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International Paint Singapore Pte Ltd 3, Neythal Road T +65 6663 3536
Singapore 628570 F +65 6264 4612

www.international-pc.com
INSTALLATION PROCEDURE SPECIFICATION
SURFACE PREPARATION
AND
APPLICATION OF CEILCOTE 242MR FLAKELINE
TO
CONCRETE ABSORBER &
MIXING ZONE OF THE AERATION BASIN
FOR
SWFGD PROJECT
CENTRAL JAVA, 2 x 1000MW COAL FIRED POWER PLANT

CENTRAL JAVA, INDONESIA
5 10th Dec 2018 REVISION ALAN Sean Kim Rusli

4 22nd Nov 2018 REVISION ALAN Sean Kim Rusli
3 14th Oct 2018 REVISION ALAN Sean Kim Rusli
2 12th July 2018 REVISION ALAN Tri Sulaiman Rusli
1 5th May 2018 REVISION ALAN Tri Sulaiman Rusli
0 22nd Feb 2018 PRELIMINARY ALAN Eddie Cheong Rusli
REV. DATE DESCRIPTION PREPARED BY CHECKED BY RELEASED
IPS IPS BY IPI
Procedure No.: CJAVA-0342-001

1
Reg. No. 198205049R
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CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

PLANT, SWFGD PROJECT Date Issue : 10th Dec. 18
CONCRETE ABSORBER & MIXING ZONE Rev. : 05
OF AERATION BASIN Page : 2 of 131
LINING INSTALLATION PROCEDURES
TABLE OF CONTENTS PAGE
1.0 SCOPE OF W ORK ....................................................... 3

2.0 APPLICATOR PRE-QUALIFICATION ................................ 3
3.0 SIGNIFICANCE ............................................................ 4
4.0 CODES, STANDARDS AND DOCUMENTS ........................ 4
5.0 FACILITIES AND EQUIPMENT ........................................ 5
6.0 CONCRETE SPECIFICATION ......................................... 5-7
7.0 SURFACE PREPARATION ............................................. 7-9
8.0 LINING SPECIFICATION ................................................ 8
9.0 LINING APPLICATION ................................................... 9 - 16
10.0 INSPECTION AND TESTING ........................................... 17 - 20
11.0 LINING REPAIRS ......................................................... 20 - 21
12.0 QUALITY CONTROL DOCUMENTATION ........................... 22 - 23
13.0 QUALITY CONTROL INSPECTION PROGRAM ................... 23
14.0 MATERIAL SHELF LIFE DATE EXPIRY ............................ 23
15.0 SAFETY…………………………………………………… 24
APPENDIX A MIXING RATIO OF CEILCOTE LINING MATERIALS ............ 25
APPENDIX B CEILCOTE 242MR FLAKELINE & 380 PRIMER SPECIFICATION26 - 34
APPENDIX C BLANK SAMPLE INSPECTION FORMS .............................. 35 – 49
APPENDIX D MATERIALS SAFETY DATA SHEETS ............................... 50 –131
ATTACHMENT 1: LINING OF PRECAST SLAB ON GROUND ………………...132 – 133
ATTACHMENT 1A: LINING OF MIXING AREA AT AERATION BASIN ………….. 134
ATTACHMENT 2: ORGANIZATION CHART ………………………………….. 135
ATTACHMENT 3: INSPECTION AND TEST PLAN …………………………….136 – 138
ATTACHMENT 4: RISK ASSESSMENT ……………………………………….139 – 150
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1.0 Scope Of Work
1.1 This specification covers the surface preparation and application of Ceilcote 242MR Flakeline for
the corrosion protection of concrete Absorber and the mixing zone of the Aeration Basin at
Central Java 2 x 1000MW Coal Fired Power Plant, SWFGD project in Central java, Indonesia.
1.2 Work includes furnishing installation services for the performance of concrete surface preparation
and application of linings as required in this specification.
1.3 To install the linings, full scaffolding access shall be provided to reach the internal walls and
overhead of the Absorber and the mixing zone of the Aeration Basin. Scaffold shall be properly
erected with full planking in all work areas. Scaffolding shall not contact wall surfaces in work
areas during lining application and surface preparation.
1.4 The execution of the surface preparation and lining shall be carefully planned in stages to obtain
optimum lining quality, free from contamination and overspray or damage to lined surfaces from
preparation in adjacent areas. Surface preparation will commence from the top and proceed
progressively to the wall base and floor.
1.5 Access scaffold shall be removed prior to preparation & lining of floor and lower wall.
1.6 Other contractors with responsibility for work within or around the Absorbers and the mixing zone
of the Aeration Basin, after completion of lining, shall be adequately notified by SC/MES/SSP
(Construction Contractor) or other responsible parties as to the special care required to protect
the internal lining from damage. Such contractors shall be responsible for all material
requirements to provide the necessary lining protection. Extra care shall be taken at all times
to ensure the completed, inspected and tested lining is not damaged during installation of
support beams and mist eliminators in the absorber. Installation Contractor shall notify
SC/MES/SSP on any damaged areas for rectification prior to dismantling the scaffold
staging.
1.7 In the event of damage or potential damage to the lining by others, the Lining Applicator and
International Paint (IP) shall be formally notified to inspect the suspected damage and effect
repairs if required.
1.8 A joint inspection shall be carried out by all parties concerned (BPI/Sumitomo/MES/SSP/IP/PT)
after the mechanical works had been completed to ensure the lined surfaces are not damaged
prior to the boxing up of the Absorber and the mixing zone of the Aeration Basin. All parties
concerned shall sign off the inspection report after completion of the inspection to confirm no
damages or repair complete to the completed, inspected and tested chemical lining.
2.0 APPLICATOR PRE-QUALIFICATION
The applicator of the lining material shall be approved by BPI (Owner) and endorsed by
SC/MES/SSP (Construction Contractor) and shall have at least five (5) years experiences in
the application of this or similar products. Previous experience must be verified by three (3)
references of similar applications and project size.
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3.0 SIGNIFICANCE
3.1 This specification defines the necessary practices for surface preparation and application of
Ceilcote 242 MR Flakeline along with tolerances where applicable.
3.2 This specification reflects the most current information available on proper and acceptable
procedures and tolerance. Where other documents and this specification differ, this specification
shall govern.
3.3 Lining and preparation works may be staggered or proceed progressively in order to meet
cleanliness requirements or over-coating times indicated in this specification. Absorber roof and
walls may be prepared and lined prior to absorber floors.
4.0 CODES, STANDARDS AND DOCUMENTS
4.1 Ceilcote Specifications and Procedures CPT-1, CPT-2, CP-11, CS-10, CP-14, CS-15, CP-16,
CP-17 and 5-40.1.
4.2 Ceilcote Product Technical Bulletins:

Ceilcote 380 Primer
Ceilcote 242 MR Flakeline
4.3 Reference Standards
ASTM D 4258 Practice for Surface Cleaning Concrete for Coating
ASTM C 811 Surface Preparation of Concrete for Application of Chemical Resistant

Resin Monolithic Surfacing
ASTM D4580 Standard Practice for Measuring Delamination in Concrete by Sounding
ASTM D 4263 Test Method for Indicating Moisture in Concrete by the Plastic Sheet
Method
ASTM D 4787 Practice for Continuity Testing for Liquid or Sheet Applied Linings applied
to concrete substrates
ASTM D 4285 Standard Test Method for Indicating Oil or Water in Compressed Air
ASTM D 4259 Standard Practice for Abrading Concrete
ASTM D 4541 Standard Test Method for Pull-Off Strength of Coating Using Portable
Adhesion Testers
ASTM E 337 Standard Test Method for Relative Humidity by Wet and Dry Bulb
Psychrometer
ASTM D 4618 Standard Specification for Design and Fabrication of Flue Gas
Desulfurization System Components for Protective Lining Application
NACE Standard Lining Over Concrete for Immersion Service

RP0892-92
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5.0 FACILITIES AND EQUIPMENT
5.1 Surface preparation, priming and lining system installation as covered by this specification shall
be carried out "on-site". The area shall be free from contaminants which may affect adhesion
between the substrate and lining materials (e.g. airborne dust, water, oil and dirt, etc.). Where
necessary areas of work shall be covered or enclosed with tarpaulin or cover to contain the lining
environment.
5.2 Welding or other work shall not be carried out in the same area during lining material installation
unless such operations are isolated to prevent possible safety hazards and/or contamination of
the surfaces to be treated.
5.3 When the lining materials have been applied and cured for a minimum 24 hours, the lined areas
shall be protected by others from damage in the event other contract operations are required or
resume in the same area. Typical protection shall be plastic sheet or tarpaulin with plywood sheet
where applicable.
5.4 Compressed Air Quality
5.4.1 Compressed air shall be checked for the presence of moisture and oil in accordance with
ASTM D4285 method prior to commencement of work and at least once every four hours,
or more frequently if deemed necessary by IP Technical Services Representative (IP
TSR). The test shall be done by operating the equipment with air only.
5.4.2 The air stream shall be directed toward a piece of clean white absorbent paper or cloth for
two (2) minutes to detect any oil or moisture. In the event oil or moisture is detected on
the test paper or cloth, the equipment shall be modified to eliminate such carry over of oil
or moisture.
5.4.3 The results of air quality test shall be reported on appropriate QC record form.
5.4.4 Compressed air systems or air compressors shall be fitted with suitable fan, water or
refrigerant after coolers, oil and moisture separators fitted and serviced at a frequency
required to adequately ensure no oil or water carry over.
6.0 CONCRETE SPECIFICATION
6.1 General Design

All concrete to receive protective surfacing shall be adequately designed for the intended use and
poured to specified grade, level, fall or flatness to provide a uniform surface free of honey
combing and sharp protrusions. The concrete must be dry, free of oil and dirt and cured
sufficiently to receive the protective surfacing prior to commencement of surface preparation.
As a minimum all corners and edges shall be cast 12 mm x 45° minimum with edges radiused
6 mm to 10 mm radius. Fins and edges caused by formwork misalignment shall be ground or
bush hammered to an even and reasonably smooth contour.
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Sharp Edges Formwork Mis-Alignment

Grind the edges to 6mm to 10mm radius Repair by Chamfering to smooth contour
All nails, timber and other surface embedments shall be removed. Nails shall not be broken or
cut-off flush, complete removal of it is required. Protruding tie bars shall be cut off at least 20 mm
below flush. All cementitious mortar repair areas shall have boundary perimeter saw cut not less
than 12 mm deep and such materials shall be mixed and cured properly in accordance with the
manufacturers written instructions.
All feathered and loose/dummy cement mortar cementitious repair materials shall be hacked out.
Bagged surfaces or render shall be stripped back to a firm substrate.
Protruding Tie Bars Tie bar Holes

The Bars shall be cut off at Fill up the holes with epoxy
least 20mm below flush grout or non shrink grout
Wood Debris & Water Leakage Mortar Repair

