Refer to 3411 STRUCTURAL STEELWORK for fabrication of structural steelwork.

Refer to the general section 1232 INTERPRETATION & DEFINITIONS for abbreviations and definitions used throughout the specification.

The following abbreviations apply specifically to this section:

Refer to the general section 1233 REFERENCED DOCUMENTS.  The following documents are specifically referred to in this section:

Health and Safety at Work Act 2015

Manufacturer's and supplier's documents relating to this part of the work:

Resene / Altex Coatings / Carboline® Product Data Sheets

Resene / Altex Coatings / Carboline® Safety Data Sheets

Manufacturer/supplier contact details

Provide a material manufacturer/supplier warranty

• Provide this warranty on the manufacturer/supplier standard form (if not available then use the standard form in the general section 1237WA WARRANTY AGREEMENT)
• Commence the warranty from the date of practical completion of the contract works.
• Condition of Warranty - Products must be applied in accordance with application and preparation procedures specified in AS/NZS 2312.1, Resene / Altex Coatings Ltd Specification and Product Data Sheets.

Refer to the general section 1237 WARRANTIES for additional requirements.

Provide an installer/applicator warranty:

• Provide this warranty on the installer/applicator standard form (if not available then use the standard form in the general section 1237WA WARRANTY AGREEMENT)
• Commence the warranty from the date of practical completion of the contract works.

Refer to the general section 1237 WARRANTIES for additional requirements

For intumescent coatings, applicators to meet the requirements of FPANZ Code of Practice for the Specification and Application of Intumescent Coatings for the Fire Protection of Structural Steel. If one or more of the FPANZ Code of Practice conditions are not met, an accredited third-party coatings inspector should be engaged to oversee application.

Trained and approved applicators are required for applying Altex Nullifire SC902.

Refer to 1270 CONSTRUCTION for additional requirements relating to qualifications.

Substitutions are not permitted to any of the specified Resene Paints or Altex Coatings Systems, components and associated products listed in this section without the express written approval from Altex Coatings Technical Services.

Refer to the general section 1270 CONSTRUCTION for details of how samples will be reviewed and how instructions to proceed will be given.  Provide the following samples for review:

Contact Altex Coatings Ltd before the shop or on-site application of fireproofing where a manufacturers product supply verification statement is required.

Provide the following compliance documentation:

• Applicator’s approval certificate from the distributor
• Manufacturer / supplier warranty
• Applicator warranty
• Applicator Quality Assurance Records - applicators QA Procedures and Inspection Test Plan (ITP) & records
• Producer Statement - Construction (PS3) from the applicator including supplier Intumescent Paint manufacturer’s - Fire Loading Schedule with the required Dry Film Thicknesses and floor plans identifying location of intumescent coatings.
• Producer Statement - Construction Review (PS4) from consultant engaged by client.
• Third Party Inspection certification
• Other information required by the BCA in the Building Consent Approval documents including maintenance, fire rest reports, remedial specification

Maintain quality assurance programs to AS/NZS ISO 9001 for surface preparation, environment conditions and coating application, as necessary to ensure that work is performed in accordance with this specification and the qualifying requirements of the contract documents.

Any reduced passive fire protection system performance which may result from the steel preparation and / or selection of specified coatings not being followed in accordance with the specification is outside the control of Resene Paints Ltd.

Notify of Hold Point work/item, do not to proceed further with work/item until advised to continue.

Inspection of the work is to take place at each of the stages as scheduled. Refer to SELECTIONS.

Confirm a written program to facilitate these inspections, including notification when each stage of the work is ready for inspection.

If qualification requirements are not met, engage a third-party independent accredited inspector to verify that the work has been carried out in accordance with the required standards and provide certification of compliance. Confirm a written programme to facilitate these inspections by an Independent Inspector, including notification when each stage of the work is ready for inspection.

All coatings inspections are to be carried out by a minimum  AMPP CIP level 1 Certified Coating Inspector (or equivalent such as CBIP Protective Coating Inspector) who has experience with intumescent coatings.

Permit the paint manufacturer to inspect the work in progress and to take samples of their products from site as requested.  This is not deemed independent inspection but supplier site assistance to help with advice and guidance only.

Test for dry film thickness of all intumescent paint system individual coatings and overall system thickness in accordance to AS 3894.3 and in accordance with FPANZ Code of Practice for the Specification and Application of Intumescent Coatings for the Fire Protection of Structural Steel.

Refer to the requirements of the Health and Safety at Work Act 2015 and WorkSafe: Guidelines for the provision of facilities and general safety in the construction industry.  If the elimination or isolation of potential hazards is not possible then minimize hazards in this work on site by using the proper equipment and techniques as set out in the MPNZA Health and Safety Program. Supply protective clothing and equipment. Inform employees and others on site of the hazards and put in place procedures for dealing with emergencies.

