC PRIMER
APCS-1B ZINC PHOSPHATE (EPOXY PRIMER)
APCS-1C ZINC RICH EPOXY PRIMER
APCS-1D POLY URETHANE TOP COAT
APCS-2E SOLVENT FREE EPOXY COATING
APCS-2G GLASS FLAKE
APCS-11C HEAR RESISTANCE COLD SPRAY ALUMINUM
APCS-17A SOLVENT BASED
APCS-17B WATER BORN
APCS-26 MASTIX EPOXY
APCS-26T POLY-URETHANE
APCS-104 A/B FUSION BOUDED EPOXY
APCS-113A HIGH BUILD EPOXY
APCS-113C VISCO ELASTIC COATING SYSTEM
APCS-3 COAL TAR
APCS-10 BITUMINIOUS
SSPC [SYSTEM SPECIFICATION OF PROCECTIVE COATING]

SSPC-SP-1 Solvent Cleaning

SSPC-SP-2 Hand Tools Cleaning

SSPC-SP-3 Power Tools Cleaning

SSPC-SP-4 Flame Cleaning

SSPC-SP-5 Sa3 [White Metal Blast Cleaning]

SSPC-SP-6 Sa2 [Commercial Blast Cleaning]

SSPC-SP-7 Brush Off Blast Cleaning

SSPC-SP-8 Pickling [Chemical Blast Cleaning]

SSPC-SP-9 Weather Followed Blast Cleaning

SSPC-SP-10 Sa2 ½ [Near White Blast Cleaning]

SSPC-SP-11 Power Tool to Bear Metal

SSPC-SP-12 Water Jetting Blast Cleaning

SSPC-SP-13 Surface Preparation for Concrete System

SSPC-SP-14 Industrial Blast Cleaning

SSPC-VS-1 Abrasive Blast Cleaning

SSPC-VS-2 Evaluating Degree of Rust of Paint

SSPC-PA-2 Dry Film Thickness [DFT]

SSPC-PA-5 WET FILM THICKNEES [WFT]

SATIP [SAUDI ARAMCO TYPICAL INSPECTION PLANE]

SATIP-H-002-01 Cement Lining of Pipes & Fittings

SATIP-H-002-02 External FBE Coating & Repairs of Field Welded Joints

SATIP-H-002-06 Renovation & Repair Coating for Submerged Service

Liquid Coatings APCS 113 A, APCS113B, APCS 113E & APCS 113F

SATIP-H-002-08 Internal FBE Coating of Field Girth Welds & Repairs

SATIP-H-002-11 Renovation & Repair Coating for Submerged Services (APCS-113C)

SATIP-H- 003- 01 Paint Application on Concrete Surfaces

SATIP-H-100-01 Paint Application of Liquid Coating Systems (Industrial Facilities)

SAIC [Saudi Aramco Inspection Checklist]

SAIC-H-1002 Concrete Coatings and Repair Materials Receiving, Storage & Preservation
Inspection

SAIC-H-1003 Concrete Coatings Pre-Installation Inspection

SAIC-H-1004 Coating and Final Inspection

SAIC-H-2001 Review Procedure: Cement- Mortar protective lining for steel water pipe

SAIC-H-2002 Receiving Inspection of Raw Materials for Cement Lining

SAIC-H-2004 Verification of Cement Lining Equipment

SAIC-H-2005 Pre-Application Inspection of Cement Lining

SAIC-H-2006 In-Process Inspection of Cement Lining

SAIC-H-2007 Final Inspection & Acceptance of Cement Lining [Includes repairs]

SAIC-H-2009 Review Procedure - Field Applied External FBE Coating and Repair Procedure

SAIC-H-2010 Review of Contractor Qualifications - Coating Personnel Certification

(In-Kingdom Field Application Only)

SAIC-H-2011 Receiving Inspection of FBE Powder & Abrasive Materials and its Storage

SAIC-H-2013 Inspection & Verification of FBE Powder Application Equipment

SAIC-H-2014 Surface Preparation for Application of External Epoxy Coating on Pipeline

SAIC-H-2015 In-Process Inspection of FBE coating Application on External Field Girth Welds
[Includes Repair / Patch-up coating]

SAIC-H-2016 Holiday Testing of External Coatings on Pipelines

SAIC-H-2018 Final Inspection of External FBE Coated Field Girth Welds before Backfill

SAIC-H-2023 Review Procedure for Liquid Coatings on Industrial Services & Pipelines-Buried
Services (APCS-113A, 113 B, 113E & 113F)

