Note: This specification was written for Clarabelle Mill's flotation cells but may have other applications.

Transcription

1 017/03/3 1/7 1.0 PURPOSE This specification describes the minimum application and performance requirements for a field-applied, elastomer spray coating either polyurethane or polyurea type. Note: This specification was written for Clarabelle Mill's flotation cells but may have other applications. 1.1 WORK INCLUDES Furnishing of all labour, supervision, materials, equipment and services for the supply and installation of elastomeric coating(s) in tanks and vessels. Contractor must comply with all Vale and Plant specific procedures during the work Preparation of the substrate surface which includes: Unbolting and removal of components to shop-spray separately where possible (i.e. baffles, wing platesing, agitator stators, etc.) Modify to make difficult-to-reach areas accessible (by flanging baffles & launder sides, adding nozzles to drain piping, etc.) Ensure all corners are rounded to min. 1/8" radius, weld seams are ground smooth, crevices & sharp overlaps are avoided, and all surfaces are smooth (free of pin holes, splatter, flux, etc.).0 SUBMITTALS.1 QUOTATIONS: ENSURE THE FOLLOWING INFORMATION ACCOMPANIES THE BID (FAILURE TO COMPLY MAY RESULT IN DISQUALIFICATION OF THE BID):.1.1 Complete description of the proposed coating system (including method of surface preparation, type of primer, coating description, physical properties, touch-up procedures, and recent applications of this product).1. Complete MSDS Sheets for all system components proposed (including primers & touch-up / repair).1.3 Comprehensive list of required utilities (electrics, compressed air, overhead cranes, mobile equipment, etc.) required for Installer's surface preparation and / or coating system application equipment.1.4 Complete description of the proposed coating system (including method of surface preparation, type of primer, coating description, physical properties, touch-up procedures, and recent applications of this product)

2 017/03/3 /7.1.5 Complete MSDS Sheets for all system components proposed (including primers & touch-up / repair).1.6 Comprehensive list of required utilities (electrics, compressed air, overhead cranes, mobile equipment, etc.) required for Installer's surface preparation and / or coating system application equipment.1.7 Proposed hoarding & ventilation measures shall be described at time of bidding.1.8 Number of factory-training technicians c/w background.1.9 Name of job supervisor c/w background in elastomer coatings.1.10 Include the (optional) cost, on a per diem basis (including travel and living expenses), for the services of a (factory) Installation Superintendent to oversee all phases of preparation and application of the coating system, including the submission of a written report upon completion 3.0 QUALITY ASSURANCE 3.1 WORKMANSHIP Personnel experienced in the application of the elastomer coating proposed shall perform the work in accordance with recognised first class standards. The finished appearance shall conform to the highest industry standards of quality in all respects. Product application & workmanship shall have a two () year warranty. 3. MATERIALS 3..1 Materials selected are to provide the maximum chemical and physical protection for the service specified. The primer shall be compatible with both the substrate, and the application. The coating system must be of first class quality and its selection for the intended service must agree with the recommendation of the manufacturer 3.. Materials shall be stored and applied per the manufacturer's recommendations (i.e. shelf life) Coating system materials (including primer & re-activation coatings) shall not contain or produce excessive amounts of hazardous chemicals which are injurious to workers or the environment (including isocyanates, solvents, MEK, etc.) 3..4 Unless specified elsewhere, cured thickness shall be 10 to 180 mils for abrasive areas, and 30 to 60 mils for general corrosion protection.

3 017/03/3 3/ Unless specified elsewhere, hardness shall be 70 to 90 Shore "A" scale for abrasive areas (i.e. floatation cell bottoms), and 90 to 100 Shore "A" for load-release surfaces (i.e. flotation cell launder lips) Operating environment is typically wet and could also be acidic & abrasive, including various process reagents Physical properties of the cured elastomer coating shall be selected to suit the application. 3.3 INSTALLER'S PROCEDURES MANUAL All training, health & safety issues, surface preparation, materials storage & spill containment, mixing, spraying, coating properties measurement & disposal shall be documented in a bound manual and be made available for viewing by Vale. Installer registration to ISO 900 (minimum) is preferred. 3.4 SELECTION AND APPLICATION General Requirements Installers shall demonstrate their training in the selection & application of the two component elastomer coating system by the manufacturer of the system proposed. Proposed coating shall be part of a compatible system, including primer, elastomer coating & repair method. Obtain all coating components and equipment from suppliers who conduct business and provide technical backup service in Canada. Where this is not possible, specify the manufacturer / supplier and provide warranty information. Use only elastomer manufacturer's approved spray equipment. Airless, hydraulic spray equipment is preferred (less overspray produced). Electrostatic spraying is encouraged for complex shapes. Fire / explosion hazards shall be minimized Health and Safety Requirements MSDS information shall be submitted with the quotation for all system materials proposed. All personnel handling these materials shall be adequately trained & provided with applicable personal protective equipment (especially breathing equipment). Adequate measures to contain & ventilate the work area of fumes, vapours & overspray mist shall be provided by the Installer.