Remove the debris completely and Saw cut perimeters for ˃12mm deep.
repair the leaks Mortar shall be mixed and cured properly.
6.2 Compressive Strength
The compressive strength of the concrete should be minimum 25 MPa. This is only one measure
of quality for consideration. It is a measure of integrity but not of surface strength.
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6.3 Surface Strength
This is a most important property required for the best performance of chemical resistant
monolithic protective surfacing. Minimum surface tensile should be 1.4 MPa. Surface strength
has a direct relationship with proper high humidity curing and placement. This aspect of the civil
work requires proper monitoring.
Where necessary the concrete surface strength shall be verified by testing to ASTM D4541.
6.4 Finishing Methods
The preferred finish for horizontal concrete surfaces is "once over" with a steel trowel. This
method provides the strongest most uniform surface. Screed, broom and wood float finishing are
less desirable since as irregular surface can result.
6.5 Surface Curing and Hardening Treatments
Do not use curing agents or hardening treatments unless they are compatible with the proposed
chemical resistant lining material. They may reduce adhesion of the protective surfacing and
may require mechanical removal. Consult Ceilcote for advice.
6.6 Concrete Cure Time
It is best to cure new concrete 28 days prior to the application of the protective lining.
6.7 Determining Dryness
6.7.1 Prior to commencement of the lining application the concrete shall be checked for dryness
by the applicator using the plastic sheet method (ASTM D4263-83) or other approved
instrument/method.
6.7.2 When using an appropriate instrument/method the moisture content of the concrete shall
not exceed 4% by weight.
6.8 Concrete Sounding Test
6.8.1 Hammer tests in accordance to ASTM D4580 shall be performed on the concrete surfaces
to identify hollow spots where concrete repair is required.
6.8.2 Sound concrete will give a high pitched sound while hollow spots will give a deep, dull
sound.
6.8.3 Any hollow concrete shall be hacked removed to expose the sound concrete and repair
with approved high strength epoxy repair mortar by the civil contractor.
6.9 GRP Inserts
All GRP inserts such as nozzles, supports etc shall be positively and adequately keyed into the
concrete structure by means of puddle flanges or other approved means and located in
accordance with construction drawing requirements.
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7.0 SURFACE PREPARATION
7.1 Common Requirements (Concrete and Steel Preparation)
7.1.1 Prior to commencement of the lining work all subject surfaces shall be inspected and
reported on the appropriate inspection form for the presence of any conditions that may
adversely affect the satisfactory performance of surface preparation and subsequent
lining work. If any unsatisfactory conditions exist, work shall not proceed until conditions
have been corrected and accepted by the IP TSR.
7.1.2 All surfaces to receive protection shall be free from oil, grease, soil, moisture or other
contaminants that may impair the adhesion of the protective lining materials.
7.1.3 All dust and grit shall be removed from the blast cleaned surface by brushing or air
blowing followed by vacuum cleaning prior to priming.
7.1.4 Care shall be taken at all times, throughout all stages prior to completion that surfaces
shall not be contaminated with finger prints (oil), perspiration (salts) or detrimental
contamination from workers clothes and footwear.
7.1.5 The blasting media shall be clean and dry with sufficient size and sharpness required to
produce the minimum profile as specified. The blasting grit shall be tested to confirm that
its conductivity value of not more than 250µS/cm. The frequency of testing shall be for
each batch number of grit or weekly whichever more frequent and follow the procedure
specified in section 10.10 below.
7.1.6 The compressed air supply for grit blasting, air atomized spray equipment, etc shall be
free of oil, dirt and entrained water as specified in section 5.4 above.
7.2 Concrete Preparation
7.2.1 Concrete shall have been cured for the minimum period described in Section 6.6 prior to
commencement of surface preparation operations.
7.2.2 Concrete shall be made ready for lining by others to meet the requirements of section 6.1
through 6.8 and 7.1 above prior to commencement of surface preparation operations.
7.2.3 Concrete surfaces to receive 242 MR Flakeline shall be prepared by grit blasting to
remove all surface laitance, loose, weak and un-bonded concrete and open up air voids in
vertical surfaces. All weak secondary surface screeds shall be removed. A properly
prepared concrete surface shall have the texture equivalent to 40-60 grade sand paper
roughness.
7.2.4 Prior to commencement of surface preparation, the concrete shall be checked for dryness
using the plastic sheet method (ASTM D4263-83) or an approved instrument in
accordance with section 6.7 and reported on the appropriate inspection form.
7.2.5 After the confirmation of dryness and within seven days from surface preparation, priming
work shall be carried out using the specified priming materials.
7.2.6 Lining application of concrete surfaces shall not proceed when any of the following
conditions exist within the working area.
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(a) Surface temperature is above 43°C or below 10°C.

(b) Relative humidity in the work area is greater than 90%.
(c) The surface temperature is less than 3°C above the dew point of the air in the
work area.
(d) Moisture or other contamination is evident on the surfaces to be blast cleaned.
(e) In the event that during blast cleaning, any of the conditions (b) and (c) exist and
cannot be modified locally, blast cleaning may proceed provided that the surfaces
affected by the conditions improve and prior to application of the primer.
7.2.7 Quality control personnel shall monitor the weather/climate change, take surface
temperature readings and conduct relative humidity and dew point check in the work area
before the start of each work shift and at intervals of not less than 4 hours thereafter.
7.2.8 All surface temperature, relative humidity and dew point readings shall be recorded in the
QC forms listed in section 12.0 below.
7.2.9 All openings shall be closed by tarpaulin to prevent rainfall to affect the quality of lining
work.
8.0 LINING SPECIFICATION
8.1 Absorber Internal Lining
8.1.1 The Absorber lining material shall be Ceilcote 242 MR Flakeline, a silica filled, glass cloth
reinforced vinylester resin based lining system as manufactured by International Paint
manufacturing site. For this project requirement on concrete the system comprises a
penetrating prime coat of Ceilcote 380 primer, Ceilcote 380 resin + S-11 Powder patching
material, followed by a conductive prime coat of Ceilcote 380 resin + C-1 Powder, a silica
filled base coat, an intermediate layer of fibreglass mat (CSM) reinforcement and a flake
reinforced topcoat. Ceilcote 242 MR Flakeline is installed by hand trowel and roller to
yield a thickness of 2.5 to 3.2 mm. Ceilcote 242 Flakeline topcoats shall be grey in colour
and spray/roller applied.
8.1.2 System Design

Application Thickness
Item Description Colour Method (W.F.T. Microns)
1st Primer 380 Primer Translucent Roller 50 – 125
Patching 380 Primer + S11 powder Grey Trowel Varied
2nd Primer 380 Primer + C1 powder Black Roller 100 – 200
Basecoat 6640 Ceilcrete + S1 Powder Grey Trowel 1,500 – 2,000
Reinforcement 6640 resin + 450gm/m2 Translucent Roller / Brush 800 – 1,000
Topcoat 242 Flakeline Grey Spray Or Roller 500 – 800
Thickness range : 2.5 – 3.2 mm

Target thickness : 2.8 mm
Minimum thickness : 2.5 mm
Note:
1) Immediately after application of the basecoat and while it is wet, one layer of 450
gram/m² CSM reinforcing shall be added and saturated before basecoat is cured.
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8.2 Cure Time
The completed lining shall be allowed to cure for a minimum of 48 hrs at 32°C prior to being
placed in service. Continuous ventilation shall be provided throughout the curing process to get
rid of any trapped solvent or moistures.
9.0 LINING APPLICATION
9.1 Blast Cleaning
All surfaces to receive lining shall be prepared by blast cleaning in accordance with Section 7.0.
Delays between surface preparation and priming shall be avoided to prevent surfaces from being
contaminated. Concrete surfaces shall be primed within seven (7) days from surface preparation
and steel surfaces shall be primed within eight (8) hours from surface preparation before visible
oxidation on prepared surface.
9.2 Product Mixing
9.2.1 All priming, patching and lining materials shall be mixed strictly in accordance with
Ceilcote recommendations Appendix A.
9.2.2 All mixing shall be done with the aid of a powered mixer fitted with an appropriate mixing
whip or jiffy blade.
9.2.3 All materials shall be power mixed prior to use or decanting to a smaller volume.
9.2.4 Mixing proportions may be varied ±30% at the discretion of IP TSR to maintain specific
working times. Where such instructions are given the appropriate lining record sheet shall
be noted.
9.2.5 All pails or cans of lining materials shall be at ambient temperature prior to opening or use
at the work area.
9.2.6 Personnel engaged in product mixing shall maintain records of lining material quantities
and batch number mixed in support of QC functions. Lining inspection reports shall
indicate lining material batch numbers.
9.3 Priming / Conductive Priming
9.3.1 Prior to application of primer coat all subject concrete surfaces must be completely dry.
This must be confirmed by testing in accordance with section 6.7 above.
9.3.2 The first primer coat on concrete surfaces shall be applied using Ceilcote 380 resin
catalyzed in accordance with this specification. This primer coat shall be applied in one
uniform coat by roller or brush taking care to firmly work the material into the concrete
surface. The purpose of this primer coat is to penetrate the concrete surface. Excess
primer shall not be applied to cause pooling or the surface to become ‘glazed’.
9.3.3 Concrete surface patching shall follow the first primer coat and precede the second
conductive primer coat. Refer the section 9.4 below for details of the patching procedure.
9.3.4 The second concrete primer coat of Ceilcote 380 + C-1 powder Conductive primer shall
be applied in one uniform coat by rolling or brushing and firmly worked into the surface.
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9.3.5 The blast cleaned steel surfaces shall be primed with Ceilcote 380 Primer prior to the
formation of any visible rust on the surface or drift of the surface condition below Sa 2.5.
Surfaces which do not meet this requirement shall be re-blasted to comply with the
specification.
9.3.6 The Ceilcote 380 Primer shall be applied by rolling or brushing at the specified thickness.
Excessive application, drips, runs and sags of primer shall be avoided.
9.3.7 The conductive Primer shall be over-coated with lining basecoat within 7 days when
exposed to direct sunlight or 14 days when sheltered from direct sunlight or as directed by
the IP TSR where more stringent requirements apply.
9.3.8 The minimum over coating intervals between application of each of the concrete primer
coats and concrete conductive primer and the lining basecoat shall be 1.5 hours and
maximum over coating intervals shall be 14 days or as directed by the IP TSR where
more stringent requirements apply.
9.3.9 Random primer wet film thickness may be taken and recorded during application. Excess
primer thickness or pooling of primer shall be avoided.
9.3.10 Application of primers shall not proceed when environmental conditions described in
Section 7.2.6 (a), (b), (c) and (d) exist within the work area.
9.3.11 Since the lining on all concrete surfaces shall be spark tested upon completion, earthing
tags shall be provided prior to lining every 6 to 8 meters for grounding the spark test
equipment. Hardened masonry nails may be inserted prior to conductive priming or a
suitable copper stranded, PVC sheathed, stub of cable may be bonded to the surface
after conductive priming. The Ceilcote conductive primer must adequately terminate onto
the masonry nail or copper cable to effect a suitable electrical bond.
9.4 Patching
9.4.1 All large holes, irregularities, etc. in the concrete surface shall be filled prior to the
application of conductive primer and basecoat in order to achieve a uniform working
surface. Patching compound consists of a mixture of catalyzed Ceilcote 380 resin and
S11 powder, to form a thixotropic putty like consistency. Typical batch includes 1 kg
catalyzed liquid to 2.5-3.5 kg of powder. More or less powder may be used to achieve
desired consistency.
9.4.2 IP project responsibility is to provide all patching material requirements up to and