SAIC-H-2024 Receiving Inspection of Paint & Abrasive Materials

SAIC-H-2025 Storage, Handling and Preservation of Paint and Abrasive Materials

SAIC-H-2026 Coating Equipment Inspection

SAIC-H-2027 Surface Preparation for Liquid Coating Systems

SAIC-H-2028 In-Process Inspection of Primer or First Coat (Liquid Coating System)

SAIC-H-2029 Inspection of Primer Coat (Prior to Top Coating)

SAIC-H-2030 In-Process Inspection - Intermediate or Top Coat Application

SAIC-H-2031 Inspection of Top Coat(s) of Liquid Coating System

SAIC-H-2032 Repair and/or Touch-up of Coatings

SAIC-H-2033 Application of Safety Color Coding & Stenciling of Equipment/Piping

Identification

SAIC-H-2034 Final Inspection of Coating for Mechanical Completion

SAIC-H-2048 Surface Preparation for Application of APCS-113 liquid Coating Systems on

Pipeline

SAIC-H-2049 In-Process Inspection of APCS-113 Coating Systems Application

SAIC-H-2050 Visual Inspection of APCS-113 Coating Systems Application

SAIC-H-2051 Final Inspection before Backfill - APCS 113 Coated Pipe

SAIC-H-2057 Review Procedure - Field Applied Internal Coatings & Repairs

SAIC-H-2058 Receiving Inspection of Internal Coating Materials for Over-the-Ditch Field Girth
Welds

SAIC-H-2059 Surface Preparation of Pipe Joints for Field Internal Coating

SAIC-H-2060 In-Process & Final Inspection of Internal coating Application on Field Girth
Welds

SAIC-H-2080 Review Procedure - External Protective Coating System for Repair &
Renovation of Buried Pipelines (APCS 113C)

SAIC-H-2081 Verification & Storage of APCS - 113C Materials

SAIC-H-2082 Surface Preparation, Application and Acceptance of APCS-113C Coating System

(Including Repairs)
RESPONSIBILTIES:
Following are the responsibilities of a Crew Supervisor i.e.

1. First, we have to check the work permit,

• Then we have to check the Equipment’s, their calibration, and Certification.
• After that I have to check the JCC (Job Certification Cards) of Crew Members (i.e. Painter, Blaster,
Applicator, Foreman) etc.
• Now check the weather condition (i.e. RH, Td, Ts, Ta)
• After verifying weather condition, we have to conduct the Blotter Test.
2. Now Check the Surface Profile after blasting the Substrate
• If our Surface Profile is according to our data sheet, then conduct Salt and Contamination test (i.e.
Bresle Simple Patch Test, Dust Test, Moisture Test …)
• After that we have to mix the paint [Pneumatics] as per as data sheet.
• Now conduct paint application as per as data sheet. [Time limit 4hr after blasting]
• Also check WFT for each coat as per as data sheet
• After coating system, we have to check DFT and the coating defects such as Sagging,
Chalking,Cissing, Blistering, Bittiness, Flaking etc and have to repair it as per as data sheet
• We also maintain good storage area and material receiving inspection.
• We have to maintain the daily progress report.
• Also we have to note the Punch list items
• We also have to conduct periodical safety meetings, Also Maintain the safety discipline
• On daily base check inspection of working area.
• Also arising RFI’s
1. EQUIPMENTS, THERE CALIBRATION, AND CERTIFICATION:
All the equipment’s will be inspected by third party and all the gauges must be calibrated. Also, the
calibration sticker must be on it. Also, we must have the Calibration certificates.
For certification check we Compare the Serial code of certificates with equipment’s stamped sticker
and also check the expiry of certificates. If any then we will request for their calibration again.

2. WEATHER CONDITION:
We have four types of weather temperature

1. Relative Humidity: RH
The amount of water vapor present in the air expressed as a percentage of air at same
temperature called Relative Humidity

2. Dew point Temperature: Td

The temperature at which the water vapor in the air condensed called Dew Point

3. Ambient Temperature: Ta
The Temperature of Air called Ambient Temperature
The air temperature (ambient) is the temperature recorded from the dry bulb thermometer

4. Steel Temperature: Ts
The Temperature of Substrate called Steel Temperature

ABRASIVE BLASTING CAN BE CARRIED OUT ONLY WHEN

1. The Relative Humidity is below 85 %
2. The Dew Point be 3 degree less then steel temperature
3. The Steel Temperature will be less than 50 degress
4. It rains, snow, or if high winds blows then we cannot do any activity.

