asmeco
PREQUALIFICATION DOCUMENT
Al Sakhra Metal Coating
®
A Division of COREMETAL Group of Companies
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INDEX TO THE PROFILE Title
Page No
Introduction............................................................................. 03 Mission Statement.................................................................. 03 Commitment to Clients........................................................... 03 Services Offered..................................................................... 04 Facilities.................................................................................. 04 Organization chart................................................................... 05 Recent Projects ...................................................................... 06 Manpower ............................................................................... 07 Equipment and Machineries ................................................... 08 Blasting & Painting Standards ................................................ 09 Inspection & Testing ................................................................ 10 Blasting Painting – Process Flow ............................................ 11 Quality control & Assurance .................................................... 12-15 Safety Policy ............................................................................ 16-18 Trade License ......................................................................... 19 Chamber of Commerce Certificate ......................................... 20 ISO 9001-2008 ....................................................................... 21 ISO 14001 - 2004 ................................................................... 22 OHSAS 18001 - 2007.............................................................. 23 Certificates .............................................................................. 24-28 Certificate of Appreciation ....................................................... 29-31 Forms and Formats ................................................................. 32-33
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INTRODUCTION AL SAKHRA METAL COATING (ASMECO) is a privately owned company established in 2013. The firm is floated and managed by hand-on personnel carrying with them the experience and knowledge accumulated for the past decade, especially in projects related to protective coatings of Oil storage tanks, Heavy off shore structure , Oil and Gas plants, Oil rigs, Pipe lines, Floating Bodies, Cement factory, Electric Substations,Chemical Plant and similar occupancies.
MISSION STATEMENT Our objective is to build an Organization that meet the specified and implied needs maintaining an unparalleled corporate integrity and financial strength within the energy sector. We aim to be the leading service provider in Abrasive blasting & Spray Painting in UAE. We shall achieve our aim by focusing on providing quality service to our customer specification
OUR COMMITMENT TO CLIENTS Our prices are always fair as we strive to build not only a successful business, but also lasting relationships with our clients. Commitment to schedule, quality of service shall not be compromised while still working to the budget of our clients and customers
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SCOPE OF SERVICES
ABRASIVE BLAST CLEANING Surface preparation and cleaning to remove all rust, Mill scale, debris, existing paint from the surface as well as to create a surface profile for adhesiveness of subsequent coating
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SCOPE OF SERVICES
WATER BLASTING
For environmentally friendly surface preparation and cleaning
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SCOPE OF SERVICES
SPRAY PAINTING
Application of paint to tanks, equipment, structure, machinery, galvanized item etc.
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SCOPE OF SERVICES
INSPECTION, TESTING AND MONITORING
We have in our possession the most modern “State of the Art” equipment for testing of surfaces being coated and to monitor atmospheric conditions while application of paint so as to comply with the standards promulgated by various international paint manufacturers
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Organisation Chart General Manager
Sales/ Marketing Manager
Sales Team
Accounts Manager
Operations Manager
Marketing Team
Project Engineer
QA/QC
Safety Engineer
Accountant
Supervisor
Blasters
Painters
MAN POWER Sl 1 2 3 4 5 6 7 8 9 10 11
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Designation
Operation Manager ................................................................................. QA/QC Manager ..................................................................................... Accounts.................................................................................................. Project coordinator................................................................................... Store keeper ........................................................................................... Painting supervisor ................................................................................. Painting Inspector ................................................................................... Blaster...................................................................................................... Spray painter............................................................................................ Pot Operators .......................................................................................... Fork Lift Operator.....................................................................................