4 017/03/3 4/ Materials Storage and Spill Containment All coating system components shall be stored per the coating manufacturer's recommendations for temperature and humidity. When coating system components are stored on-site, a spill containment plan shall exist to capture all reasonable quantities of spilled material. A fire hazard shall not be created due to the on-site storage of coating system components Inspect Substrate / Vessel Construction Prior to surface preparation, inspect and assess condition and integrity of substrate, with Vale representative Surface Preparation Clean substrate as required - degrease, scrape & remove all flaking rust and any existing coatings. Surface preparation shall be "near-white" blast cleaning (SSPC - SP10) using high-pressure water blast (with grit injection and coating-compatible, rust inhibitor) or dry grit blasting. Minimize host metal removal. Installer's compressed air hosing shall incorporate adequate water removal means otherwise use an airless grit blast system. All weak or thin plate shall be reported to owner before proceeding. Preferably, surface profile shall be according to the coating manufacturer's specification. Otherwise, 5-7 mils maximum profile height shall be achieved. Silica sand shall not be used for surface preparation. Dry grit blasting may not be practical / economical indoors due to airborne particles and expense of required hoarding. Surfaces shall be vacuum-cleaned just prior to priming. Prepared surfaces shall be primed / precoated within the coating system manufacturer's recommendations (typically 4-8 hours) Primer Any spray or roller-applied primer, used as part of a coating system, shall not contain excessive thinners and / or solvents Mixing Components Coating components shall be blended per manufacturer's recommendations, in calibrated, proportional equipment and under specified conditions of temperature and pressure.

5 017/03/3 5/ Elastomer Coating Application and Curing Coatings shall be applied per manufacturer's recommendations, in thickness that allow for proper cure, preclude running and avoid "pull away" (due to shrinkage). Precoats may be applied to fill minor surface irregularities or produce a better bond to substrate. Subsequent layers shall be applied within a specified time to avoid the need for MEK activation coatings. (Urethanes may be applied in up to 40 mil thick layers) The presence of moisture on the substrate shall be considered - either as free water or ambient humidity (water contamination of some coatings can cause foaming, pinholes and / or poor bond). If airassisted spray is used, allowances shall be made for sufficiently removing moisture from the compressed air. Full cure time shall be observed before surface is exposed to process conditions. Contractor / installer shall certify when elastomer coating is cured Solvents, Activation Coatings Elastomer coatings shall be "100% solids" such that excessive thinners and/or solvents are avoided to reduce the emission of volatile organic compounds. The need for MEK activation coatings shall be minimized either between interrupted coats or as part of touch-up / repair procedure Disposal "Left over" coating system components, cleaners and job waste shall be collected, stored and either reused or properly disposed per the Installer's QA manual. Collect & remove all overspray Labelling When equipment is lined with an elastomeric coating, a note shall be stencilled on the opposite side of the equipment stating: "DO NOT WELD OR BURN - EQUIPMENT LINED WITH ELASTOMER"

6 017/03/3 6/7 3.5 TESTING THE INSTALLER SHALL CONDUCT AND DOCUMENT THE FOLLOWING TESTS IN ACCORDANCE WITH THE INSTALLER'S QA MANUAL Coating Thickness Measurement (mils) - several representative areas shall be randomly selected on the vessel and each sample shall meet the specified nominal thickness +/- 10 % 3.5. Hardness Measurement (Shore "A" scale) - several representative areas shall be randomly selected on the vessel, and each sample shall meet the manufacturer's published nominal hardness +/- 5 % Tensile Strength Measurement (ASTM D638) - an 8"x 8" size "retain sample" shall be made for each 1000 sq. ft of surface and / or each new batch of product and / or each new day of project (made on a similar substrate); a randomly selected area on each "retain sample" shall meet the manufacturer's published tensile strength +/- 10 % Adhesion / Peel Strength Measurement (ASTM D903) - an 8"x 8" size "retain sample" shall be made for each 1000 sq. ft of surface and / or each new batch of product (made on a similar substrate); a randomly selected area on each "retain sample" shall meet the manufacturer's published peel strength +/- 10% Pinhole (Spark) Test - use a low, voltage Holiday Detector (or equal) to inspect the entire coated surface; locate & document indications; repair & recheck any problem areas. 3.6 DEVIATION FROM SPECIFICATION Quotations for alternative components or equipment, in whole or in part for the coating specified, are permitted where it is considered that savings in capital or operating costs or any improvement in service may be obtained by deviating from this specification. Clearly identify alternatives in the quotation and where necessary submit a separate alternative quotation, fully covering the all items. 4.0 REFERENCE DOCUMENTATION The following documents are related to this specification and shall be used to their latest revision: Act Regulation 854 SSPC ASTM D638 ASTM D903 Occupational Health and Safety Act Regulations for Mines and Mining Plants Society for Protective Coatings Standard Test Method for Tensile Properties of Plastics Standard Test Method for Peel or Stripping Strength of Adhesive Bonds

7 017/03/3 7/7 5.0 REVISION AND TRANSITION NOTES Revision notes describe: what was changed, and if applicable, why it was changed, and the plan to implement the change, including whether changes are retroactive. Note: The revision notes are a summary of the changes and may not necessarily be a complete list. A risk code is entered for each revision and if applicable, the revision notes will describe how risk was addressed for the revision. Risk Code A Risk Category This revision is a minor change and/or introduces no risk. B C Risk has been addressed for this revision by the reviewer and approver. Low risk or no new hazards identified. For this revision, a PHR or other risk management tool has been used to address risk and minimize hazards. This risk assessment has been documented and is available through Central Engineering. Rev Revision Notes Risk Code Approved by Reviewed by Issue Date YYYY/MM/DD 1 First Issue - Re-write of Reference Standard MDF MDF 013/03/1 017 Review Format updated no other changes A A.Alaeddine M.Fogarty 017/03/3