3. BLOTTER TEST METHOD:

This method is to check the compressed air supply shall be free of oil, moisture and contamination

Procedure:

Start the air compressor for five minutes. Attach a piece of blotter paper to a clip board, then allow
the air at a pressure of 50 psi for one minute at a distance 45 – 60 cm between the nozzle and
blotter paper. Satisfactory results shall be no water or oil contamination on the blotter.

Note: SESE-H-001 is refer for blotter test

4. SURFACE PREPARATION METHODS:
The cleanliness and roughness of a substrate called Surface
preparation.The surface profile will as per as data sheet

Other name: Surface profile, anchor pattern, key, peak to trough height is name of blasted surface

Methods of surface preparation

1. Solvent cleaning 2. Flame cleaning
3. Mechanical cleaning 4.Abrasive blasting

PROCEDURE FOR DIAL MICROMETER WITH REPLICA TAPE:

➢ Zero the dial micrometer. Clean the anvils (paper or fingers) and allow the contacts to come
together, release the locking screws and adjust the bezel so that the zero is immediately
behind the large needle
➢ Remove the backing paper from the replica tape and ensure that the small white disc with
the black ring is detached also. Stick the replica tape to the area to be measured
➢ Using a pen or pencil end, or the specially provided plastic stick, rub firmly and evenly all
over the area of the Mylar. This causes the testex paste to pass into the troughs and the
peaks of the blast will butt up to the transparent Mylar
➢ Remove the replica tape and check. The Mylar area should no longer be white (now grey),
and pinpricks of light should be visible through the Mylar when held up to the light.
➢ Place the testex paste area between the anvils of the micrometer and allow them too gently
close together. From the final reading on the gauge deduct 50um as a Mylar size.
➢ Also we have two grades
Coarser Grade: 20 – 64 um

X-Coarser Grade: 38 – 115 um

SURFACE COMPARATOR
➢ We use surface comparator for asses the roughness of blast cleaned steel
6. BLASTING EQUIPMENTS/ ABRASIVE BLASTING:
• Air Compressor
• After Cooler
• Air Receiver Tank
• Air Filter Other accessories CO Monitor (Carbon Mono Oxide),
• Abrasive Pot Other accessories: Hoses & Twin line Hose, Dead Man
Handle
Blasting Hoods
• Air less Spray Machine Other Accessories Sucking Rod, Hoses, Tip, Tip Hood, Nozzle
Spray Gun
• Sand Paper, Grinder, Brushes 125mm, Roller, Hygrometer, DFT Gauge, WFT Gauge, Replica
Tape,, Needle Gauge, Salt Contamination Test Meter, Holiday Test Detector.

AIR COMPRESSOR
A machine that takes ambient air from surrounding and discharge it at a higher pressure

AFTER COOLER [De-Humidifier]

It is used for cool and compresses the hot air, receiving from the Air Compressor Machine.
Also remove moister from air.

AIR RECEIVER TANK

It is also called surge tank. It is located in between the Air Compressor and the blasting pot shall be
manufactured and stamped in accordance with international laws, (ASME section VIII) Hydrotested
at a pressure of 250 psi.

AIR FILTER
Air Filter is used to clean the cool air, receiving from the Air Receiving Tank

AIR LESS SPRAY MACHINE

Air less spray machine is used for paint application. In Aramco the minimum ratio of Air less spray
machine is 45:1

ABRASIVE POT
This is the blasting equipment, we put abrasive in this pot for blasting activity.
5. SALT CONTAMINATION TEST ON BLASTED SURFACE FOR DETERMINED
PRESENCE OF SALTS SULPHATES OR CHLORIDES

BRESLE SAMPLE PATCH [ Quantitive Test ]

This test gives 95% accurate report. A rubber diaphragm is stuck onto the surface and distilled water
injected and extracted several times to produce a solution of any salts present. Then we drop the solution
in Salt Contamination Meter and note the reading. If the amount of salts present is greater 40 mg/m² 0r
50 ppm (parts per million) then the area should be washed down with clean water, then reblasted and
retested.
SALT CONTAMINATION METERS

Salt contamination meters measure the resistivity or conductivity of a given sample and convert this value
into a concentration (mg/m²).