Nos 1 1 2 2 1 2 1 10 8 8 1
REcent Projects Sl Project name
Client
Main Contractor Metric Ton Country
1 Sheik Zayed Grand Ministry of Masri 500 Mosque (AESS Std residential affairs Engineering Coating)
Abu Dhabi UAE
2 Abu Dhabi Presidential DOPA Mutitech 750 Palace Car parks 3 RO Plant Structures Qatar Water Electricity Acciona 750
Abu Dhabi UAE Qatar
4 CICPA – Island Harbor and artificial Reefs (Al Mirfa CICPA Harbor)
CICPA
AST Overseas
300
Abu Dhabi
5 Car Parking AESS Standard Structures
Kuwait University
Hardco
700
Kuwait
6 FEWA Contract:71E/2015, 132/33/11KV, substation works in Northern Emirates
FEWA
German Steel
300
Ajman
7 Supporting structures for Dubai Al Ghurair 400 Dubai Frame Muncipality 8 Caterpillar project/Pipe Line Madhan Oceaan rubber 30,000 internal & External coating Facory Sq mtr 9 Heat Exchanges for Qatar Qatar Gas Serck Services 7 X 100 Gas Tons vessels
Dubai, UAE
10 CANOPY & CAR PARKING SHADES
Qatar petrolium
Hardco
200
Qatar
11 Tilt Down Poles
Qatar petrolium
Gulfturrets
300
Qatar
12 King Khalid International KKIA-Saudi Cladtech 5000 Airport Sq mtr
Saudi Arabia Qatar
Saudi
13 Monopoles And Tower Etisalat Gulfturrets 500 Abu Dhabi, UAE 14 New York University stadium Structures
New York University Hardco 300
Abu Dhabi, UAE
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EQUIPMENT & Machineries Sl No
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Item Name
Unit
Qty
1
Dew point meter - DPM-1E
Nos
2
2
Surface profile gauge
Nos
2
3
Chloride test kit
Nos
1
4
DFT gauge (456 elecometer)
Nos
2
5
Needle pressure gauge
Nos
1
6
Steel temperature gauge
Nos
2
7
Whirling Hygrometer
Nos
2
8
Dew point calculator
Nos
2
9
ISO comparator
Nos
1
10
Manual Blasting Machine 200 Ltr Capacity (12 Bar )
Nos
10
11
Air Compressor ( 875 CFM capacity ) (10.5 Bar pressure)
Nos
3
12
Air Compressor ( 425 CFM capacity ) (06 Bar pressure)
Nos
2
13
Airless spray paint machine 75:1
Nos
6
14
After Cooler Model RA 250 connect to 750 CFMcompressor
Nos
4
15
Paint mixing machine (Pneumatic type)
Nos
4
16
Paint mixing machine (Pneumatic type)
Nos
4
17
Fork lift (07 TON)
Nos
1
18
Diesel generator 14 KV capacity
Nos
1
19
Petrol Generator 06 KV capacity
Nos
4
BLASTING AND PAINTING STANDARDS: Environmental conditions : ISO 8502-4 a) Ambient & steel temperature, b) Relative humidity, c) Dew point  Abrasive Testing : ASTM D 4940 a) Grading & cleanliness, b) Size, c) Oil, moisture, rust scale, etc. d) Chloride content Surface Cleanliness: ISO 8501 100% visual of all surfaces Dust level test: Residual dust on Blast cleaned surface ISO 8502-3 Chloride Test: Salt content on blasted surface ISO/TR 15235 (Elcometer SCM 400) ISO 8502-6, 9 (Bresle method) Blasting Profile: Roughness / Surface profile ISO 8503-5 (Replica tape) ISO 8503-1 (Comparator) Pin Hole Test: Holiday detection NACE RP 01 88 Voltage, ref. Table 1 DFT : Dry film thickness ISO 19840 / SSPC-PA2 Pull of Test for Adhesion: Pull-off test ISO 4624 & ASTM D 4541 sample/block. Paint Curing Test: Curing test (for IOZ primer) ASTM D 4752 (MEK test)
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INSPECTION & TEST PLAN All surface finishes and painting shall be inspected by an Certified painting inspector for workmanship in accordance with the approved Quality Plan and “ COMPANY” Any work rejected due to poor workmanship or incorrect application of the coating shall be corrected by remedial action as directed by “CLIENT”.
All finished dry film thickness shall be tested by use of Magnetic Dry Film Thickness Gauges (Type 1 & 2) on both ferrous and non-ferrous surfaces to determine the required total dry film thickness, and shall be in accordance with SSPC Steel Structures Painting Council SSPA-No.2. “Measurement of Dry Paint Thickness”.
Calibration of the Magnetic film thickness gauge’s shall be carried out, in accordance with the above, on the job site and agreed between the inspector and contractor. Any layer or total system which does not meet the required dry film thickness specified shall be brought to the required thickness using the material of the last coat applied.