including 0.5 kg/m². Others will be commercially responsible for all patching requirements
in excess of 0.5 kg/m². Therefore the usage of patching materials shall be a function of
the work quality plan and all patching material use appropriately reported on the
applicable QC report form.
9.4.3 Prior to conductive priming, all wall to floor and wall to wall joints shall be evenly coved at
a minimum of 10 mm radius. The coving material shall be similar to that used for patching
(see 9.4.1 above).
9.4.4 Prior to conductive priming at GRP wall inserts the concrete to GRP joint shall be also
coved at a minimum of 10 mm radius.
9.4.5 All patching will be rolled or brushed lightly with a styrene dampened roller/brush to
smoothen out trowel marks and avoid later sanding wherever possible.
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9.4.6 Prior to Ceilcote conductive priming, all contraction joints and all crack repairs shall be
laminated and bridged with a 100 mm to 150 mm wide layer of chopped strand mat
(CSM) saturated with catalyzed 380 primer resin to exclude all entrapped air. If the
substrate surface is rough or uneven it will first require smoothing with a scratch coat of
patching material and the CSM applied prior to the cure of the patching material.
9.5 Application of Ceilcote 242 MR Flakeline Basecoat
9.5.1 Prior to application of the lining basecoat, the conductive primer shall be tack-free.
9.5.2 Prior to the application of the basecoat, the conductive primer shall be randomly checked
for styrene sensitivity in accordance with section 10.8 of this specification and results
recorded. Primed surfaces that do not exhibit styrene sensitivity shall be sweep blast
and/or power sand to meet the requirements of the specification.
9.5.3 Primed surfaces that have been contaminated with dust shall be vacuumed clean and/or
wiped with styrene and allowed to dry prior to lining to ensure removal of contamination.
9.5.4 Application of basecoat shall not proceed when environmental conditions described in
Section 7.2.6 (a), (b), (c) and (d) exist within the work area.
9.5.5 Prior to application of the basecoat all components shall be mixed in strict accordance
with section 9.2 above observing material pot life and working time parameters.
9.5.6 Spread a uniform coat of Ceilcote 242 MR Flakeline basecoat mixture onto the primed
surface using a steel finishing trowel to achieve a nominal thickness of 1.5 mm.
9.5.7 Random wet film thickness readings shall be taken and recorded during application of the
basecoat.
9.5.8 Immediately after application of the basecoat, while it is still uncured (wet), press pre-cut
pieces of 450 gm/m² chopped strand mat (CSM) fiberglass reinforcing firmly into the
basecoat and smoothen out wrinkles with a dry roller or a wall paper brush.
9.5.9 Where two or more pieces of mat reinforcing are to be joined allow a minimum 25 mm
overlap at edges.
9.5.10 Immediately apply catalyzed 6640 Resin liquid to fully saturate the mat. The reinforcing
layer shall be rolled again with a ribbed roller to remove entrapped air until no voids or dry
areas (white patches) in the mat are apparent. Allow the basecoat and saturated
reinforcing layer to cure tack free and cool to ambient temperature, shaded from direct
sunlight, prior to proceeding with subsequent steps.
9.6 Preparation of Ceilcote 242 MR Flakeline Basecoat/Saturant Layer
Prior to application of the topcoat, lightly power sand all seams in the mat reinforcing and areas
that have protruding glass fibers thereby achieving a uniform surface. Vacuum of excess dust
and wipe the entire area clean with styrene dampened rags and allowed to dry.
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9.7 Application of Ceilcote 242 Flakeline Topcoat
9.7.1 Prior to application of the topcoat, the basecoat shall be tack free and have set less than
14 days. The basecoat shall be randomly tested for styrene sensitivity in accordance with
Section 10.8 of this specification and results recorded.
9.7.2 Surfaces not meeting the time intervals of 9.7.1 above, and not exhibiting styrene
sensitivity shall be abraded by power sanding or grit blasting, or prepared as directed by
IP TSR. At least 75% of the original surface must be uniformly prepared prior to
application of the topcoat.
9.7.3 All dust and contamination generated by preparation work shall be removed by
vacuuming then wiping with styrene and allowed to dry.
9.7.4 Application of the topcoat shall not proceed when any of the environmental conditions
described in Section 7.2.6 (a), (b), (c), or (d) exist within the work area.
9.7.5 Prior to application of the topcoat all components shall be mixed in strict accordance with
section 9.2 above observing material pot life and working time parameters.
9.7.6 The topcoat shall be uniformly applied by spraying or roller/brushing to the required
thickness of 500 to 800 microns WFT per coat. Roller and brush application will require
multiple coats to achieve the required thickness. Colour shall be Grey.
9.7.7 Random wet film thickness (WFT) readings shall be taken and recorded during installation
of the topcoats. The WFT should take into consideration the anticipated 20% reduction of
thickness upon cure of the lining topcoat.
9.8 Terminations
9.8.1 All temporary lining termination’s as work progresses, or at the completion of each day’s
work, shall be progressively stepped back to expose no less than 25 mm each of primed
surface, base coat, CSM reinforcement. Masking tape shall be used to form all
terminations with plastic sheet to prevent overspray, drips and runs.
9.8.2 At Absorber GRP fittings the lining reinforcement and topcoat shall extend no less than 50
mm onto the grit blasted and primed external surface of the GRP. The balance of GRP
surfaces shall be protected from grit blasting and lining. GRP surfaces to be over coated
may first be power sanded prior to grit blasting if preferred.
At the Absorber sump outlet GRP nozzle a special procedure will be necessary. After
surface preparation, first primer and patching, apply a 50 mm plastic masking tape
centrally over the concrete to GRP joint line. Then overlay two (2) layers of CSM 50 mm
onto the GRP fitting. After laying the lining basecoat and terminating approximately at the
joint line extend the CSM reinforcement 75 mm onto the GRP fitting. Install the 242
Flakeline topcoat over the CSM reinforcement.
9.8.3 Masking tape shall be removed from terminations prior to curing of the lining.
9.8.4 All permanent lining terminations shall be formed as straight lines using suitable masking
tape and plastic sheet to prevent overspray.
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9.8.5 Where the lining must be penetrated for hold down bolts, except at inlet and outlet flange
faces, all such penetrations shall be sealed using Ceilcote design practice. This involves
removing all drilling debris from the hole and partially filling the hole with catalyzed resin
(Ceilcote 380 Resin) through the support base plate. The expanding bolt shall then be
inserted allowing excess resin to over flow and fill any void under the base plate. Tighten
down the holding down bolt and only after this remove any excess resin from around the
support base plate using a clean rag moistened with T410 cleaning solvent. On vertical
surfaces the Ceilcote 380 resin may be thickened by the addition of S11 Powder (see
section 9.4.1).
9.8.6 Lining termination at Seawater Header penetrations and the embedment of Access Door
opening shall be reinforced with an additional layer of Chopped Strand Mat (450
grams/m²).
9.8.7 Lining termination at C276 alloy lined Absorber Inlet Duct and Nozzles by the Absorber
Wall concrete lining shall be such that the embedded alloy C276 angle shall be
overlapped by 242MR Flakeline, extending a minimum of 25mm onto the embedded
C276 alloy angle.
9.9 Lining Reinforcements
All inner and outer corners of the concrete absorber and at every protruding surface due to
reinforcement pads embedment shall be reinforced with two (2) ply 450 gm/m² chopped strand
mat (CSM) fiberglass mats after successful completion of spark testing on the 242MR Flakeline.
The reinforcement layers shall extend approximately 100mm width at each side of the corner.
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9.9.1 The application interval between the two (2) ply fiberglass mat reinforcement layers and
the 242MR Flakeline topcoat shall not exceed 7 days when exposed to direct sunlight or
14 days when sheltered from direct sunlight or as directed by IP TSR.
9.9.2 Prior to application of the fiberglass mat reinforcement layers, the 242MR Flakeline
topcoat shall be checked for styrene sensitivity.
9.9.3 Surfaces which do not exhibit styrene sensitivity shall be prepared by brush/sweep
blasting or power sanding to achieve a uniformly abraded surface over at least 75% of the
area.
9.9.4 Dust contamination on the surface of the 242MR Flakeline topcoat shall be removed. The
surface shall be styrene wiped and allowed to dry prior to application of the fiberglass mat
reinforcement layers.
9.9.4 The fiberglass mat layers shall be applied by roller or brush at the specified width. The
first ply fibergass mat layer shall be tack-free prior to the application of the 2nd layer.
9.9.5 The finished surface of fiberglass mat reinforcement layers shall be uniform and free of air
bubbles, and air blisters and protruding glass fibers.
9.9.6 Any protruding glass fibers and surface irregularities shall be removed by power sanding
to obtain a uniform surface. Seams and overlaps in the reinforcing mat layer shall be
lightly power sanded to smooth prominent edges, styrene wiped clean and saturate with a
coat of the 6640 Ceilcrete resin.
9.10 Lining of Nozzles and Manway Flanges
9.10.1 All hastelloy embedded flanged nozzles are not required to be lined. The edge of the
hastelloy nozzles adjacent to the Absorber wall shall be overlapped by the 242MR
Flakeline to facilitate proper sealing and termination.
9.10.2 Carbon steel embedded manhole and blind flanges shall be lined with Ceilcote 242MR
Flakeline in accordance to section 9.3 to 9.8 of this procedures.
9.10.3 Blind flange lining shall follow the requirements of the equipment lining specification with
the additional requirement of flange facing in accordance with section 9.11 below.
9.10.4 All manway cover or blind flanges shall also be additionally reinforced with 1 ply FRP Mat
overlay.
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9.10.5 The inside of 242MR Flakeline lined manways shall be additionally reinforced with 1 ply
FRP Mat overlay, terminating 100 mm only the Absorber shell wall.
9.10.10All manway cover or blind flanges shall also be additionally reinforced with 1 ply FRP Mat
overlay.
9.11 Facing of Flanged Nozzles
9.11.1 Upon completion of lining and all quality control checks of the manhole flange, the flange
faces shall be faced for flatness.
9.11.2 Sand the face reasonably flat and square by hand using a sanding block and coarse to
medium grit sandpaper or emery cloth or an orbital sander. The entire surface shall be
abraded.
9.11.3 Check for approximate flatness using a straight edge.
9.11.4 Check for approximate squareness using a straight edge and tape measure / steel rule.
9.11.5 Select a suitable faced plywood board 15 to 25 mm in thickness (larger flanges need to
use thicker board than small flanges).
9.11.6 Cut the board slightly larger than the flange face and pre-wax the faced surface with two
thick coats of floor wax allowing each coat to dry. Keep the wax and the waxed board
away from the prepared flange face.
9.11.7 Wipe the flange face clean with styrene and allow the styrene to dry or wipe dry with a
clean cloth.
9.11.8 Apply Ceilcote 242MR Flakeline to the flange face in accordance to section 9.3 to 9.6 of
this procedures.
9.11.9 Apply an even brush or roller coat of catalyzed Ceilcote 242 Flakeline in accordance to
section 9.7 to the flange face adjusting thickness for any high or low spots on the surface.
9.11.10Immediately fit the facing board, waxed face to the wet coating. Slide the board a little in
a rotating manner to spread the coating and assist trapped air to escape. Then clamp the
board with minimal pressure just to hold it in place but not distort the board.
9.11.11Remove the board after four hours and trim the inner and outer edges and then bolt holes
using a hand file fitted with a proper handle.
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9.11.12Manway cover faces and similar flanged connections shall be similarly faced and
moulded flat against the previously lined and faced vessel flange. The surfaces shall be
separated using plastic sheet.
9.12 Removal of Ceilcote 242MR Flakeline
9.12.1 In the unlikely event that Ceilcote 242MR Flakeline is required to be removed due to
change in plan. It can be done by Ultra High Pressure Water Jetting at between 25,000 to
30,000 psi.
9.12.2 Care should exercise in term of safety, trained and qualified worker with close supervision
is necessary for Ultra High Pressure Water Jetting works.
10.0 INSPECTION AND TESTING
10.1 Instruments and Equipment
10.1.1 The following or equivalent instruments and equipment are required for quality control
inspection and testing.
(a) Surface thermometer with a range between 0°C and 120°C.