TEST TO DETECT THE PRESENCE OF DUST ON A SUBSTRATE

A piece of adhesive tape is stuck onto the surface and snatched off, the dust/finings sticks to the tape. By
then sticking the tape onto white paper the dust can easily be seen

TEST TO DETECT THE PRESENCE OF MOISTURE ON A SUBSTRATE

A very simple test for the presence of moisture is to sprinkle with talc or powdered chalk and then lightly
blow away. The powder will stick to areas where moisture is.

TEST TO DETECT THE PRESENCE OF OIL OR GREASE

Other than ultra violet light, oil and grease can be detected by dropping solvent onto the suspect area and
absorbing the solution on Whatman or blotting paper. The solvent will evaporate and oil or grease will give
a darker appearance.

6. ABRASIVES
None metallic (Mineral)

Copper Slag, Nickel Slag, Boiler Slag, Glass Bead, Aquamarine (Olivine), Garnet Metallic (Recyclable)

Metallic (Non-Mineral)
ACI (Angular Chilled Iron), Steel Grit, Steel Shot, Grit and Shot Mix, Garnet

Garnet:
• Mostly we use garnet abrasives, It size is about 30-60 mesh
• Use in blasting pot for cleaning surface and roughness of steel
• In Garnet Calcium Carbonate is present 1.0% by volume
• Mesh is the unit of BS 410 (SIEVES TEST)
7. HOLIDAY TEST MACHINE
The discontinuity of coating called Holiday.
• For coatings of thicknesses above 500 um we use a HIGH VOLTAGE HOLIDAY DETECTOR
• For coatings of less than 500 um it is normal to use a WET SPONGE PINHOLE DETECTOR.
TEST FOR HOLIDAY:

• First check the Holiday Machine calibration.

• Then set the voltage with voltmeter (JEEP METER / G-Meter) as per as data sheet as per coating
specification.
• For Earthing use AWG 4 wire and an earthing rod, attach one end of AWG 4 wire with rod (fix the
rod in the ground) & other end is connected to Holiday machine.
• Now for field test we make a holiday (about 1.6mm which will be repair later on) for testing
purpose.
• Fix the electrode having no gap with surface,
• The maximum speed of electrode during test will be 300mm/s
• Mark all holiday if founded during test
• Now repair the holiday
• After repairing again conduct the holiday test until there will be no holiday detected

REPAIR METHOD:

• Apply sand paper on marked holiday defect.

• Past the Masking Tape in square shaped.
• Then apply paint.
• After application of paint, we will remove the masking tape and again conduct the Holiday Test,
until there will be no holiday detected

Holiday checking voltage as per coating:

• APCS-104 A/B [FBE Coating] 1500 – 2000 volt 1.5 - 2.0 KV

• APCS-113A [High Build Epoxy] 2400 ± 50 volt 2.4 KV
• APCS-113C [Zinc Rich Epoxy] 10,000 – 15,000 volt 10 – 15 KV

Note: 1. if found more than 5 holidays per 12 meter long pipe for FBE. Than the cause of damage shall
be determined and contacted to the Contractor.
2. More than 3 holidays on any girth weld [FBE Coating], the coating shall be completely blasted
off and the area is to be recoated.
3. For calibration of holiday detector we use JEEP meter or VOLT meter, Holiday detector
positive terminal we attach with volt meter positive and negative terminal with the negative
the of voltmeter. If the results are same on the both devices it means it is calibrated.
4. The calibration of holiday detector need 2 times in 8 hours.
5. Holiday test will conduct only when surface temperature is less the 80 C°
8. COATING FAULTS
Bittiness:
The presence of particles of gel, foreign matter (like Tin) in a coating material, or projecting from
the surface of a film called Bittiness

Blistering:
The formation of dome shaped projections or blisters in the dry film of a coating material. Blisters
may contain liquid, vapor, gas or crystals

Bloom:
A deposit resembling the bloom on a grape that sometimes forms on the floss film of a coating
Causing loss of gloss and dulling of color.

Chalking:
The formation of a powdery layer on the surface of a coating material called Chalking.
and caused due to the degradation of the binder.

Cracking :
Generally, the splitting of a dry film coating material usually as a result of ageing called
CrackingIt is due to the material age i.e. Binder Age

Hair cracking:
Cracking that comprises of fine cracks, which may not penetrate (not cleared) the top coat, they
occur erratically (Not in one pattern) and at random.

Mud cracking:
A network of deep cracks that form as the film of a coating material dries, especially when it has
been applied to an absorbent substrate. Mud cracking is associated primarily with highly
pigmented water borne paints.