Obtain from Resene Paints Ltd & Altex Coatings Ltd the safety data sheet for each paint product used and comply with the required safety procedures. Keep sheets in application shop and on site.

Use only Resene Paints Ltd & Altex Coatings Ltd products which are guaranteed for consistency and performance under AS/NZS ISO 9001 and when prepared, mixed and applied as directed in the Resene Engineered Coatings Systems & Altex Coatings Ltd Coatings Manual or refer to www.resene.co.nz, www.altexcoatings.co.nz.

Southwest™ Type 5GP, a cementitious, non-combustible, inorganic fireproofing product, tested to AS 1530.4 and BS 476.21.  Available as a spray-on, single component powder mixed with clean water providing a 30-to-240-minute fire rating for interior structural beams, columns and hollow sections.  Refer to SELECTIONS.

Can also be used on steel joists, decks, walls, roofs, girders, floors and precast units.

NOTE: Southwest Type 5GP does not provide any corrosion protection to the steel substrate.  Refer to Altex Coatings if corrosion protection is required.

Nullifire® SC601, solvent based single component, fast drying intumescent coatings, tested to BS 476.21.  Applied by airless spray, it provides fire protection of interior steel against structural failure for up to 60 minutes. Refer to SELECTIONS.

Nullifire® SC802 Series single component fast drying water-based intumescent coatings tested to BS 476.21.  Applied by airless spray, they provide fire protection of interior steel against structural failure for up to 120 minutes. Refer to SELECTIONS.

Nullifire® SC902, a fast track two-component intumescent capable of being applied as a thin film up to high film thicknesses in a single coat application.  Applied by airless spray it provides fire protection of interior and exterior steel against structural failure for up to 120 minutes. Refer to SELECTIONS.

Resene Paints Armourcote 220 is a high performance inhibitive barrier chemically cured epoxy primer. Complies with AS/NZS 3750.13.  May be applied over mild steel for interior and exterior use. Refer to SELECTIONS.

Carboguard® 635, a two-component epoxy coating suitable for use as a corrosion resistant primer or as an epoxy intermediate coat. May be applied onto mild steel and hot-dip galvanized steel (HDG), for interior and exterior use. Refer to SELECTIONS.

Armourzinc 120 and Armourzinc 125 are two component, high solids, zinc rich epoxy primers for the protection of steel surfaces, where high corrosion resistance is required. Applied by conventional or airless spray methods. Refer to SELECTIONS.

Pro-Seal® Intumescent Seal Coat, a single pack solvent-based coating used as a seal coat over Nullifire® SC601 Intumescent base coat to provide protection from weather, rain and moisture as well as seal the intumescent prior to applying polyurethane finish coats. Also used to promote the cure of Nullifire® SC601 to achieve a Shore D50 level of hardness before finish coating. Refer to SELECTIONS

Uracryl 400 Series aliphatic acrylic urethane finish for interior and exterior suitably primed structural steel.  Available in a range of colours and gloss levels. Refer to SELECTIONS.

Imperite IF 503 & Imperite IF 502 (Semi-Gloss) epoxy reactive acrylic finish for interior and exterior suitably primed structural steel.  Available in a range of colours and gloss levels. Refer to SELECTIONS.

Enamacryl (Gloss) or Lustacryl (semi -gloss), or Spacecote (Low Sheen) new generation acrylic enamel finish for interior and exterior suitably primed structural steel. Available in a range of colours and gloss levels. Refer to SELECTIONS.

Refer to SELECTIONS for type.

Refer to 1270 CONSTRUCTION for requirements relating to delivery, storage, and handling of products. Store paint containers in accordance with selected product Technical Data Sheets and any Health and Safety at Work (Hazardous Substances) regulations.

For off-site coated steelwork, implement protective measures and care during transport, storage, and erection of steelwork. If off-site steelwork is to be stored for pro-longed periods and exposed to the weather, stack, and cover to eliminate ponding of water and periodically wash down to remove surface contamination.

Refer to 1250 TEMPORARY WORKS & SERVICES for protection requirements.
Refer to 1270 CONSTRUCTION for requirements relating to defective or damaged work, removal of protection and cleaning.

Check work previously carried out and confirm it is of the required standard for specified finish. Carry out such additional preparatory work as required to bring the substrate to suitable condition.

Carry out off-site and on-site preparation and coating application in accordance with conditions as per Technical Data Sheet for specified Resene / Altex products.  Do not carry out preparation or painting when the ambient relative humidity exceeds 85%, or when the steel surface temperature is within 3°C of the dew point.