(b) Sling psychrometer and U.S. Weather Bureau Psychrometric Tables or Dew Point
& Relative Humidity Calculator.
(c) Magnetic or electronic dry film thickness gauges (for steel substrate only) with a
range suitable for measuring 25 to 4,500 microns.
(d) Moisture meter.
(e) Keane-Tator Profile Comparator Disc complete with Magnifier at 5X enlargement
or other approved gauge (for steel substrate only)
(f) Shims for calibrating dry film thickness gauges.
(g) Wet film thickness gauge suitable for measuring up to 3,000 microns.
(h) Conductivity Meter plus accessories.
(i) 40 to 60 grit sand paper.
(j) High Voltage DC Holiday Detector with audible alarm suitable for use up to 20,000
volts.
(k) Adhesion tester
(l) Barcol Hardness Tester
10.2 Instrument Calibration

10.2.1 All test instruments shall be regularly calibrated and records maintained where applicable
of each identified instruments calibration history. Calibration certificates shall be made
available on site for verification by Owner or Construction Contractor inspections, when
necessary.
10.2.2 The frequency of calibration shall be as follows:-
(a) Sling psychrometer - not required.

(b) Electronic psychrometer and dewpoint instruments - 12 months.
(c) Electronic surface thermometer - 12 months.
(d) Magnetic/electronic dry film thickness gauge - at the lining thickness range prior to
each work shift (no record required).
(e) Moisture meter - 12 months.
(f) High Voltage DC Holiday Detector - 12 months.
(h) Profile comparator - not required.
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(i) Wet film thickness gauges - not required.

(j) Adhesion Tester – 12 months
(k) Barcol Hardness Tester – verify against the shim plate provided with the tester.
(no record required)
10.3 Concrete Surface Inspection
10.3.1 Prior to acceptance of equipment for lining operations concrete surfaces shall be
inspected and reported by the IP TSR for any conditions which do not conform to this
Specification section 6.0 above. Rectification shall be carried out by others as required to
meet the specified requirements prior to acceptance for lining works.
10.3.2 The degree of roughness achieved by grit blasting shall as a minimum be comparable
with the surface texture of 40 - 60 grit sand paper. Excess roughness should be avoided
however all ‘Bug-Holes’ and voids must be fully opened.
10.3.3 Prior to commencement of lining operations the concrete surfaces shall be tested and
results recorded on the appropriate inspection form by IP TSR for dryness in accordance
with Section 6.7.
10.3.4 Prior to application of the primer blast cleaned concrete surfaces shall be visually
inspected and results recorded on the appropriate inspection form for compliance with
specified requirements.
10.3.5 The applicator shall randomly check primed and basecoat surfaces for styrene sensitivity
in accordance with section 10.8 of this specification and record results before proceeding
with the lining.
10.4 Wet Film Thickness Testing
Random wet film thickness tests shall be taken and reported by the applicator during the
installation of the designated lining system. Five (5) measurements shall be taken for
approximately each ten (10) square meters of lining. Measurements shall be taken on the
basecoat and topcoat layers as a guideline to total thickness.
10.5 Dry Film Thickness Testing (Applicable For Carbon Steel Substrate Only)
Dry film thickness of the completed lining shall be measured using an approved magnetic or
electronic thickness gauge and generally in compliance to SSPC-PA2.
10.5.1 The average dry film thickness of the lining shall be taken in increments no greater than 5
square meters with at least three measurements per increment. Each measurement shall
consist of the average of three readings taken with 6 square centimeters.
10.5.2 The average dry film thickness measured for each increment shall not be less than the
minimum, allowed in this specification. Areas that do not conform shall be marked with
chalk for repair.
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10.6 Spark Testing
10.6.1 The finished lining system shall be spark tested to determine the presence of pinholes in
accordance with Ceilcote Procedure 5-40.1, ASTM D5162 and ASTM D4787 as
applicable. The results of spark testing shall be recorded on the appropriate inspection
form.
10.6.2 The voltage required and procedure shall generally be, in accordance with Ceilcote
Procedure 5-40.1, based on 4 volts per micron of lining thickness and shall be limited to
10,000 volts maximum for absorber internal lining.
10.6.3 After spark testing equipment earthing tags where fitted shall be removed. If these are
sited within the lined area the surface shall then be patched and lining repaired as
necessary in accordance with section 11.2 of this specification.
10.7 Styrene Sensitivity
To check styrene sensitivity, wipe a small area (approx. 16 to 64 square centimeters) with a cloth
dampened in styrene. Rub the wetted area with a clean finger. If the surface is softened or
becomes tacky, the surface is deemed styrene sensitive and acceptable for further application.
10.8 Compressed Air Quality
10.8.1 Compressed air shall be checked for the presence of moisture and oil in accordance
with ASTM D4285 method prior to commencement of work and at least once every four
hours, or more frequently if deemed necessary by IP TSR. The test shall be done by
operating the equipment with air only.
10.8.2 The air stream shall be directed toward a piece of clean white absorbent paper or cloth
for two (2) minutes to detect any oil or moisture. In the event oil or moisture is produced
on the test paper or cloth, the equipment shall be modified to eliminate such carry over
of oil or moisture.
10.8.3 The results of air quality tests shall be reported on the appropriate QC record form.
10.9 Blasting Grit Quality
10.9.1 Blasting grit shall be tested with salt conductivity test to confirm that its conductivity
value of not more than 250µS/cm of soluble chloride salts.
10.9.2 The test shall be carried out strictly adhering to ISO 11127-6 test method.
10.9.3 The frequency of testing shall be once for each designated batch of grit or weekly
whichever more frequent.
10.9.4 The grit shall also be visually checked to ensure that it contains no detrimental foreign
particles and that it is not salvaged grit (recycled).
10.9.5 The results of blasting grit quality tests shall be reported on the appropriate form.
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10.10 Adhesion Testing (Optional)
10.10.1 Lining adhesion shall be checked after the lining is fully cured, on a separate sample
steel panels which have been prepared and lined in accordance with this specification
and at the same time at the Absorber lining. A minimum of one test panel shall be
prepared.
10.10.2 Steel panel 450mm x 600mm with a minimum thickness of 6.0mm shall be provided by
client.
10.10.3 The lining shall be staggered exposing 75mm to 150mm each of basecoat, CSM
reinforcing layer and topcoat. 50mm of primer shall be exposed but shall not be tested
separately.
10.10.4 Adhesion testing shall generally follow the procedures of ASTM D 4541-85. A minimum
of six (6) dollies shall be adhered to each of the lining segments (basecoat and topcoat).
After the adhesive has cured (min. 24 hours at 30° C) the coating around the dollies
shall be cut through using a diamond cutter taking care not to disturb the dollies.
10.10.5 The result of the test shall record the location/description of each dolly site and not
respective proportions of adhesion/cohesive/adhesive failure by percentage.
10.10.6 The anticipated adhesion strength should be approximately 400 psi. It is also expected
that the failure mode would be cohesive within the lining material.
10.11 Hardness Testing (Optional)
10.11.1 The degree of final cure of the lining shall be determined after 72 hours at 30°C by
Barcol hardness test performed only on sample panels prepared for adhesion testing.
10.11.2 Randomly distributed readings shall be made with not less than a total of ten readings.
The highest and lowest readings shall be ignored and the other reading averaged to
determine the average lining hardness.
10.11.3 Typical hardness values of 30-40 indicate an acceptable rate and degree of cure.
11.0 LINING REPAIRS
11.1 Pinholes
11.1.1 Abrasive blast or grind back the lining to the basecoat layer at the pinhole and feather the
lining back for a distance of 50 mm to 75 mm.
11.1.2 Vacuum then wipe the prepared area with styrene to remove dust.
11.1.3 Apply a layer of basecoat material and CSM reinforcement, checking wet film thickness to
achieve proper lining thickness and overlapping the existing prepared basecoat by not
less than 25 mm, in accordance with sections 9.5 and 9.7 above as applicable.
11.1.4 After cure of the basecoat apply a layer of topcoat material, checking wet film thickness to
achieve proper lining thickness and overlapping the existing prepared topcoat by not less
than 25 mm, in accordance with sections 9.7 and 9.8 above as applicable.
11.1.5 After cure, re-spark test the repair area only in accordance with section 10.7 above.
11.1.6 Repeat steps 11.1.1 through 11.1.5 until no pinholes can be detected.
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11.2 Mechanical Damage and General Repairs
11.2.1 Abrasive blast or grind back the lining to the basecoat layer at the damage and form a
neat square or rectangle for repair. Feather the lining edge back for a distance of 50 mm
to 75 mm all around the perimeter of the damage. If the concrete/steel substrate is
exposed re-blast the steel and prime in accordance with sections 7.3 and 9.3 of this
specification.
11.2.2 Vacuum then wipe the prepared area with styrene to remove dust.
11.2.3 Apply a layer of basecoat material, checking wet film thickness to achieve proper lining
thickness then apply the CSM reinforcing taking care to step each progressively up the
feathered edge. Follow the procedures of sections 9.5 and 9.7 of this specification.
11.2.4 Apply a layer of topcoat material, checking wet film thickness to achieve proper lining
thickness and taking care to overlap the topcoat no less than 25 mm over the existing
prepared topcoat. Follow the procedures of sections 9.7 and 9.8 of this specification.
11.2.5 After cure, re-spark test the repair area only in accordance with section 10.7 above.
11.3 Mechanical Damage and General Maintenance Repairs After the Lining System has been
Placed in Service
11.3.1 Maintenance inspections and repairs shall be carried out in a professional manner by
suitably qualified and experienced personnel. Lining maintenance repairs shall be carried
out by an applicator with at least five (5) year experiences in the application of the
specified lining materials in FGD systems of a similar size and concept. Previous
experience shall be verified by three (3) applicable references.
11.3.2 Wash down the lined surfaces with copious amounts of potable water at high pressure to
remove loose materials and chemical contaminants that may hinder the quality of repair /
works. Commence at upper levels working towards the bottom.
If the lined surfaces have oil or similar residues, degrease. Remove all residues by
solvent wiping followed by detergent washing.
11.3.3 Linings shall be inspected following the guidelines of ASTM 4619 “Standard Practice for
Inspection of Linings in Operating Flue Gas Desulfurization Systems”.
11.3.4 If concrete repairs are necessary cut back the lining 150 mm from the ‘repair’ zone to
prevent damage then complete all necessary repairs in accordance with this specification.
11.3.5 Remove any loose or de-bonded lining by scraping or sanding.
11.3.6 Grit blast the exposed concrete surfaces to the requirements of section 9.1 above with the
requirement of surface profile and then remove all grit residues.
11.3.7 Wash down the grit blasted surfaces with a 1% solution of potable water and sodium
bicarbonate at high pressure then rinse down with clean potable water. Remove all
excess water and allow the surfaces to dry.
11.3.8 Feather back the lining edge for a distance of 50 to 75 mm all round the damage to form a
neat square or rectangular for lining repair.
11.3.9 Re-blast the repair area to the requirements of this specification section 9.1 above.
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11.3.10 Vacuum the area to remove dust.
11.3.11 Apply with layers of basecoat material, checking wet film thickness to achieve proper
lining thickness. Follow the procedures of sections 9.2, 9.4 & 9.5 of this specification.
11.3.12 Apply a layer of topcoat material, checking wet film thickness to achieve proper lining
thickness and taking care to overlap the topcoat no less than 25 mm over the existing
prepared topcoat. Follow the procedures of sections 9.2 and 9.7 of this specification.
11.3.13 After cure, re-spark test the repair area only in accordance with sections 10.7 above.
12.0 QUALITY CONTROL DOCUMENTATION
12.1 The following data shall be recorded in the Field Quality Control Inspection Record Forms.
(a) Wet-bulb temperature, dry-bulb temperature, surface temperature, relative humidity and
dew point in the work area before the start of each work shift and at intervals of not less
than 4 hours thereafter. Inspection Form PT-001C.
(b) Concrete and steel surface cleanliness prior to acceptance. Form PT-001A/B.
(c) Concrete construction finish and surface condition prior to acceptance. Form PT-001B.
(d) Concrete surface preparation. Form PT-001D.
(e) Steelwork construction (where applicable) prior to acceptance. Form PT-001A.
(f) Steelwork surface preparation (where applicable) prior to acceptance. Form PT-001D.
(g) Priming and surface patching. Form PT-001E.
(h) Wet film thickness of basecoat and topcoat. Form PT-001J.
(i) Dry film thickness of lining system (where applicable). Form PT-001K.
(j) The number of pinholes and their location in accordance with Section 10.7 Form PT-001L.
(k) Batch number of lining materials used referencing location and equipment number.
Forms PT-001E, PT-001F and PT-001G..
(l) The results of styrene sensitivity tests. Forms PT-001E, PT-001F, PT-001G and PT-001H.
(m) Quality of compressed air. Form PT-001D.
(n) Quality of blasting grit. Form PT-001D.
(o) Non-conformance report. Form PT-001M.
(p) Final visual inspection and release. Form PT-002.
(q ) Pull-Off Adhesion Test Record. Form PT-001N
(r ) Barcol Hardness Test Record. Form PT-001Q
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12.2 Quality control record forms are attached and listed below:-
w PT-001A - Acceptance Inspection of Steel Equipment