Dry spray:
The production of a rough or slightly bitty film from sprayed coating materials where the particles
are insufficiently fluid to flow together to form a uniform coat

Flaking: Lifting of the coating materials from the substrate in the form of flakes or scales

Holidays:
A defect due to faulty (poor) application techniques seen as areas where the film of a coating
material of insufficient thickness or where there is a complete absence of coating materials on
random areas of the substrate.

Pin holing:
The formation of minute holes in the wet film of a coating material that forms during application
and drying, due to air or gas bubbles in the wet film which burst.

Curtaining/sagging:
A downward movement of a coat between coating that results an uneven area of coat having a
thick lower edge. It occurs due to over application of Paint or large quality of Thinner
9. Abrasive Blasting Grades /SURFACE PREPARATION METHODS

Sa 1: (LIGHT BLAST CLEANING)

When viewed without magnification, the surface shall be free from visible oil grease, dirt
and poorly adhering mill scale, rust, paint coatings and foreign matter

Sa 2: (THOROUGH BLAST CLEANING)

When viewed without magnification, the surface shall be free from visible oil grease, dirt
and most of the mill scale, rust, paint coatings and foreign matter. Any residual
contamination shall be firmly adhering

Sa 2 ½: (VERY THOROUGH BLAST CLEANING)

When viewed without magnification, the surface shall be free from visible oil grease, dirt
and from mill scale, rust, paint coatings and foreign matter. Any remaining traces of
contamination shall show only as slight stains in the form of spots or stripes.

Sa 3: (BLAST CLEANING TO VISUALLY CLEAN STEEL)

When viewed without magnification the surface shall be free from visible oil grease, dirt,
and shall be free from mill scale, rust, paint coatings and foreign matter. It shall have a
uniform metallic color.

10. RUST GRADES / DEGREE OF CLEANLINESS

Rust Grade A Steel surface largely covered with adherent millscale with little if any rust.

Rust Grade B Steel surface, which has begun to rust and from which the millscale has begun to
flake.

Rust Grade C Steel surface on which the millscale has rusted away or from which it can be

Scraped, but with slight pitting visible under normal vision.

Rust Grade D Steel surface on which the millscale has rusted away and on which general pitting is
visible under normal vision.
 APPROVED PROTECTING COATING SYSTEM (APCS)
Above Ground Coating System

1. APCS - 1A ( IN-ORGANIC ZINC) (Pipeline & Piping)

Total Coat System: Three coats

Primer Coat (In Organic Zinc) 65 -100um
Mid Coat (Mastic Epoxy) 105 -150um
Top Coat (Mastic Epoxy) 105 -150um
Cleanliness Level: Sa2 ½ (SSPC-SP10)
Surface Profile: 40-65 micrometers, minimum-maximum
Total DFT: 275-400 micrometers
Application of APCS-1A:

• First, we have to check the weather condition [ i.e. RH, Td, Ts, Ta]

• Then we check all the instruments their calibration and certification

• After blasting we have to check the surface profile as per as data sheet

• Also conduct test for salts and contamination like Bresle Sample patch test,

Moisture Test, Dust test, Oil and Grease Test etc.

• After that we have to mix the paint as per as data sheet

• Then apply Paint application as per as data sheet

• Check WFT for each coat as per as data sheet

• Also check the coating defaults if any repair it

• Finally after curing we have to check the DFT as per data sheet

Repair:

Top Coat of APCS 1A

Curing Check Method:

For curing can be checked by Methyl Ethyl Keaston’s (MEK), We take a cotton pad and
wet in the solution and hold it on the substrate for 1 mint and rub it for 30 seconds. If
the color is removing then paint is not cured.
2. APCS – 1B ( ZINC PHOSPHATE) (Steel Structure & Piping)

Total Coat System: Three Coats

Primer Coat (Zinc Primer) [55-100 um]
2 Coat of (Mastic Epoxy) [110-150 um]
Cleanliness Level: Sa2 ½

Surface Profile: 40 - 65 microns

DFT: 275 - 400 microns

Application of APCS-1B:

• First, we have to check the weather condition [ i.e. RH, Td, Ts, Ta]
• Then we check all the apparatus their calibration and certification
• After blasting we have to check the surface profile as per as data sheet
• Also conduct test for salts and contamination like Bresle Sample patch test,
Moisture Test, Dust test, Oil and Grease Test etc
• After that we have to mix the paint as per as data sheet
• Then apply Paint application as per as data sheet
• Check WFT for each coat as per as data sheet
• Also check the coating defaults if any repair it
• Finally, after curing we have to check the DFT as per data sheet