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BLASTING AND PAINTING PROCESS Flow Chart
Receipt of Materials
QC Inspection
Cleaning
QC Inspection
Abrading Abrading && Cleaning cleaning
Primer paint application
QC Inspection
Top Coat Painting
QC Inspection
Packing
Delivery
Blast Cleaning
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QUALITY CONTROL & QUALITY ASSURANCE Applicable Standards The international standards applicable for BLASTING AND PAINTING is (1) ISO (2) SSPC, (3) NACE. Our Organization can do the Job as per the standard and quality Quality Control & Assurances department has a devised process control procedure where reading of process parameters are taken from time to time & recorded. Any deviation from standard requirements are notified & are got rectified through production staff; thus having a good control over process & subsequently final product quality.
QUALITY CONTROL SURFACE PREPARATION FOR CARBON STEEL: All rough welds, burns, weld spatter, laminations and all other sharp surface projections shall be rounded to 2 mm radius prior to further surface preparation. Any grinding done after grit blasting shall be blast cleaned to obtain proper anchor pattern. All bolt holes shall be drilled and smoothed before cleaning. All surfaces to be coated shall be Abrasive blast cleaned for carbon steel surfaces to remove dirt and achieve surface roughness as required by the paint manufacturer. Or as per steel structures painting council (SSPC), ISO 8501-1 or as per client specifications. Any kind of abrasive material used for blasting shall be dry, clean and soluble salt free. Abrasive type and size shall be selected in order to assume the required profile and roughness of substrate. Abrasives shall be reusable metallic grit mixtures or reusable mineral type such as garnet or corundum. Conductivity of abrasive shall be less than 150, 10-6 siemens/cm as per ASTM D4940.
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PAINTINg PROCEDURE Any oil, grease, dust or foreign matter de-
Cleaning shall be discontinued each day
posited on the surface shall be removed.
in sufficient time to permit the surface
In the event rusting occurs after comple-
cleaned to be primed before the end of the
tion of surface preparation, the surface
working day.
shall again be cleaned in accordance with ISO 8502 - 3. Surface roughness of blast
Dry blast cleaning operations shall not be
cleaned surface shall be within range.
conducted on surfaces that will be wet after blasting and before painting. If rela-
If salt contamination is more, all surfaces
tive humidity is greater than 80 percent or
shall be high pressure fresh water washed
when the metal surface temperature is less
(3000 psi), The chloride levels of water
than 3°C above the ambient dew point. And
washed surface prior to paint application
maximum temperature 50°C
shall be checked as per client specification. However in no circumstances this val-
Extreme care shall be exercised to prevent
ue does not exceeds as mentioned in the
damage when blasting near, machined sur-
spec.
faces and factory – coated items. These surfaces shall be adequately protected.
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APPLICATION
Coating PROCEDURE As per project specification Paint system shall be used for equipments. The type, brand, number of coats, colour and thickness shall be as outlined in specification issued by coating manufacturer’s and the product technical data sheets shall form part of this procedure, and shall be strictly adhered to. Primers and finish coats for any particular system shall be from the same manufacturer to ensure compatibility. Unless the paint manufacturer’s issues written compatibility statement.
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Surfaces shall not be coated in rain, wind, fog, mist or in areas where injurious airborne elements exists, when the steel surfaces temperature is less than 3°C above dew point or the relative humidity is greater than 80% and when the surface temperature is greater than 50°C unless higher temperature is agreed by paint manufacturers. Blast cleaned surfaces shall be coated with one complete application of primer as soon as practicable, but in no case later than 4 Hours as abrasive blasted. Before application of each coat, stripe coat shall be applied by brush to all welds, edges, corners and areas with difficult access To the maximum extent practicable, each coat of material shall be applied as a continuous film or uniform thickness free of pores. Any thin spots or areas missed in the application shall be re-coated and permitted to dry before the next coat is applied. Each coat shall be in a proper state of cure or dryness before the application of the succeeding coat to avoid the peel off subsequent coat etc. Material shall be considered dry for re-coating when an additional coat can be applied without the development of any detrimental film irregularities, such as lifting, loss or adhesion of the undercoat.