w PT-001B - Acceptance Inspection of Concrete Equipment
w PT-001C - Psychrometric Readings
w PT-001D - Surface Preparation
w PT-001E - Priming and Patching
w PT-001F - Basecoat
w PT-001G - Topcoat
w PT-001J - Wet Film Thickness Summary (Concrete Substrate)
w PT-001K - Dry Film Thickness
w PT-001L - Spark Test
w PT-001M - Non-Conformance Report
w PT-002 - Final Visual Inspection and Acceptance
w PT-001N - Adhesion Test Record
w PT-001Q - Hardness Record
13.0 QUALITY CONTROL INSPECTION PROGRAM
13.1 Nominated owner inspections shall be arranged in accordance with any documented
requirements. These inspections shall be coordinated with IP TSR, inspection/testing as
described at section 10.0 and 13.2 below where applicable. This is particularly relevant for spark
testing since additional or repeated spark testing may be damaging to the lining and should not
be performed without prior written approval of IP.
13.2 The QC inspection program shall be as set out in the Inspection and Test Plan.
14.0 Material Shelf Life Date Expiry
14.1 Where a lining material batch shelf life date expires before the material is fully consumed the
balance of the affected batch shall be quarantined and withheld from further use until approved
for use by the Technical Manager.
14.2 Where shelf life date expired material appears suitable for use and is free from gelling and hard
settlement it shall be pot life tested by IP TSR in accordance with manufacturing quality control
procedures and the results reported to Technical Manager for comparison with original
manufacturing QC results and current testing of retained samples.
14.4.3 The Technical Manager shall authorize to IP TSR the use of any shelf life date expired material
based on acceptable testing results and assessment. Where such materials are authorized for
use the written instruction shall form part of the prescribed quality records of the project. Such
authority shall be valid only for 30 days at which time the material must be retested successfully
for pot life and confirmed free of gelling or hard settlement prior to re-authorization for a further 30
days.
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15.0 SAFETY
15.1 The Project Site Manager shall appoint one Safety Representative to be responsible for the
safety of construction/ lining works to be carried-out on site.
15.2 The Safety Representative shall be responsible for the implementation of the site safety
procedure, safety target and other safety and first aid requirements of the client.
15.3 The Safety Representative or his deputy shall attend scheduled safety meetings of the client and
submit to the client all required safety reports.
15.4 The Safety Representative shall attend all site tool box meetings and at such time ensure that all
personnel are aware of the safety requirements and procedures for the work.
15.5 The Safety Representative shall ensure that all required and valid work permits, including
confined space entry permits are in place prior to commencement of work.
…… END……..
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APPENDIX A
Metric Mixing Ratio (Volume)

For Ceilcote 242MR Flakeline
Ceilcote 380 Primer : Two Percent (2%) Hardener No. 2 to Ceilcote 380 resin
or 20 mL Hardener No. 2 per Litre of Ceilcote 380 resin
Conductive Primer : Three Percent (3%) Hardener No. 2 to Ceilcote 380 resin
Ceilcote 380 resin or 30 mL of Hardener No. 2 per Litre of Ceilcote 380 resin
+ C-1 powder
Add 0.144 kg of C-1 Powder per Litre of catalyzed resin
Patching Material : Two Percent (2%) Hardener No. 2 to Ceilcote 380 resin
Ceilcote 380 resin or 20 mL Hardener No. 2 per Litre of Ceilcote 380 resin
+ S-11 powder
Add 2.5 – 3.5 kg S-11 Powder per Litre of catalyzed resin
Ceilcote 242 MR : Two Percent (2%) Hardener No. 2 to Ceilcote 6640 resin
Flakeline Basecoat or 20 mL of Hardener No 2 per Litre of Ceilcote 6640 resin
6640 resin + S-1 Powder
Add 2.3 kg to 2.7 kg S1 Powder per Litre of Catalyzed 6640 resin
Saturating Resin : Two Percent (2%) Hardener No 2 to Ceilcote 6640 resin

6640 resin or 20mL of Hardener No 2 per Litre of Ceilcote 6640 resin
Ceilcote 242 Flakeline : Two Percent (2%) Hardener No. 2 to Ceilcote 242 Flakeline
Topcoat or 20 mL of Hardener No. 2 per Litre of 242 Flakeline
OR 0.30 Litre of Hardener No 2 to 15.14 Litre of Ceilcote 242 Flakeline
Note : Mix only enough materials for immediate use and follow mixing instructions (clause 9.2)
carefully using proper equipment and adequate safety protection.
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APPENDIX B
CEILCOTE 242MR FLAKELINE AND 380 PRIMER

SPECIFICATION
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APPENDIX C
BLANK SAMPLE INSPECTION REPORTS
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PROJECT NO :
LINING Q.C. RECORD ITEM NO :
ACCEPTANCE INSPECTION OF LOCATION :
STEEL EQUIPMENT SIGNATURE
INSPECTION NOTICE NO : BPI SC MES SSP IP PT
CLIENT’S INSPECTOR :
INSPECTOR :
IP'S INSPECTOR :
SPECIFICATIONS OKAY
SUBSTRATE / SURFACE
REQUIREMENT (ü)
CONDITION
Cleanliness
Debris None
Oil or Grease or Contaminants None
Wax Markings None
Standing Water None
Construction
Dimensional Check Complies with
Contract Dwg
Manholes 450 Æ or 300 x 500
Nozzle Design Flanged
Nozzle Sizes ³ 50 mm
Nozzle Lengths see Spec 3-2.2
Abnormal Deflection on Tank Bottom None
Sharp Corners/Edges Rad. 3 mm/6 mm
Inaccessible Parts to Coat/Grind None
Bolt Holes/Perforations Rad. 3 mm/10 mm
Plate Defects: Scabs, Rollovers, None
Laminations
Layout Marks Round Bottom
Internal Components
Attachments Removed
Testing
Hydrostatic Tests & Repair Completed
Welding
Welding, No Intermittent Welds Continuous
Sharp Edges None
Laps / Rollovers None
Undercuts None
Porosity None
Spatter None
Accessibility to Grinding Yes
Smoothness Yes
Additional Comments :
Form No: PT-001A

