Method Statement for Protective Coating

Work Methodology

References

1. Project Quality Plan (PQP)
2. Project Executive Plan (PEP)
3. Integrated Management System Manual (IMS)
4. Environmental Management Plan ((EMP)
5. Safety & Health Management Plan
6. Emergency& Response Plan (ERP)
7. Traffic Management Plan (TMP)
8. Survey Quality Plan (SQP)
9. Contract Specification
10. Approved Construction Drawing
11. Approved Shop Drawing
12. Other Related Method Statement

Materials

1. Estotect MMA PRIMER
2. Estotect MMA
3. Estopatch SRF
4. Estopatch Fine
5. Estobond Acryl

Plant and Equipment

1. Gloves
2. Goggles
3. Face Mask
4. Short Haired Roller
5. Adhesive Tape
6. Spreading trowel
7. Mixer
8. Sky Lift

Manpower

1. Site Supervisor
2. Operator
3. Painter

Construction Procedure

Surface Inspection

1. Segments would have to be inspected and approved by Consultant for application of protective coating (for any surfa imperfections). The substrate (new or existing) should be clean, sound and free from contamination such as mortar, loose particles, dust, paint splashes, oil and grease. Oil and grease contamination must be completely removed by grinding down to sound, clean concrete. Alternatively, captive/grit-blasting technique can be used to provide the required substrate.
2. Clean the substrate surface using broom/brush to remove dust debris. For stubborn dust stains, wipe the surface using clean damped cloth or sponge and use adequate water for such hard to clean surface if needed. (DO NOT use high pressure water jet to clean the surface as it may remove or increase the size of blowholes/pitted areas that has been patch repaired earlier).
3. Where these methods are considered impracticable, alternative methods may be considered but a clean, sound and dry substrate must still result. In particular it is essential that the substrate does not suffer from conditions of rising damp. Estop must approve any alternative preparations prior to commencement of work, as Estop will not accept responsibility under any other condition.

Application of Estopatch Fine

1. Repair should use a cement based material. The product most suitable for the repair of voids and holes shall be Estopatch Fine for equivalent cement based material. Blow holes and areas of pitting shall be patched and make good using Estopatch Fine mix with Estobond Acryl. This material use to concrete substrate before primer coating and MMA coating.
2. The Estopatch fine should be suitable for thin layer patching up to the thickness of 3mm, fine enough to fill blow holes, and able to bond well to the concrete substrate.
3. For powdery surface and loose particle, clean the substrate surface with running water (DO NOT use high pressure water jet onto the substrate surface as it may remove the blow holes/pitting areas that has been patched earlier).
4. For hard to reach areas, wipe surface to be repaired using a clean damped cloth.
5. Apply the Estopatch Fine mortar onto the prepared areas.
6. The diluted Estobond Acryl shall be added to Estopatch Fine at water powder ratio 0.18-0.22. Using handheld electric mixer (600 rpm) stir the products for at least 3 minutes until a homogeneous mortar paste is formed.
7. For dust stains, wipe surface with a clean damped cloth or sponge. Dilute Estobond Acryl with water at 1:10 ratio.
   

Application of Primary Coating

1. Prepared substrates should be primed using Estotect MMA Primer at 2 coats. Apply Estotect MMA Primer at the rate of 10-12 mm² per liter for total 2 coats with allowance of time to dry in between coating around 15-30 minutes (the time of drying shall varies with the weather). Apply the primary coating using a short hair roller/spray machine.

Application of Estotect MMA – 1 st Top Coat

1. After opening of the Estotect MMA tin, pre-mix the material with slow speed mechanical stirrer (400-600 rpm) for at least 1 minute or until the required consistency.
2. After application of Estotect MMA Primer, apply the first coat of Estotect MMA using a short hair roller/spray machine. Ensure all primed areas are fully blinded. Allow the surface to dry (approximately 4-6 hours or subject to weather condition) before proceeding to the second coat. For application of Estotect MMA, the coverage shall be between 5-6m² per liter (for total 2 coats).
3. The newly applied coating must be allowed to dry and cure for at least 4 hours.

Application of Estopatch SRF

1. This material use after primer coating and 1st coating of MMA before 2 nd coat of Estotect MMA silver grey.
2. Concrete substrate to be patch with Estopatch Fine for repair of voids, blowhole in accordance to the method statement.
3. After concrete surface preparation, apply 2 coats of Estotect MMA Primer in accordance to the method statement.
4. After priming coats, apply 1 st coat of Estotect MMA silver grey in accordance to the method statement.
5. If any visible blow hole / pinholes appear after 1 st coating of Estotect MMA silver grey, it shall be patched by using Estopatch SRF mixed with Estotect MMA silver grey accordingly.
6. After completing all necessary repairs, continue with the 2 nd coating of Estotect MMA silver grey with roller.

Application of Estotect MMA 2 nd Top Coat – Final Coat

1. Application of the final top coat shall be carried out at the site to ensure consistent colour shading. A skylift as shown in Figure 1 below shall be used for the application of the protective coating for the box girder superstructure at site. A skylift would allow flexibility in the control of the movement directly by the painter himself.
2. Clean the substrate surface using broom/brush to remove dust debris. For stubborn dust stains, wipe the surface using clean damped cloth or sponge and adequate water for such hard to clean surface if needed.
3. After opening of the Estotect MMA tin, stir the material with slow speed mechanical stirrer (400-600 rpm) for at least 1 minute or until the required consistency.
4. Apply the final (2 nd coat) of Estotect MMA using a short hair roller/spray machine. Allow the surface to dry (approximately 4-6 hours or subject to weather condition). For application of Estotect MMA, the total coverage shall be between 5-6m² per liter (for total 2 coats) therefore for application of one coat, the coverage of 2.5-3m² per liter shall be observed.
5. The newly applied coating must be allowed to dry and cure for at least 24 hours.