APPLICATION METHOD Spray application shall be in accordance with the following: ďƒ˜ The equipment used shall be suitable for the intended purpose, shall be capable of properly atomizing the paint to be applied, and shall be equipped with suitable pressure regulators and gauges. The air caps, nozzles and needles shall be those recommended by the manufacturer of the equipment for the material being 15 sprayed.
DRYING OF COATED SURFACE No coat shall be applied until the preceding coat has dried. The material shall be considered dry for re-coating when other coat can be applied without the development of any film irregularities such as a lifting or loss of adhesion to undercoats, and the drying time of the applied coat does not exceed the maximum specified for it as a first coat.
APPLICATION OF THE RECOMMENDED PAINTS
Paint shall be applied in a uniform layer, with overlapping at the edge of the sprayed pattern. The spray pattern shall be adjusted so that the paint is deposited uniformly.
According to the painting manual & specification, only recommended & approved paint material shall be used.
During application, the gun shall be held perpendicular to the surface and at a distance, which will ensure that a wet layer of paint is deposited on the surface. The trigger of the gun shall be released at the end of each stroke. Only areas inaccessible to the spray gun shall be painted by brush if not accessible by brush, daubers or sheepskin shall be used. Brushes shall be used to work paint into cervices and blind spots, which are not adequately painted by spray. The areas where to prohibit coating deposition shall be masked. If these surfaces are coated, the component shall be cleaned and restored to its original condition. ďƒ˜Wet paint shall be protected against contamination from dust & other foreign matter.
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SaFETY POLICY
SAFETY FIRST
We are committed to providing a safe and environment friendly working atmosphere regardless of how challenging this can be owing to conditions in which we operate. The management is directly involved in chalking out general and project specific safety policies so that the employees and clients are assured of the safety of personnel and properties respectively
The aspect of safety is conceived in the following lines: •
Assessment of conditions in which a work is to be performed
•
Analysis of risks involved in executing a particular work
•
Suggesting and implementing risk eliminating measures
•
Recording activities and monitoring safety implementation practices
•
Recognizing and rewarding for adhering to safety standards
•
Analyzing incidents and accidents if any
•
Promoting prescribed environment friendly activities
•
Recycling of waste to the extent possible
•
Meticulous housekeeping
•
Disposal of hazardous/non-hazardous waste as per ruler
•
Making safety a “Way of Life” rather than “A Rule to Follow”
•
Imparting training to all employees on safety and environment
•
Conducting Regular Tool Box Talks to constantly impress upon workers
Safety First YOUR LIFE DEPENDS ON IT 18
Safety Mission Statement The basic mission is to record “Zero-Incident� months, Month after Month It is the policy of ASMECO that all aspects of its operations shall be conducted in a safe and environ-friendly manner. We recognize that safeguarding the health and welfare of our employees is of the highest priority. Our management team believes that accident prevention is a constant shared responsibility. We expect every individual employed by our company to uphold the standards of OSHAS as well as the safety standards set forth through International Standards, by providing necessary and adequate facilities for implementing them. In addition, all our employees are held directly accountable for the prevention of accidents, for their own personal safety, and for the safety of their coworkers. Our commitment extends not only to its employees but to all subcontractors, clients and visitors on our job sites. Our goal is to maintain an accident-free work environment, by subscribing to sound operational practices that will result in safe working conditions and efficient construction operations.
Monitoring Safety The management ensures its policies are put in practice by ensuring the following: Proper PPE (Personal Protective Equipment) shall be used based on the job safety analysis and associated risk assessment. Whatever is being executed should have a work permit and this shall be duly authorized at adequate level. Every independent activity shall have specific JOB SAFETY ANALYSIS Statement. Every site and workshop where an activity take place shall be provided with adequate Fire extinguisher. It shall be the responsibility of the project to adhere to standard, accepted and project specific housekeeping at all time. Every project team shall conduct daily and emergency toolbox talk meeting to brief all the individuals involved in the project.