Inspection Grade: ________
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PROJECT NO :
ACCEPTANCE INSPECTION OF LOCATION :
CONCRETE EQUIPMENT SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
SPECIFICATION OKAY
SUBSTRATE / SURFACE CONDITION REMARKS
REQUIREMENT (ü)
No Debris None
Standing Water None
Dimensional Check Complies with
Contract Dwg
Sharp Edges (3 mm / 6 mm) Radiused
Chamfers and/or Large Radius Yes
Concrete Cure / Dryness (Minimum Confirmed
Acceptable Moisture Contents ≤ 4% by
weight)
Honey Combs None
Structural Cracks None
Surface Contamination None
Laitance (Excessive to Thin Film) None
Curing Agent / Form Oil None
Bug Holes (Excessive to Formed Conc) None
Water Leaks None
Protruding Reinforcement / Tie Bars None
Unbonded Render / Surface Repairs None
Formwork Joints Contoured Yes
Formwork Tie Bar Cone Patching Firm
Concrete Penetration Design (Wall/Soffit) Acceptance
Surface Mounted Equipment Removed
Lining Termination Points Confirmed
Expansion Joints / Isolation Joints Acceptable
Other Joints Acceptable
Surface Strength (Minimum Acceptable Acceptable
Tensile Strength ≥ 1.4 MPa)
Hydrostatic Testing Completed
Additional Comments: ________________________________________________________________

___________________________________________________________________________________
___________________________________________________________________________________
Form No: PT-001B

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PROJECT NO :
PSYCHROMETRIC READINGS LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
DRY W ET REL. SURF. DEW POINT DIFF. REMARKS
DATE TIME BULB BULB HUM. TEMP. °C +/- °C COND.
°C °C % °C
Min. 45 10 3 °C Above Dew
Acceptance Criterions Point Of Air In
Max. 90 43 Work Area
Legend
ACC : Acceptable
NA : Not Acceptable
Form No: PT-001C

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PROJECT NO :
SURFACE PREPARATION LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
Surface Preparation
Date Time Location Comp. Air Abrasive Check
Surface Surface Remarks
Check
Cleanliness Profile
Oil Water Type & Size Chlorides
New copper slag or
No Oil Or garnet abrasive grits: Maximum
Equivalent Of
Moisture Is Concrete Substrate: 250µS/cm Clean, Dry And
Grade 40 To 60
Acceptance Criterions Apparent On Grade 30-60 Of Soluble No Surface
Sand Paper
Test Paper or Hastelloy Cladding / Chloride Contaminations
Roughness
Cloth Mild Steel: Salts
Grade 10-30
Legend:
ACC : Acceptable
NA : Not Acceptable
Note: Where necessary attach location diagram.
Form No: PT-001D

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PROJECT NO :
PRIMING AND PATCHING LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
1st Prime Coat Surface Patching 2nd Prime Coat
Date Time Location Material: _________ Material: ___________ Remarks
Batch No. WFT Resin WFT Batch No. WFT

Batch No.
Form No: PT-001E

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PROJECT NO :
BASECOAT LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
Primer Surface Check Basecoat
Material:
Date Location Wet Film Remarks
Styrene Visual
Cleanliness Batch No. Thickness or
Sensitivity Defects
No. of Layers
Legend:
ACC : Acceptable
NA : Not Acceptable
Form No: PT-001F

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PROJECT NO :
TOPCOAT LOCATION :
SIGNATURE

INSPECTOR :
IP'S INSPECTOR :
Basecoat Surface Check Topcoat
Material: ________________
Date Location Wet Film Remarks
Styrene Visual
Cleanliness Batch No. Thickness or
Sensitivity Defects
No. of Layers
Legend:
ACC : Acceptable
NA : Not Acceptable
Form No: PT-001G

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PROJECT NO :
WET FILM THICKNESS SUMMARY LOCATION :
(CONCRETE SUBSTRATE) SIGNATURE
INSPECTOR :
IPS INSPECTOR :
AVERAGE WET FILM T HICKNESS
LOCATION MATERIAL: __________________ MEASUREMENT SUMMARY REMARKS
BASECOAT T OPCOAT T OTAL T HICKNESS
Form No: PT-001J

- 43 -
\

PROJECT NO :
DRY FILM THICKNESS LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
DATE LOCATION LINING SYSTEM AVERAGE DFT REMARK
DFT READINGS
Form No: PT-001K

- 44 -
\

PROJECT NO :
SPARK TEST LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
Spark Test Data Date of Retest Certification
Date Location Mat’l: ________ Voltage:_ Fault
Number of Faults Repair Initial Date
Form No: PT-001L

Inspection Grade: _______
- 45 -
\

PROJECT NO :
NON-CONFORMANCE REPORT LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
Non-Conformance Noted: .....................................................................................................................

..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
Corrective Action Required: ..................................................................................................................

..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
Date: ................................................................
Non-Conformance
Corrected On: ................................................... Verified By: ...................................................
Comments: ...........................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
Form No: PT-001M

- 46 -
\

PROJECT NO :
ADHESION TEST RECORD ITEM NO :
ASTM D 4541-95 LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
DATE LOCATION REF PULL OFF TEST RESULT (PSI) REMARKS
AREA NO. VALUE OBSERVATIONS
Form No: PT-001N

- 47 -
\

PROJECT NO :
Hardness Record ITEM NO :
B.S. 2782 PART 10, METHOD 1001 : 1977 LOCATION :
SIGNATURE
OWNER’S INSPECTOR :
INSPECTOR :
IP'S INSPECTOR :
RECORDED HARDNESS
DATE LOCATION / AREA AVERAGE
MATERIAL:
Form No: PT-001Q

- 48 -
\

PROJECT NO :
Lining Q.C Record ITEM NO :
FINAL VISUAL INSPECTION AND ACCEPTANCE LOCATION :
SIGNATURE
INSPECTOR :
IP'S INSPECTOR :
LOCATION NON-CONFORMANCE AND REFERENCE REMEDIAL ACCEPTANCE DATE AND I NITIAL
Form No: PT-002

- 49 -
\

APPENDIX D
MATERIALS SAFETY DATA SHEETS
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Attachment-1: Lining of Precast Slab on Ground
(1/2)
132/150
Attachment-1: Lining of Precast on Ground
(2/2)
133/150
Attachment-1a: Lining of Mixing area at Aeration
Basin (1/1)
STEP 2
STEP 3
STEP 2
A
STEP 1
LINING
DIREC
TION
LINING
DIREC
TION
LINING
DIREC
TION
ER
W
PO
E
BL
CA
A
STO
C
M AT K
ERIA
LININ L
G
PAN
EL
STEP 4
COM
PRE
SSO
R
SECTION A-A
134/150
Attachment-2: Organization Chart
Organization Chart (SSP)
(1/1)
ABSORBER FOUNDATION AND SUPER STRUCTURE
SC
Dupty Site Manager
F. UMESAKI
QC/QA
Safety QA/QC Manager
HENDRIK ANANG
HSE/Representative
RISQI
Safety Officer
ERNEST
MES
Project Manager
T. TAKASAKI
Dupty Project Manager

K. YAMAGUCHI
QC
Safety Mgr QA Site Manager Site QC Manager Site Engineering Manager
RIC PHILLIPS Site QA Manager K. ITAGAKI K. OCHIDA H. ARAI
HSE/Representative S. SASAGAWA
Wartono General Construction Mgr
Safety Officer QA Engineer S. MITSUE Chief SV
Febry AGUS SETIYONO Hartono
Construction Leader
T. SHINDO
SSP
Project Manager
GOFAR ISKANDAR
HSE/Security Mgr Technical Manager
SIDIK HIDAYAT ANDREE WIRANGGA
Site Manager
HSE/Representative ABDILLAH MASDUQI
MAHESA
PT Polyline Technologies (Lining Aplicator) PT International Paint (Material Vendor)
Safety Officer
AGUS S, DESY
PUJI Project Manager
Abdul Rohman Marketing
Surveyor Superintendant Site Engineer QC RUSLI ADI N
FAHRUR ROZZI RITAUDIN DAYANTO KURNIA Site Manager Technical Support
Efriyanto TRI RAMDANI S
Supervision
Supervisor Supervisor Mechanic Equipment Logistic Rinja Ugnene M.
Excavation Structural Heru Alifudin Wahyu Safety Officer Supervisor QC
Joko Susanto Anggit Slamet Andress Turiman Mujihantoro
Skill & Unskill Labor, Equipment, Mechanic, Material Control, etc Aplicator Lining/Schaffolder/Electrician/Helper
135/150
Attachment-3: Inspection and Test Plan
(1/3)
INSPECTION & TEST PLAN (ITP) Organization :

ITP Cover Sheet PT. SATYAMITRA SURYA PERKASA Revision 0
SSP Drawing No. Sheet No. : 1 of 1
CHEMICAL LINING WORK INSPECTION & TEST PLAN
Job Name CENTRAL JAVA PROJECT Date : 12-Oct-18
Change Control INSPECTION/TEST/VERIFICATION CODE DOCUMENT DISTRIBUTION
Rev Date Description of Change A1 : Full Inspection/Test
Copy No. Recipient C/UC
A2 : Spot Inspection/Test
H : Hold Point
S : Surveillance
W1 : Full Witness Inspection/Test (100% Witness)
W2 : Spot Witness Inspection/Test
DOCUMENTATION
R1 : Documentation Review
R2 : Spot Documentation Review
F1 : For Information Only
Originated Reviewed Approved

by by by
NAME
Position
Date
Signature
Disc. Ref :
136/150
(2/3)
Doc. No. : SSP/ITP/CJP-020

Company's Name :
PT. SATYAMITRA SURYA PERKASA CHEMICAL LINING WORK INSPECTION & TEST PLAN
Project : CENTRAL JAVA 2 X 1000 MW POWER PLANT Loc. / Structure : ABSORBER TOWER & AERATION BASIN AREA Print Date : 12-Oct-18
Job No. : 1607 - C Revision : 0 Sheet No. :
ACTIVITY / INSPECTION CODE
No WORK ITEM METHOD INSPECTION ACCEPTANCE CRITERIA /REFERENCE VERIFYING DOC. TIME INSPECTION/ FREQUENCY
SSP MES SC BPI
A. LINING WORK PREPARATION

Measurement & Visual
A.1 Instrument & Equipment Project Specification, Method Statement Before being used for testing A1 W1 N/A N/A
Check
A.2 Instrument Calibration Project Specification, Method Statement Calibration Certificate Every one year (12 month) A1 R1 R1 R2
Check
A.3 Concrete Surface Inspection
Measurement & Visual Every prior to commencement of the
A.3.1 - Acceptance Inspection of Steel Equipment Project Specification, Method Statement PT-001A A1 W1 W2 W2
Check lining work/Before Aplication
Every prior to commencement of the
A.3.2 - Acceptance Inspection of Concrete Equipment Visual Check Project Specification, Method Statement PT-001B A1 W1 W2 W2
lining work/Before Aplication
A.3.3 - Psychrometric Reading Measurement Project Specification, Method Statement PT-001C Minimal once every 4 hours A1 W1 W1 W2
Measurement & Visual Every prior to commencement of the