Concrete Coating Procedure:

• First we take the release
• Then we conduct the moisture test
• After that we will grind the concert substrate for roughness, feathering and
removing contamination from the substrate.
• Also perform the filler process by Epoxy Filler and Grout Epoxy as required
• The we conduct sanding
• After sanding we apply the sealer
• Now we will perform Paint application of two coat of Mastic Epoxy (APCS 26)

Repair: APCS – 1B
3. APCS – 1C ( ZINC RICH EPOXY)

Total Coat System: Three Coat System

Primer Coat (Zinc Rich Epoxy) 40-75um
Mid Coat (Mastic Epoxy) 105-150um
Top Coat (Mastic Epoxy) 105-150um

Cleanliness Level: Sa2 ½ (SSPC-SP10)

Surface Profile: 25 - 40 microns
DFT: 250 – 375 micron
Repair: APCS – 1C

4. APCS – 26 (MASTIC EPOXY)

Total Coat System: Two Coats self prime

Primer Coat (Mastic Epoxy) 150 – 200um
Top Coat (Mastic Epoxy) 150 – 200um
Cleanliness Level: Sa2 ½ (SSPC-SP10)
Surface Profile: 40-65 microns
DFT: 300 - 400 microns
Repair: APCS – 26

Note: We used APCS 26 & 26T for Aluminum/galvanized

5. APCS – 26 T (POLY-URETHANE)
APCS-26T are applied when we required gloss, retention, and abrasion resistance

Total Coat System: Two Coat System

Primer Coat (Mastic Epoxy) 300 - 400um
Top Coat (Poly-Urethane) 40 - 60 um
Cleanliness Level: Sa2 ½ (SSPC-SP10)
Surface Profile: 40 - 65 microns
DFT: 340 - 460 microns
Repair: APCS – 26T
6. APCS – 1D (Poly Urethane Top Coat)

Total Coat System: Three Coats

Primer Coat (In Organic Zinc) 65 - 100 um
Mid Coat (Mastic Epoxy) 100 - 150 um
Top Coat (Poly-Urethane) 25 - 65 um

Cleanliness Level: Sa2 ½ (SSPC-SP10)

Surface Profile: 40-65 microns

DFT: 190 - 315 microns

Application of APCS-1D:

• First we have to check the weather condition [ i.e. RH, Td, Ts, Ta]

• Then we check all the apparatus there calibration and certification

• After blasting we have to check the surface profile as per as data sheet

• Also conduct test for salts and contamination like Bresle Sample patch test,

Moisture Test, Dust test , Oil and Grease Test etc

• After that we have to mix the paint as per as data sheet

• Then apply Paint application as per as data sheet

• Check WFT for each coat as per as data sheet

• Also check the coating defaults if any repair it

• Finally after curing we have to check the DFT as per data sheet

Repair: APCS – 1D
 Under Ground Coating System

1. APCS – 104 A/B FBE ( FUSION BOUNDED EPOXY )

It is a Powder coating System; it can be done only at shop, at site we can apply only on joints.

Coat System: Powder Coats

Cleanliness Level: Sa2 ½ SSPC-SP10)

Surface Profile: 5200 Microns

Holiday Voltage: 1500 - 2000 Volts

Procedure:

• First we have to check the weather condition [ i.e. RH, Td, Ts, Ta]
• Then we check all the apparatus there calibration and certification
• After blasting we have to check the surface profile as per as data sheet
• Now we have to fit an electrical coil on joint
• This Electric Coil heat up the joint
• Now fit another electrical coil , which spray the powder paint
• Its temperature is as per as data sheet , Generally its temperature is 350 – 400 degree
• The powder spry coil machine rotate clockwise and anti clockwise
• We set the number of rotation according for DFT purpose
• It consist of three curing time (Jelly Time, Drying Time, Curing Time)
• Its Surface Profile is about 5200 Microns
• At last we have conduct the Holiday Test for pinholes it founded, repair it
• After repair Again conduct the Holiday test

Repair: 1. for areas greater than 0.2 m² Use APCS – 113A [High Build Epoxy]
2. for areas less than 0.2 m² Use Stopaq Epoxy
3. For External FBE Coating containing more than 3 holidays shall be
Blasted off and recoated.
4. The curing time of APCS-104 A/B is about 1 minute
2. APCS – 113 A (HIGH BUILD EPOXY )