For intumescent coating systems, monitor and record environmental conditions before and after application and at maximum 4 hourly intervals as part of the project Q&A documentation. The minimum conditions monitored are:

• Air temperature
• Steel temperature
• Dew point
• Relative humidity

Apply coatings strictly in accordance with the manufacturer's stated requirements. Ensure that the manufacturer's latest product data sheets are available for reference during preparation and painting.

Ensure that materials used, and systems applied are approved by the manufacturer for the surface and conditions of exposure, and that materials used within each painting system are compatible with each other and are from the same manufacturer.

Complete surface preparation before commencing painting. Apply paint in the specified sequence using the specified paint. Allow full drying time between coats to the manufacturer's stated requirements. Do not expose primers, undercoats and intermediate coats beyond a few days before applying the next coat.

Ensure that surfaces being painted are clean, dry and that ambient conditions are such that condensation does not occur before the paint reaches surface-dry condition.

Before handling or applying the next coat of paint, give each coat the required drying time required by the manufacturer.

Where high film builds of intumescent are required, apply in thinner multiple coats.  Ensure that surfaces being painted are clean, dry and that ambient conditions are such that condensation does not occur before the paint reaches surface-dry condition.

Ensure clips, hangars, supports, sleeves, precast concrete panel connections and other attachments specified under other work sections are placed and fixed before the application of the coating.

Protect adjoining surfaces and areas to prevent contamination from overspray or fallout of materials.

Refer to the general section 1270 CONSTRUCTION for general requirements.

Do not paint:

• Faying face of high strength friction grip (HSFG) bolted joints
• Areas for site welding keeping 75mm clear all round

Remove all slag.
Ensure that all cut edges are ground to a smooth 2mm radius.

The following applies:

Pre-clean steelwork to SSPC SP1 (AS 1627.1), then carry out abrasive blasting or power tool preparation after completion of the fabrication.  Apply required coating to the coating manufacturer's requirements.  Apply primer coat within 4 hours of preparation. Work off site wherever possible. Surfaces that are in contact or near contact are to receive specified coating before assembly.

Prepare steelwork in conditions approved for the application of coatings.  Carry out off site preparation and coating applications under cover, in a controlled environment and with adequate lighting.

Remove oil and grease by the use of solvents.  Scrape and power disc prepare to Class St3 standard in accordance with AS 1627.2 (SSPC SP3) and avoid producing a polished surface. Check that no burrs or sharp arrises remain which may prevent full coating thickness to be attained.

Remove oil and grease by the use of solvents.  Abrasive blast clean to Class 2½ finish to AS 1627.4 (SSPC SP10) and achieve a blast profile between 38 - 75 microns. Clean to bright metal but avoid producing a polished surface. Select a suitable blast media type and equipment such that the cleaned surface profile between peaks and valleys does not exceed one third of the dry film thickness. Check that no burrs or sharp arrises remain which may prevent the full coating thickness being attained.

Round all cut edges to a smooth 2mm radius prior to galvanizing.

Do not dichromate quench as part of galvanizing process prior to duplex coating. Remove grease, oil and other solvent-soluble contaminants by solvent wiping with D30 Degreaser/Dewaxer. Allow to dry and proceed with the next operation immediately. Abrade galvanized surfaces via controlled sweep blasting or abrading to a matt finish.

Zinc primers must be free from zinc salts, remove if present. Remove grease, oil and other solvent-soluble contaminants by solvent wiping with Altex D30 Degreaser/Dewaxer. Allow to dry and proceed with the next operation immediately.

All zinc primed surfaces are to be lightly abraded to achieve a surface key. Areas of smooth or glossy surfaces are to be abraded to a matte finish.

Ensure all substrates are clean and free of loose scale, dirt, oil, grease, condensation, or any other substances that would impair adhesion. Degrease steel where necessary and wire brush to remove loose rust.

Ensure building area is watertight before commencing installation. Mix and apply Altex Cementitious fireproofing to prepared substrate in accordance with selected Resene or Altex product Technical Data Sheet and manufacturer's requirements to specified DFT to achieve required FRR.

Each coat of paint and completed paint system to have the following qualities and properties:

• Uniform finish, colour, texture, sheen and hiding power
• Correct number of coats applied and DFT achieved
• Free of defects such as pin holing, alligatoring, blistering, staining, overspray, peeling, runs, sags and wrinkling.

Apply specified Altex or Resene primer to prepared steelwork in accordance with the primer manufacturer's Technical Data Sheet and to the required DFT for the specified Intumescent Coating System, refer to SELECTIONS for details.  Test and record DFT as part of the project Q&A documentation.