A.3.4 - Surface Preparation Project Specification, Method Statement PT-001D A1 W1 W2 W2
Sound Check & Visual Every prior to commencement of the
A.3.4.1 - Concrete Sounding Test Project Specification, Method Statement SSP.C.Form.CST-01 A1 W1 W2 W2
B LINING WORK APLICATION

B.1 Priming and Surface Patching Project Specification, Method Statement PT-001E During Aplication A1 W1 W1 W1
Check
B.2 Basecoat Project Specification, Method Statement PT-001F During Aplication A1 W1 W1 W1
Check
B.3 Topcoat Project Specification, Method Statement PT-001G During Aplication A1 W1 W1 W1
Check
B.4 Wet Film Thickness Testing Measurement Project Specification, Method Statement PT-001J During Aplication A1 W1 W1 W1
B.5 Dry Film Thickness Testing Measurement Project Specification, Method Statement PT-001K After Aplication A1 W1 W1 W1
Project Specification, Method Statement, ASTM
B.6 Spark Testing (Pinholes) Visual Check PT-001L After Aplication A1 W1 W1 W1
D5162 and ASTM D4787
B.7 Styrene Sensitivity Visual Check Project Specification, Method Statement PT-001E, PT-001F, PT-001G, PT-001H After Aplication A1 W1 W1 W1
Project Specification, Method Statement, ASTM
B.8 Compressed Air Quality Measurement PT-001D Minimal once every 4 hours A1 W1 W1 W1
D4285
Project Specification, Method Statement, ISO 11127-
B.9 Blasting Grit Quality Measurement PT-001D once for each designated batch of grit A1 W1 W1 W1
6
Project Specification, Method Statement, ASTM D
B.10 Adhesion Testing Measurement PT-001N After Aplication A1 W1 W1 W1
4541-85
B.11 Hardness Testing Measurement PT-001Q After Aplication A1 W1 W1 W1
C LINING WORK REPAIR
C.1 Non-Confermance Report Project Specification, Method Statement PT-001M If any damage A1 W1 W1 W2
Check
C.1 Final Visual Inspection and Acceptance Project Specification, Method Statement PT-002 If any damage A1 W1 W1 W2
Check
137/150
Page 1 of 1
(3/3)
Date
SSP.C.Form.CST-01
CONCRETE SOUNDING TEST RECORD

Rev. 0
Report No. Page
of
CJP/MES-SSP/
Project : Central Java Project 2 X 1000 MW Contract No : 1607 - C
Owner : PT. Bhimasena Power Indonesia Structure : □ Civil □ Architectural
Client : MES JO
Noted : Records only for surface need repair

Hammer Sound Hammer Sound
Result Result
No. Location Photo Before Repair Photo After Repair Remarks
OK Not OK OK Not OK
1 See attachment Photo

□ □ Photo
□ □
2 See attachment Photo

□ □ Photo
□ □
PT. SSP MES SC BPI
Print Name
Signature
Date
138/150
Attachment-4: Risk Assessment
(1/12)
PT. Satyamitra Surya Perkasa
CENTRAL JAVA PROJECT
General Engineering & Construction Hazard Identification, Risk Assessment & Preventative Measures
Pages 1 of 10
Doc Rev. 1
Doc no.
NOTE; THIS IS THE MASTER HIRADC. ANY CHANGES OR COPY SELECTION  APPLICABLE
ADDITIONAL INFORMATION MUST BE HIGHLIGHTED. AND PASTE INTO STATUS NOT APPLICABLE
: : :
Day/Date Thrusday, august 16, 2018 Location ABSORBER TOWER Job PerformedBy SSP
:
Job Description
Residual Additional Control

Initial Risk
Impact - Risk Improvement
Hazard Legal &Other
Probability
Probability
NO Risk Category Impact - Risk
Status
Severity
Severity
Requirement Initial Control
Risk
Risk
1 Communication - Lack of effective - Poor 3 A M - Supervisor will conduct a 1 E L - Every employee
toolbox talks preparation well prepared and effective shall sign the
and - Ineffective toolbox talk to all workers toolbox talk
APPLICABLE
participation. task - Allow for questions and - The toolbox talk
Poor knowledge discussions will stipulate
communication everything that
has been
discussed.
- Retain the proof in
the HSE system.
A
P
2 . PPE - Falling objects - Injury 3 A M Act 1/1970 on - General related PPE - 1 E L - Protect other
139/150
(2/12)
Pages 2 of 10
Doc Rev. 1
Doc no.
Requirements - Struck by safety Safety helmet, safety people with

- Step into gloves, eye protection, welding screens
- Cut by PER/MEN/1/19 safety shoes/boots, clothes - Protect people
- Pinch 80 on reflection, ear protection, below by using
- Burn Construction dust masks. welding blanket
- Drown Safety - Welding – Apron, welding - Defective PPE will
helmet compatible with be
PER 4 MEN safety helmet, welding destroyed/dispose
1985 Driven gloves, kerpus. d of immediately.
machinery - Drowning protection – Life - Supervisor and
- Vest Safety officers will
Act 32/2009 - WAH –Double lanyard body ensure that all
Environmental harness – Safety helmet employees is
chin strap equipped with
Per 1 - For sand blasting, special good PPE
MEN/1982 suits and breathing
Pressure apparatus must be used
vessels - Working with chemical
material – use respirator
MEN/187/1999 chemical mask equipped
Per4 Men/1988 by cartridge
3 Supervision - Unsafe actions - Slip – trip – 3 A M Electrical 1 E L If a Supervisor need to
- Qualified supervisor
APPLICABLE
fall appointed as HSE leave the working
- Unauthorized Manpower Act representative always area, he must be
smoking 13/2003 present replaced by another
Water Service - Qualified Safety officer qualified person.
regular inspections
Act 16/2005)
Fire
4 Ergonomics - Poor working - Injury 3 A M Prevention - Ensure to maintain 1 E L Regularly complete
position - Strain/Sprain comfortable body position Ergonomics check-list
- Lifting/pulling during working conditions. to ensure compliance
Reg. Kep
and retain in HSE
APPLICABLE
activities - Refrain from continuous
186/Men/1999 system
- Office activities. bending position
B3 control
- Chair - Max weight per man=25Kg
/table/work and woman 20Kg
bench
positioning
140/150
(3/12)
Pages 3 of 10
Doc Rev. 1
Doc no.
Vibrations - Carpal Tunnel - Use good insulated hand The higher the
HAVS Syndrome gloves vibration, the lesser
(Hand/Arm - Pad machine grips to time of operation at
Vibration absorb vibration one time.
Syndrome) - Alternate operator every 30 Maximum value of
APPLICABLE
minutes frequency weighted
acceleration (12 m/s2)
in any direction* not
more than 1 hour per
day.
5 Environmental - Poor / Unsafe - Slip/Trip/Fall 3 A M - Supervisor will ensure 1 E L - Remove

Impact Housekeeping - Step onto nail regular cleaning and proper construction/unwa
Poor/unsafe - Cut/scratch stacking and storage is nted material
APPLICABLE
Stacking and done during the day. ASAP
Storage - Donate recycle
practice regularly and
retain proof
thereof.
- Prevent huge
accumulation.
- Poor Hygiene - Bad odor 3 A M - Supervisors shall ensure 1 E L - Empty domestic
- Domestic waste - Poor health that toilets are maintained waste bins
bins not - Environmental as per schedule and regularly
maintained spill checklist - Ensure domestic
APPLICABLE
- Toilets not - Do not overfill domestic waste bins have
maintained waste bins and ensure they lids
are sufficient and effectively - Retain proof of
positioned. toilet checks and
domestic waste
bins management
in the HSE system
Noise - Local 3 A M 1 E L - Supervisors are
APPLICABLE
- Noise measurement shall
community be recorded as required. responsible to
disturbance - Areas with 85dB and more ensure
- Hearing requires ear protection and compliance
damage danger signs.
141/150
(4/12)
Pages 4 of 10
Doc Rev. 1
Doc no.
Illumination - Slip/trip/fall 3 A M - Minimum illumination 100 1 E L - Supervisors and

Lux Safety officers will
APPLICABLE
- Ensure sufficient lighting for ensure
the specific job task. compliance
- Access into
under-illuminated
areas only
allowed with a
torch/lamp.
Poor B3 Spillage/waste 3 A M - Oil/fuel storage bunds 1 E L - material regularly
management exposed to the properly covered to - removal by the
environment prevent water appointed B3
accumulation vendor controller.
- Bunds are water tight
- B3 waste to be contained at
the waste storage area
- Mobile vehicles/equipment
and fuel-driven
generators/pumps, etc
APPLICABLE
protected by possible
leakage with bund
6 Working at - Fall - Serious injury 5 A E - See Step 1.1 on PPE 2 D L - Scaffolding

Heights or death - Ensure solid hand railing certified safe by
installed scaffold inspector
APPLICABLE
- Ensure lifelines secure, - Installation of life
sufficiently tensioned and lines and vertical
double clamping both ends. fall arrest
- Ensure every floor opening equipment
closed with solid fall declared safe.
protection. - Ensure 100%
- Areas to be sufficiently hook-up on
illuminated after hours. heights.
O
N
7 Excavation - Engulfment - Serious 5 A E - Ensure that the excavation 2 D L - Proof of daily
142/150
(5/12)
Pages 5 of 10
Doc Rev. 1
Doc no.
work - Fall into injury/death Edge slopes has been excavation

- Suffocation declared safe by inspections to be
- Confined space engineering retained.
- Poor access or - Ensure that the excavation - Maintain solid fall
egress is inspected daily. protections
- Ensure sufficient protection - Maintain soft
against flooding. barricading and
- Ensure solid fall protection danger signs.
on edges closer than 2 - A ladder will be
meters (soft barricading available for exit
may be installed on or access every
minimum 2 meters from the 12 meters.
edges with danger signs)
8 Hot works - Fire - Injury/burns 3 C C - See Step 1.1 on PPE 2 D L - Maintain good and
(Welding, - Damage - Ensure that a powder fire clean
APPLICABLE
grinding, extinguisher is close-by housekeeping.
cutting) - Ensure that the area is clear
from burnable, flammable,
explosive material.
9 Electrical - Electric shock - Injury/burns 5 A E - Ensure that all electrical 2 D L - Ensure that
Safety - Fire - Damage regular checklists
tools are checked to be safe
- ELCB not - Ensure that electrical cable are done by
A APPLICABLE
installed or leads and plugs are water electricians and
functional proof and off the ground retained in the
from wet surfaces HSE system
- Ensure that ELCB is - Ensure that
installed on the DB boards Electricians are
qualified.
P
10 Manual Tools - Poor tool - Injury 3 A M Check tools before use to 1 E L - Ensure that
143/150
(6/12)
Pages 6 of 10
Doc Rev. 1
Doc no.
maintenance be in good/safe condition regular checklists