Coat System: Liquid Epoxy Coating

Application: Wet on Wet

Cleanliness Level: Sa2 ½ (SSPC-SP10)

DFT: 600 - 1000 Micron

Holiday Voltage: 2400 ± 50 volts DC

Procedure:

• First we have to check the weather condition [ i.e. RH, Td, Ts, Ta]

• Then we check all the apparatus there calibration and certifications

• After blasting we have to check the surface profile as per as data sheet

• Now apply the paint application i.e. wet on wet

• At last we have conduct the Holiday Test for Holiday it founded, repair it

• After repair Again conduct the Holiday test until there will be no holiday detected

Repair: APCS – 113 A ,

APCS – 113 C if approved
 3. APCS – 113 C (VISCO ELASTIC COATING SYSTEM )

Coat System: Coating with Backing Tape

Application: Wrapping (Inner / Outer)
DFT: 600 – 1000 Micron
Holiday Voltage: 10,000 - 15,000 volts DC

Condition:
• 1 The steel pipe temperature should not exceed 70ºC during the application.
• 2 The steel pipe should not be wet or moist during the application. If it is wet, the pipe should be dried with a dry
rag.
• Allow proper accessibility to the pipeline from all directions for free movement of labor during the application.
• In "Subkha" areas, the bell hole should be drained properly and continuously for a dry working condition during
the application..
• the wrapping-band over the Inner immediately

Inner Application Method

• The Wrapping-band shall be applied onto the steel pipe without tension.
• Start the first wraparound of one complete circumferential wrapping around the pipe at 2o’Clock is made before
starting the next wrapping.
• The second wraps should be performed from 10 o’clock with a minimum overlap of 25-30mm
• The Third wrap is same first wrap with a minimum overlap of 100mm
• When a roll of the wrapping-band is finished, the next roll should be used starting at a distance of at least 100
mm before the end of the finished roll.
• After the pipe is completely wrapped, another circumferential wrap is done at the pipe end. This acts as a "seal"
to ensure that the end of the wrapping-band will not be removed.
• Any areas of blisters of the wrapping-band shall be pressed or "massaged" by hand to improve the wrapping.

Outer Application Method

• The outer wrap over the wrapping-band shall be applied with tension.
• The wrapping of the outer wrap shall start 5 mm from the start of the wrapping of the inner wrapping to remain
exposed.
• The first wrap is done on inner as double at same position without advancing the roll.
• Subsequent wraps with 50% longitudinal overlap should be maintained regardless of the width of the roll.
• If a roll of outer wrap is finished, the succeeding roll should be at least 25 cm before the end of the finished outer
wrap roll.
• When the entire length of Visco-elastic coated pipe has been over-wrapped with an outer wrap, a final wrapping
similar to the first wrap i.e. double at same position without advancing the roll.
• Any areas showing blisters entrapped air should be removed with by using roller. The rolling action should be
done longitudinally along the pipe, starting from the blister toward the edge of the outer wrap.
• Backfilling can be performed immediately after the applied coating system has been checked, inspected, and
approved by the inspector

Repair Procedure
• Patch repair is done when the coating is removed for “window” inspection or if it is damaged by heavy earth
moving equipment. The patch repair procedure shall be as follows:
• Cut out the damaged area using a sharp blade cutter. Chamfer the surrounding coating.
• Use new patch of wrapping band to cover the area where the coating is removed. Do not overlap the patch on the
sound coating. Use several strips of the wrapping and if necessary to b applied next to each another (minimum 10
mm overlap with one another).
• Install the outer wrap over the Wrapping band patch on the whole pipe circumference.
• Several wraparounds over the new patch of wrapping band until it is completely covered, and the outer wrap is
at least 100 mm away from the edges of the Wrapping-band.

Note: Self overlap will be 100mm, Adjusting overlap will be 25-30mm and Existing overlap will be 100mm
 4. APCS-3 (COAL TAR EPOXY)

Coat System: Multi Component Epoxy Coating

Part - A Base
Part - B Curing
Thinner Thinner For Viscosity
Steel Surface Preparation:
Coat System: Two Coat System
Surface Profile: 65 - 100 Microns
DFT: 400 – 600 Micron (Per Coat DFT 300 Micron)

Concrete Surface Preparation:

Coat System: Three Coat System
DFT: 720 – 900 Micron (Per Coat DFT 300 Micron)
Defects: Crocodile and Cracking (due to sunlight)
Repair: a. Repair procedure is same as other defects,
b. Apply Finish coat and back fills as soon as possible
Note:
1. APCS-3 is used for Buried Concrete & Buried Steel
2. APCS-3 is not suitable for direct Sun Light
3. APCS-3 is suitable for Hydro-Carbons present in soil, while APCS-10 is not
Suitable for Hydro-Carbons presence in soil

__________________________________________________________________________________________________________________

5. APCS-10 (BITUMINOUS)

Coat System: Single Component Epoxy Coating

Consist of Base Only, Having no Curing agent.
Also No need of thinner to mix (a Minute amount)

Concrete Surface Preparation:

Coat System: Two Coat System
DFT for Buried: 750 Micron (Minimum)
DFT for Immersion: 1150 Micron (Minimum)
Defects: Bubbles are commonly occurred

Note:
• Not suitable for direct sunlight & Hydro-Carbon Solvents.
• From Geo-Technical report we will know about the presence of Hydro-Carbons in soil or not,
the Test is conducted by third party by taking the sample of Soil & Tested]
• Not recommended for shop application
• To control the defect, apply application at morning or Evening time not as direct sun light
• We can apply brush or roller after setting down the bubbles for repair
 DEFINITIONS

CORROSION The degradation of metal by chemical or electro chemical change called

corrosion
Paint The material which changes the substrate color and gives some
protection to underlying surface

Coating Coating is used for protection the substrate from corrosion also give color

POT LIFE The period of paint after mixing in which the paint should be use

SHELF LIFE The period of time that coating can be used from the date of manufacture

Induction Period The period of paint after mixing in which the paint should be stand before
used, when the component chemically co-react

Primer Coat Anti-corrosive to protect the steel

Intermediate / Mid Coat Protects underlying coating builds thickness and provides good adhesion

Top / Finish Coat It gives the uniform glossy colors.

Thixotropic Coating A type of coating that thickness or gels in short time but it becomes more
fluid when stirred.

Visco Elastic Coating None cured coating with Visco Elastic properties that can be applied in
the form of wrapping on the pipe body

Tie Coating A tie coat is used to tie incompatible paint system together, example is
maintenance coating.

Approved Coating A coating material that meets the requirements of that applicable APCS or
SAMSS, and approved by Coating team

Quality System An Organizational structure, Procedures, Applications, and resources

which are implemented by quality management.

Hold Point The inspection of level that client inspection is must through RFI & we
cannot precede our activity until the inspection is done by the client (PID)

Witness Point Witness point is the inspection of level in which we can continue our
activity without client inspection as per RFI timing

Surveillance Point An inspection point where the Inspection Department Representative/

QCI conducts routine visit/inspection without a Request for Inspection
(RFI)

Review Point A review point is an inspection point by which quality documents are
required to be submitted for review and information of Saudi Aramco.
INSPECTION LEVEL Inspection requirements or Levels for the materials & Equipment’s
There are 5 Inspection Levels in SAEP-1151. [I.e. level 0, 1, 2, 3 and 4]

Level - 0 Only Documentation Required, No Inspection needed

Level - 1 Final Inspection required prior to Shipping

Level - 2 PIM (Pre-Inspection Meeting), one or more unspecified in-progress visits

for Surveillance, Hold, and witness point, and final inspection and release
for shipment

Level - 3 PIM (Pre-Inspection Meeting), one or more unspecified in-progress visits

for Surveillance, Hold, and witness point, and final inspection and release
for shipment
Inspections shall be on a regular basis (daily, weekly or bi-weekly)
Level – 4 Resident inspectors continually monitoring the work

NCR NCR is the non-conformance report a QC have right to arise the NCR if
construction is not follow the procedure
RFI RFI is request for inspection and it is communication document between
client to contractor we arise the RFI when the activity is ready for
inspection and we rise before 24 hours.
SCHEDULE Q Minimum Quality requirements from client to contractor is called the
schedule Q
ADHESION TEST Cross cut we used for adhesion if we have thick coating and if we have
thin coating we used Dolly test but we do it as per approved procedure
from client. (13mm we cross 2 cut in X form and in intersection we try to
peel off if it peel off or cube form it will be rejected. And if it could not
peel off then it will be passed.
CHECK CURING TEST For curing can be checked by Methyl, Ethyl, Keaston’s (MEK), we take a
cotton pad and wet it with the solution and hold it on the substrate for 1
mint and rub it for 30 seconds. If the color is removing then paint is not
cured.
COATING DEFAULTS