training on the safety aspect of the particular project. Every site and workshop where an activity take place shall be provided with adequate First aid kit To ensure health and safety is considered in all planning and work activities To involve our employees in the decision making process through regular communication, consultation and training To provide a continuous programme of education and learning to ensure that our employees work in the safest possible manner. To ensure all potential accidents/incidents are controlled and prevented and the work team is totally committed to our objectives Ensuring that open and honest communications exist between management and all our employees
Every person newly joining in the company or project team shall be properly inducted imparting
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CERTIFICATES
20
TRADE LICENSE
21
CHAMBER OF COMMerce
22
ISO Certificate 9001:2008
23
ISO Certificate 14001:2004
24
ISO Certificate 18001:2007
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This is to certify that M/s. Al Sakhra Metal Coating (ASMECO)
P.O.BOX 37321, Sharjah, U.A.E. is our approved Paint Applicator
Elvis Sequeira Business Head – PC (UAE & Qatar) Berger Paints Emirates Limited Co. (LLC) P. O. Box : 27524 Dubai, UAE 01-JULY-2015
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APPROVED APPLICATOR CERTIFICATE – HEMPEL PAINTS
Al Sakhra/PC Sales Dubai/01/2015 07 June 2015
TO WHOMSOEVER IT MAY CONCERN This is to certify that M/s. Al Sakhra Metal Coating, P O Box: 37321, Sharjah, UAE, is one of the Approved Applicators of Sigma Paints Saudi Arabia Limited. Based on the documentation and customer project references provided to us and projects which they have done with us, they have demonstrated sufficient expertise in application of Coating Systems for Oil & Gas and Infrastructure Market Segments. We are pleased to recommend M/s. Al Sakhra Metal Coating for the application of our Coating Systems, as the coating applicator has necessary expertise, trained manpower and equipment to execute major Painting Projects. Issuing an approved applicator letter does not constitute any responsibility on our part for successful execution of the job and quality assurance. Sigma Paints Saudi Arabia Ltd shall at all times be held harmless and indemnified against all third party claims. In case you require any further clarifications, please feel free to contact us. Thanking you and assuring you of our best services at all times. Yours faithfully For Sigma Paints Saudi Arabia Limited
Jayakrishnan Key Account Manager – Technical Sales Protective Coatings
Dubai Branch : Sigma Paints Saudi Arabia Ltd License # 224149, P O Box No : 52781, Dubai, United Arab Emirates Tel. : 00971 4 885 6700 (Warehouse) / 00971 4 354 9307 (Sales Office) Fax. : 00971 4 885 6033 (Warehouse) / 00971 4 354 9308 (Sales Office) Sigma Paints Saudi Arabia Ltd. Paid up Capital : SR 24,200,000 Sigma Paints is a member of PPG Industries
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asmeco facility IN sharJAH BLASTING & PAINTING AREA
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70,000 SQFT
PAINITNG BOOTH
29
30
painting inspection aREA
31
pROJECT gALLERY
32
33
34
35
36
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Al Sakhra Metal Coating and Painting (ASMECO ) Tel: +971 6 5540 990, Fax: +971 6 5540 619 P.O Box: 95801, Sharjah- United Arab Emirates E-mail : mail@asmeco.net | www.asmeco.net
ASMECO Fire Protection LLC P.O.BOX : 119770, Burj Khalifa street,
Business Bay, Dubai-UAE Tel No: + 971 4 5620309, Fax: +971 4 5516091 Email: shani@asmeco.net, website: www.asmeco.net
Group Companies Embosal Tube Mill LLC Tubes and Pipe Mill Email: mail@embosal.com | www.embosal.com
Core Metallic Ind. LLC - Machine Shop CNC Machining & Tooling, Mandrel Manufacturing Email: cmims@coreindustry.net | www.coreindustry.net
Core Metal L.L.C : Steel Stockist Structural Steel,GI, Aluminium & SS Email: mail@coremetal.net | www.coremetal.net
Core Metallic Ind. LLC - Expanded metal
Core DSC Technical Services LLC Design & Engineering Email: mail@coredsc.com | www.coredsc.com
Core Green Solutions LLC Renewable Energy Provider Email: mail@baarik.net |www.baarik.net
Core Metallic Ind. LLC - Fabrication Structural & Architectural Steel Fabrication Email: mail@coreindustry.net | www.coreindustry.net
CorePac Industries LLC Packing Material Manufacturing Email: mail@corepac.net | www.corepac.net
Core Metallic Ind. LLC - Metal processing Waterjet, Plasma, Punching & Perforation Email: mail@coreindustry.net | www.coreindustry.net
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Email: cmims@coreindustry.net | www.coreindustry.net