(Chisels – remove) are done and
mushroom regularly) retained in the
- Refrain from using home- HSE system
made tools
11 Fire Prevention - Firefighting - Injury/Damage - Keep in a dry/shielded 2 D L -Every Fire

equipment not place extinguisher shall be
maintained - Remove from site on a monthly checklist
when any rust evident - Ensure serviced as
- Check normal per service provider
pressure and sealed. routine.
- Retain proof of
checklist in HSE
system
APPLICABLE
12 Transport - Accident/coalition - Injury/Damage - Supervisor must be in 2 D L - “On-Site” vehicles
NOT APPLICABLE
control during the must be checked
transit operation of daily by checklist
deliveries to be in good/safe
- An experienced condition. Retain
flagman in control of proof in the HSE
vehicle movement. system.
13 - Loading, Crane - Crane topple 2 D M - Prevent people underneath 1 D L - Crane operator
O
N
144/150
(7/12)
Pages 7 of 10
Doc Rev. 1
Doc no.
Unloading Operations over suspended loads, and crane

and lifting - Poor - Injury/death - Apply taglines on both certified.
operations Supervision - Damage sides of the lifted material - All lifting and
- Poor soil - Boom for stability. rigging work to be
stability Collision - Apply whittle warning done by
- Failure to follow - Toolbox talks before work competent and
the procedure - Communicated lifting plan trained personal
- No flagmen in - Inspect Crane to be safe - Ensure flagmen
control - Inspect Lifting Gear are experienced
- Poor and color coding and trained
maintenance Ensure crane proximity - Maintain proof of
- Swing not demarcated and safe equipment
controlled distance from other inspections and
equipment. color coding in
Maintain effective radio HSE system.
communication with crane - Ensure no person on
operator. top or underneath a
- Ensure stable soil stability. crane during
If in doubt, apply base operation.
plates. - Before unloading
mobile equipment
from a trailer, ensure
that it is checked to
be safe and
operational.
- Manual - Injury 3 A M - Ensure that the lifting rope - Do not exceed 25
NOT APPLICABLE
Operations - Damage and pulley assembly is Kg of weight
Overhead pully inspected and safe to use. - Ensure to have a
- Barricade the ground floor helper.
area.
- Ensure that the material
lifting bucket is secure and
safely attached to the rope.
14 Re-bar - Poor Injury 3 A M - Do toolbox talk before start - Ensure
APPLICA
operations Supervision - Struck by working continuous
NOT
- Poor - Cut/scratch - Apply PPE – see Step 1 Supervision and
housekeeping, - Slip/trip/fall - Ensure good housekeeping Safety officers
stacking and - Pinch – See step 4 inspection.
145/150
(8/12)
Pages 8 of 10
Doc Rev. 1
Doc no.
storage - Puncture - Focus on the job - Retain proof of

practices - Safe lifting operations – see inspections in the
- step 12 HSE system.
- Cap dangerous re-bar.
15 Concrete - Install - Struck by - Apply PPE – see step 1 - Formwork is

Activities formwork - Cut/scratch - Prevent splash of concrete heavy. Team work
NOT APPLICABLE
- Slip/trip/fall into eyes. is important. Rely
- Pinch - Focus on Ergonomics – on
See step 4 crane/mechanical
- WAH – see step 6 assistance.
- Control B3 – see step 5 - Ensure formwork
(formwork lubrication). is stable and
sufficiently
supported.
Pouring - Injury - Ensure concrete pump is - Apply warning
NOT APPLICABLE
Concrete - Damage stable withoutriggers on signs.
-. Unstable - Fall down/into solid soil surfaces - Beware of
concrete pump - Restrict access close to restricted area or
- Too close to concrete pump. excavations.
excavations. - Use base plate if
Restricted area. necessary
16 Weather Wet conditions - Slip/trip/fall 3 A M - Avoid excessive wet areas - Maintain an

conditions - Slippery where possible increased safe
NOT APPLICABLE
- Maintain safe distance from following distance
road edges
- Refrain from driving on
muddy soil roads if
possible.
146/150
(9/12)
Pages 9 of 10
Doc Rev. 1
Doc no.
Dusty/windy - Vehicle - Use PPE – see step 1 1 E L - Monitor predicted
APPLICABLE
conditions accidents - Related contractors to do weather forecasts
- Poor visibility - Health issue effective dust suppression.
Unhealthy - Local
environment Community
complains
17 Pressurized Poor - Explosion - Ensure that the pressure 1 E L - Retain proof of

Equipment Maintenance - Rupture vessel has a certificate of vessel inspection
- Injury compliance in the HSE
APPLICABLE
- Ensure safety valve system.
installed and sealed - Ensure that the
- Ensure that air pipe hoses are of the
connections to the vessel correct rating.
are secured by standard
clamping - Do NOT use this
- Ensure that good pressure air to clean/blow
gauges are installed people.
18 Scaffold Erection - Poor - Collapse 5 A E - Ensure that scaffold 1 E L - Ensure that the
and dismantling Supervision, - Injury/death erectors are medically fit scaffold erector
inspection and - Ensure that the scaffold applies the
maintenance inspector is qualified. GREEN/RED
- Ensure that he inspects the tagging system.
scaffolding regularly - Ensure to comply
APPLICABLE
- Apply sufficient warning with OSHAS 18001
signs standards. Do not
- Prevent people from throw anything
working underneath down to the
scaffolding. ground. Use tag
- Apply fall protection netting ropes.
when required.
- Dismantling scaffolding
must be done controlled
and a red tag must be
applied.
19 Rotating or - Poor - Pinch 5 A E - Rotating equipment shall - Supervisor to
O
N
147/150
(10/12)
Pages 10 of 10
Doc Rev. 1
Doc no.
Sliding Supervision, - Struck by be safely guarded perform careful risk

equipment inspection and - Cut/scratch - No not wear loose clothing assessment.
maintenance - Rotate or long hair with rotating - Beware of sliding
equipment. equipment which
- Apply danger signs could cause
pinching
20 Earth Moving - Dump trucks - Injury - All equipment shall be Ensure loading and
works - Graders - Damage checked to be safe for unloading soil areas
NOT APPLICABLE
- Compactors operation every day. for dump trucks are
- Front-end - Ensure that an experienced securely compacted
loaders flagman control the moving to prevent trucks from
- Excavators activities. toppling-over.
- Prevent operations close to Monitor operators for
excavations. fatigue. Rest enough
- Ensure operators to be
certified.
21 Radiography X-Ray - Injury 5 A E - Ensure that the - Isotopes kept on
exposure - Death Radiography delivery site overnight shall
vehicle has related be stored in a
NOT APPLICABLE
signage on all sides. certified bomb-pit.
- The storage box shall - Radiography shall
be sufficiently be done after-
insulated and secured hours and all
on the truck warning signs and
- Operators shall be rotating lighting
- equipped with displayed as per
exposure meters. requirements.
22 Confined Spaces - Poor - Asphyxiation 5 A E - Ensure high level of 1 E L - Work with PTW
A
P
148/150
(11/12)

Pages 11 of 10
Doc Rev. 1
Doc no.
Supervision. - Explosion access control - Supervisor must

- Poor Access - Dehydration - Follow site procedure apply strict control
control - Regularly test gas and - Ensure to have a
- Dangerous oxygen levels. fire extinguisher
gasses and - Ensure good insulated close-by.
low oxygen lighting. - Persons who will
levels act as stand
byEnsure good
communications
with access
controller outside
- Provide Look
Book entry
confined space
area perform time
rotating system
- Install adequate
Blower / exhaust
ventilation
-
23 Deep Water Poor - Drowning 5 A E - Wear a life jacket on or - Supervisors shall

supervision - Motion close to water. ensure
sickness Diving compliance.
- Dizziness, - Check and inspect diving - Keep equipment
fatigue and gear and equipment checklists in the
regularly as per checklist HSE system as
nausea
- Strict adherence to the proof of
diving plans. compliance.
Boating - > than 1.2 meters
N/A
- Do not overload the boat. depth is
- Ensure safe railings to considered unsafe.
prevent pinching against - < than 2 meters to
objects. water edges is
- Ensure safe mooring under considered as
supervision. unsafe.
- Prevent mooring in high - Working above
wave conditions. water may also
require fall
protection.
149/150
150/150

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International Paint Singapore Pte Ltd 3, Neythal Road T +65 6663 3536

Singapore 628570 F +65 6264 4612

INSTALLATION PROCEDURE SPECIFICATION

APPLICATION OF CEILCOTE 242MR FLAKELINE

CONCRETE ABSORBER &

MIXING ZONE OF THE AERATION BASIN

CENTRAL JAVA, 2 x 1000MW COAL FIRED POWER PLANT

5 10th Dec 2018 REVISION ALAN Sean Kim Rusli

Procedure No.: CJAVA-0342-001

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

TABLE OF CONTENTS PAGE

1.0 SCOPE OF W ORK ....................................................... 3

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

1.0 Scope Of Work

2.0 APPLICATOR PRE-QUALIFICATION

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

4.0 CODES, STANDARDS AND DOCUMENTS

4.2 Ceilcote Product Technical Bulletins:

4.3 Reference Standards

ASTM D 4258 Practice for Surface Cleaning Concrete for Coating

ASTM C 811 Surface Preparation of Concrete for Application of Chemical Resistant

ASTM D4580 Standard Practice for Measuring Delamination in Concrete by Sounding

ASTM D 4259 Standard Practice for Abrading Concrete

NACE Standard Lining Over Concrete for Immersion Service

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

5.0 FACILITIES AND EQUIPMENT

5.4 Compressed Air Quality

6.0 CONCRETE SPECIFICATION

6.1 General Design

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

Sharp Edges Formwork Mis-Alignment

Protruding Tie Bars Tie bar Holes

Wood Debris & Water Leakage Mortar Repair

6.2 Compressive Strength

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

6.3 Surface Strength

6.4 Finishing Methods

6.5 Surface Curing and Hardening Treatments

6.6 Concrete Cure Time

6.7 Determining Dryness

6.8 Concrete Sounding Test

6.9 GRP Inserts

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

7.0 SURFACE PREPARATION

7.1 Common Requirements (Concrete and Steel Preparation)

7.2 Concrete Preparation

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

(a) Surface temperature is above 43°C or below 10°C.

8.0 LINING SPECIFICATION

8.1 Absorber Internal Lining

8.1.2 System Design

Thickness range : 2.5 – 3.2 mm

CENTRAL JAVA 2 X 1000MW COAL FIRED POWER Doc. No. : CJAVA-0342-001

8.2 Cure Time

9.0 LINING APPLICATION

9.1 Blast Cleaning

9.2 Product Mixing

9.3 Priming / Conductive Priming