The maximum average thickness of primer (measured according to ASFP TGD 11 guidelines) for an item to be coated with intumescent should not exceed a dry film thickness (DFT) of 150 microns. Any single spot reading shall not exceed 250 microns and any 3-point average reading should not exceed 200 microns DFT.

If shop primed, allow for patch priming on site after erection

Clean and prepare areas of damaged priming and areas left clear for site jointing to a standard comparable with the shop cleaning specified. Degrease to remove chemical fume deposits resulting from welding as well other contamination. Apply priming coat/s to same standard as shop primers, ensuring thorough coating of bolts, nuts and connection areas. Re-prime if the primer fails, or more than the specified primer re-coat time has lapsed before the final coating system is applied.

Confirm surface preparation is in accordance with Altex Technical Data Sheet for specified intumescent coating. Ensure surface is clean and dry, ready for intumescent coating. Lightly abrade primer coat to provide a key.

If system includes primer, ensure primer condition is suitable and confirm primer is within re-coat time. Ensure primer DFT summary documentation has been provided however the on-site applicator should carry out their own readings to confirm DFT of primer. Proceeding with the application of intumescent coating implicitly accepts the condition and DFT of primer.

Ensure each steel section is adequately identified and required intumescent coating type and thickness confirmed.

Apply selected Altex intumescent coat/s to coating manufacturer's requirements and the required DFT specified for each fire rated structural steel member. If the on-site application of intermediate and/or finish coats is via brush/roller multiple coats may be required to achieve the nominated dry film thickness.

Spray application (conventional or HVLP) on site is recommended for repair and touch up of MIOX or Metallic finishes.

For shop applied intumescent coatings, allow to mask off areas within 100mm of steel requiring to be site welded prior to shop application. After site welding has occurred allow to clean and prepare area, apply primer and intumescent coating on-site in accordance with manufacturer's requirements.

For fire rated bolted connections allow to apply Intumescent coating at the same DFT of adjacent beam/column, plus finish coat if required.

For galvanized bolts allow to degrease, abrade, and apply an approved primer coat prior to the intumescent coating of galvanized bolts.

Contact Altex Coatings Ltd for FR Galvanized Bolt painting specification.

Apply intumescent coating to the required DFT specified for each fire rated structural steel member. Note the DFT's are item specific and are to be obtained from the Fire Loading Schedule issued by Altex Coatings Ltd. If DFT for fire rated sections are not detailed within, contact Altex Coatings Ltd for details. Refer to SELECTIONS for details.

Where DFT testing has confirmed that intumescent coating DFT is less than acceptable criteria, further application of coating is required. Ensure that the application is within the re-coat time of intumescent coating. Ensure surface is clean, dry and free from contamination, then apply intumescent coating to manufacturers requirements.

Where DFT testing has confirmed that intumescent coating DFT is more than manufacturer's acceptable criteria, contact manufacturer for corrective procedures.

For systems with decorative and/or protective (non-intumescent) topcoat, lightly abrade intumescent coat to provide a key. Apply topcoat / coats by spray, brush or roller in accordance with the relevant product Altex Technical Data Sheet and manufacturer's requirements. Refer to SELECTIONS for dry film thickness.

For systems with decorative and/or protective (non-intumescent) topcoat, if a high-quality aesthetic finish is required, a thorough sand of the Intumescent coating is recommended prior to applying the topcoat. When sanding intumescent coatings always ensure adequate film build is maintained to provide the required DFT.

Unsealed Nullifire SC601 will not withstand prolonged rain/water contact, even under optimum curing conditions during construction. Where exposure to weather, rain and/or water contact may occur, temporary protection must be supplied. Application of Altex Pro-Seal intumescent sealer coat will provide weather protection during construction once the required dry film thicknesses are achieved (refer to Altex Coatings).
Also apply Altex Pro-Seal intumescent sealer to Nullifire SC601 in the following situations:

• when shop applying the intumescent or to mitigate the risk with water, rain or weather contact while in laydown areas or during on-site construction.
• when steel sections are adjacent to glazing which will be in direct sun contact
• to promote the hard cure of Nullifire SC601
• to permit the application of a wide range of architectural finishes.

Ensure that unsealed Nullifire SC601, unsealed Nullifire® SC902, Nullifire® SC802, and Southwest Type 5 GP coated steel sections are not exposed to any water, rain, or moisture contact both during application as well as during the design life (refer to Altex Coatings).

Refer to 1270 CONSTRUCTION for completion requirements and if required commissioning requirements.

Refer to 1270 CONSTRUCTION for general test and certification requirements at completion.

~

Refer to ~ for structural steelwork schedule for Intumescent Coatings.

Hold Point Schedule: