09 97 13 STEEL COATINGS_0001.pdf

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STEEL COATINGS

SECTION 09 97 13 - STEEL COATINGS

PART 1 - GENERAL

1.1 SUMMARY

A. This specification section covers the field preparation and cold galvanizing (protective coating) of existing structural steel members, assemblies, and metal fabrications at designated locations in Elev. 1&2 shaft, after abatement operations detailed in Section 13

80 00. Remedial coatings shall be applied to existing elevator structure at the top and bottom sections of the elevator shaft at locations indicated in the drawings.

1. Field Painting: Prepare and paint all existing structural steel members of the elevator structure not scheduled for stainless steel Grade 304L replacement.

2. Field repair painting: Repair all damaged hot-dip galvanizing and field applied coatings:

a. Repair galvanizing before installation in the shaft.

b. Repair field coatings and galvanizing after installation and before close-out.

3. Protection: Throughout the work, protect and do not prepare or apply coating to the following elements:

a. Elevator rail assemblies and components other than to repair damaged galvanizing.

b. All new, hot-dip galvanized threaded rod, washer, and nut for attachment of wall anchors (single and tandem) to shaft walls.

B. Preservation of Wildlife Ecosystem and Safety to Workers and Carlsbad National Park

Patrons.

1. The specified coating system is a water-borne zero-VOC inorganic zinc-rich alkaline silicate that hardens and initially provides cathodic protection and ultimately densifies and transforms into a rather impervious barrier coat while in service.

2. This coating system is judged to have minimal deleterious impact on its surrounding ecosystem at Carlsbad Caverns National Park. Many types of solvents are used in paints and coatings, which unfortunately can be harmful to wildlife and mammals. As a zero-VOC coating with water as its solvent component, the attempt is to enhance performance and service life of the elevator structure and stay true to the motto and creed, do no harm.

C. Related Sections include the following:

1. Section 05 12 00 - Structural Steel Framing

2. Section 05 50 00 – Metal Fabrications

3. Section 13 80 00 - Lead Abatement

4. Section 01 33 23 - Submittal Procedures

1.2 REFERENCES

A. ASTM International

1. A36/A36M – Standard Specification for Carbon Structural Steel.

2. ASTM A239: Locating the Thinnest Spot in a Zinc (Galvanizing) Coating in Iron or Steel Articles by the Preece Test (Copper Sulfate Dip)

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3. ASTM A325: Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.

4. ASTM A780: Repair of Damaged Hot Dip Galvanizing

5. ASTM A490: Standard Specification for Structural Bolts, Alloy Steel, Heat

Treated, 150 ksi Minimum Tensile Strength.

6. B117: Test Method for Salt Spray (fog) Testing.

7. D16: Terminology Relating to Paint, Varnish, Lacquer, and Related Products.

8. D520: Type III Specification for Zinc Dust (Metallic Zinc Powder)

9. D610: Standard Test Method for Evaluating Degree of Rusting on Painted Steel

Surfaces.

10. D714: Standard Test Method for Evaluating Degree of Blistering of Paints.

11. D1654: Standard Test Method for Evaluation of Painted or Coated Specimens

Subjected to Corrosive Environments.

12. D1212: Standard Test Methods for Measurement of Wet Film Thickness of Organic

Coatings.

13. D3363: Standard Test Method for Film Hardness by Pencil Test.

14. D4060: Test Method for Abrasion of Organic Coatings by the Taber Abraser.

15. D4417: Standard Test Methods for Field Measurement of Surface Profile of Blast

Cleaned Steel.

16. D4541: Test Method for Pull-Out Strength of Coatings Using Portable Adhesion-

Testers.

17. D4585: Practice for Testing the Water Resistance of Coatings Using Controlled

Condensation.

18. D4587: Standard Practice for Fluorescent UV-Condensation Exposures of Paint and Related Coatings.

19. D5162: Standard Practice for Discontinuity (Holiday) Testing of Nonconductive

Protective Coating on Metallic Substrates

20. D5894: Standard Practice for Cyclic Salt Fog/UV Exposure of Painted Metal, (Alternating Exposures in a Fog/Dry Cabinet and a UV/Condensation Cabinet).

21. D6386: Standard Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated

Iron and Steel Product and Hardware Surfaces for Painting.

22. E376: Measuring Coating Thickness by Magnetic-Field or Eddy Current

(electromagnetic) Test Methods

B. Code of Federal Regulations:

1. 40 CFR 59, Subpart D (EPA Method 24), Volatile Organic Compounds (VOC) content limitations.

2. 29 CFR 1910.1000-1500, Subpart Z, “Toxic and Hazardous Substances.”

3. 29 CFR 1910.134, toxic exposure limits.

C. Federal Specification Conformance Data

1. Federal Standard 313, “Material Safety Data Sheets - Preparation and Submission”

2. Federal Specification DOD-P-21035B, Type II (formerly MIL-P-21035)

Galvanizing Repair Specification

3. Federal Specification MIL-P-26915A, Type I, Class B (USAF Zinc Dust Primer)

D. The Society for Protective Coatings (SSPC)

1. PA 1: Paint Application Specification No. 1

2. PA 2: Measurement of Dry Coating Thickness with Magnetic Gages

3. PA Guide 3: A Guide to Safety in Paint Application

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4. SSPC Painting Manual, Volume 1, “Good Painting Practice,” and Volume 2, “Systems and Specifications”

5. SP 1: Surface Preparation Specification No. 1, Solvent Cleaning

6. SP 2: Surface Preparation Specification No. 2, Hand Tool Cleaning

7. SP 3: Surface Preparation Specification No. 3, Power Tool Cleaning

8. SP 7/NACE No. 4: Surface Preparation Specification No. 7, Brush-Off Blast

Cleaning

9. SP 10/NACE No. 2: Surface Preparation Specification No. 10, Near-White Blast

Cleaning.

10. SSPC SP 11: Surface Preparation Specification No. 11, Power Tool Cleaning to

Bare Metal

11. VIS 1: Standard Pictorial Surface Preparation Standards for Painting Steel

Surfaces.

12. SSPC-PS 12.00: Guide to Zinc-Rich Coating Systems

13. SSPC Paint 20: Zinc-Rich Primers, Type I, Inorganic

14. SSPC-PS 29: Zinc-Dust Sacrificial Primer, Performance Based

E. American Institute of Steel Construction

1. AISC Specification for Structural Joints Using ASTM A325 or ASTM A490 Bolts

1.3 DEFINITIONS

1. Cold Galvanizing: A method of applying a zinc coating to structural steel members, assemblies, and fabrications at ambient temperatures to achieve long-term corrosion protection.

2. Cathodic Protection: Reduction or prevention of corrosion of a metal surface by making it a cathode in an electrolytic cell.

3. Galvanic Action: When two dissimilar metals come into electrical contact with each other in the presence of an electrolyte, the less noble metal (zinc) will sacrifice itself (corrode) to protect the more noble metal (steel, iron, or aluminum).

4. ASTM D16 – Terminology Relating to Paint, Varnish, Lacquer, and Related

Products.

5. SSPC Environmental Zones Definitions – SSPC Painting Manual, Volume 1.

6. Contractor: Contractor refers to General Contractor or the specific painting sub-contractor responsible for the work.

7. Contractor Quality Control Representative: The inspector working on behalf of the contractor to ensure that the job is in conformance to the specification requirements and any deviations from conforming work are corrected.

8. Inspector: Independent coatings inspector working on behalf of the owner to ensure contractor conformity to specification requirements.

9. Block-out: An area on a steel member that is masked (blocked-out) prior to the galvanizing process to prevent galvanizing of that area.

1.4 SYSTEM DESCRIPTION

A. A water-borne, two component, metallic zinc coating, containing 93 percent zinc in the dried film, that imparts cathodic protection to ferrous and nonferrous metals, hot-dip galvanized steel, cast iron, and aluminum surfaces through its galvanic action, with no

VOC content. This coating, in its dry form, is non-toxic and essentially free of such heavy metals as lead, cadmium, barium, antimony, arsenic, chromium, copper, mercury, molybdenum, selenium, silver, and tellurium.

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1.5 SUBMITTALS

A. Submit to Contracting Officer the following information pertaining to materials to be provided, for approval:

1. List of materials to be provided, identified by manufacturer’s name, product name, or stock number, and indicating surfaces to which they are to be applied. Maintain at least 1 copy of list at project site.

2. Manufacturer’s product data sheets (including printed statement of VOC content and chemical components) and manufacturer’s material safety data sheets for coatings and related materials, and other potentially hazardous materials as defined in Federal Standard 313.

3. Schedule indicating significant dates such as delivery, removal, completion of shop work, finish completion, etc.

4. Contractor shall furnish certification that the materials furnished under this specification meet or exceed the requirements herein.

5. Contractor shall furnish certification that surface preparation of the substrate to be coated has performed satisfactorily, as herein specified.

6. Documentation from the coating manufacturer that zinc-rich primer meets the Class

B slip coefficient per AISC Specification for Structural Joints Using ASTM A325 or ASTM A490 Bolts.

B. Coating manufacturer information for Field-Applied Coatings:

1. Approved list of application equipment to be used on this project.

2. Manufacturer’s mixing, handling, and application instructions for coatings and related materials.

3. Manufacturer’s inspection plan including the number and frequency of site visits by manufacturer’s technical representative.

4. Manufacturer’s statement of maximum permissible surface chloride concentration on substrate prior to coating.

5. Provide a letter certifying products are free of, or do not exceed limits allowed by

OSHA, local, state, or federal regulations for, asbestos, lead, chromate, cadmium, arsenic, selenium, silver, barium, and mercury.

6. Provide a letter certifying products that comply with the VOC content requirements when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

7. Manufacturer’s qualifications.

8. Manufacturer’s technical representative qualifications.

9. Written approval of the Contractor, or any coating subcontractor engaged by the

Contractor, by the manufacturer of the specified coatings.

10. List of 5 similar projects using the specified coatings completed in the past 5 years for approval by Contracting Officer. Similar projects are considered as those projects that have comparable scale, coating systems, substrates, and substrate conditions, and are located in comparable environmental conditions as defined by

SSPC Environmental Zones Definitions 1B, 2A, 2C, or 3B. For each project reference submitted, include project description, contact with address and telephone number, surface area coated, description of coating system used, the substrate, the substrate condition, and the environmental conditions.

11. Samples for review of coating color and texture.

12. Decoding information so field personnel can verify shelf lives and other coded information.

13. Pinhole repair procedure for approval by Contracting Officer.

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C. Contractor:

1. List of 5 projects similar to Work specified in this Section, completed in the past five years for approval by the Contracting Officer. Similar projects are considered as those projects that have comparable scale, coating systems, substrates, and substrate conditions, and are located in comparable environmental conditions as defined by SSPC Environmental Zones Definitions 1B, 2A, 2C, or 3B. For each project reference submitted, include project description, contact with address and telephone number, surface area coated, cost of the work, description of coating system used, the substrate, the substrate condition, and the environmental conditions.

2. Documentation that contractor has previously applied the specified manufacturer’s coating system or similar systems in production quantities similar to this Project for approval by Contracting Officer. Include list of such projects with description, surface area coated, coating system description, and contact with address and telephone number.

3. Contractor qualifications in the Quality Assurance Section.

4. Supervisor qualifications in the Quality Assurance Section.

5. Painter qualifications in the Quality Assurance Section.

6. Quality control representative qualifications in the Quality Assurance Section.

D. Samples for Verification: For each type of coating system and in each color and gloss of finish coat indicated.

1. Coating Samples for steel substrate on steel, 1/4 x 6 x 12 inches.

2. Coating Samples for galvanized steel substrate on galvanized steel, 1/4 x 6 x 12 inches.

3. Coating Samples

a. Label each coat of each Sample.

b. Label each Sample for location and application area.

4. Provide minimum 1-quart unopened container of each coating component from each batch used on the project prior to application.

E. Submit repair procedures for damage, defects, or other nonconformances in the coating for the Contracting Officer’s approval. Repair procedure shall comply with the most stringent requirements of SSPC-PA 1 and the manufacturer’s written recommendations.

F. Safety Plan: Submit to Contracting Officer a written plan of action that covers operational requirements for safe application of coatings, means of protection of surrounding areas from contamination, handling, storage, and disposal of waste, hazardous, and toxic materials. Plan requirements will comply with applicable government regulations and most stringent requirements of the following:

1. Manufacturer’s Safety Data Sheets

2. SSPC-PA Guide 3

3. Toxic material exposure limits, per 29 CFR 1910.1000 and 29 CFR 1910.134

4. Do not perform welding and painting operations simultaneously within the contained area.

5. Provide adequate ventilation.

6. Personnel must avoid inhalation of vapors and contact with skin and eyes.

G. Protection Plan: Submit to Contracting Officer a plan of action for environmental monitoring, testing, collection, and disposal of lead or other hazardous containing materials.

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1. Comply with requirements of Section 13 80 00 - Lead Abatement.

2. Protect the property of the National Park Services.

3. Coatings inadvertently applied to surfaces not scheduled for coating shall be completely removed and surfaces returned to original condition to the Contracting

Officer’s satisfaction.

4. The contractor shall use a water-borne inorganic zinc-rich protective coating in which there are no volatile organic compounds (VOC) that requires power tool cleaning surface preparation. No blast media.

H. Environmental Control Plan: Submit to Contracting Officer a plan of action for a temporary enclosure to control the local environment (temperature, humidity, ventilation, etc.) for preparation of surfaces and application and cure of coatings. The Plan shall also comply with the requirements of Specification Section 13 80 00 Lead Abatement

(environmental controls).

I. Enclosure Plan: Submit to Contracting Officer a plan of action for a temporary enclosure to prevent the deposition of water or other contaminants on the prepared surface before coating application, on coated surfaces during the coating application, and on surfaces of the complete coating system until cured.

J. Transportation, Storage, and Installation Protection Plan: Submit to Contracting Officer a plan of action for protecting shop coated galvanized steel prior to, during, and after transit to the job site.

1. Plan shall include provisions to protect, handle, and store galvanized steel from damage.

2. Plan shall include provisions to prevent deposition of chloride and other contaminants onto the galvanized steel.

3. Plan shall include provisions to keep galvanized steel and the coated galvanized steel protected from weather, sunlight, and free from contact with the ground and positioned to minimize water holding pockets, soiling, contamination, and deterioration of the coating and galvanizing.

4. Keep coating containers closed when not in use and store away from incompatible materials. Ideal storage temperature is typically between 35 to 100 degrees

Fahrenheit.

K. Inspection Plan for Field and Shop Coating: Submit an inspection plan that systematically lists the inspection hold points, test methods, and acceptance criteria for each procedure in each phase of the project work including a sample of a daily Quality Control log. Plan shall include list of testing and inspection equipment to be used. It shall also include but not be limited to:

1. Pre-surface preparation for obvious defects and contamination to be removed in accordance with the specified preparation.

2. Measurement of ambient conditions of temperature, humidity, and dew point.

3. Evaluation of surface preparation, application, compressor, and power tool equipment to verify cleanliness and avoid contamination.

4. Evaluation of surface preparation and profile for conformance with standards.

5. Observation of coating mixing and application for conformance to manufacturer’s instructions and mockup(s).

6. Determination of dry film thickness of each coat applied for conformance to manufacturer’s instructions and mockup(s).

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7. Monitor cleanliness and time between coats. Each coat shall be inspected for cleanliness before application of subsequent coats.

L. Warranties agreed upon by the coating manufacturer, applicator, and National Park

Services.

1.6 QUALITY ASSURANCE

A. The Contracting Officer may at his/her discretion hire a Coating Inspector.

B. Contracting Officer will periodically observe progress, evaluate quality, and perform tests of the coating both in the field and in the shop.

C. General

1. Review specifications for requirements affecting Work of this trade. Conflict between these specifications and coating manufacturer’s requirements or specifications, or other pertinent specifications, shall be immediately brought to the attention of the Contracting Officer in writing. The more stringent requirement shall govern the work unless approved by the Contracting Officer.

2. Do not apply materials from different manufacturers to the same component unless approved by all of the different manufacturers and the Contracting Officer. Provide materials that are not available from the manufacturers from sources recommended and approved in writing by the manufacturers.

3. Work in-place shall be subject to inspection testing. Work found to be unacceptable shall be immediately replaced with new, acceptable work.

4. Only prepare enough surface area that can meet the surface preparation requirements and be coated in the same 8 to 10 hour work shift.

5. Provide lighting of at least 25 foot candles on the surface to be coated.

D. Manufacturer Qualifications

1. A company specializing in the manufacture of high-performance coatings with a minimum of 10 years of experience.

2. Manufacturer’s technical representative shall perform site visits throughout the project, including:

a. During the mockup to establish the standard quality to be used on the project.

b. Periodic inspections (a minimum of 2 field visits) for conformance with requirements shall include:

1) Inspecting coating surface preparation.

2) Measuring surface profile.

3) Inspecting coating application.

4) Measuring wet film thickness.

5) Measuring dry film thickness of cured coating.

6) Measuring adhesion of cured coating.

c. A final site visit to review completed work.

d. As necessary to advise the Contractor of procedures and precautions for use of the materials.

3. Manufacturer’s technical representative shall provide a written report within three days for each site visit summarizing observations and documenting if surface preparation and coating application is in accordance with the specifications and manufacturer’s recommendations.

4. At completion of work, manufacturer’s technical representative shall perform a final inspection of completed work and issue warranty.

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E. Contractor Qualifications:

1. Contractor shall have current SSPC-QP-1 Field Applications of Coatings Complex

Structures certification.

2. Contractor shall have current SSPC-QP-2 Industrial Hazardous Paint Removal certification.

3. A partial listing of certified contractors may be found using the web links below:

a. SSPC QP1, QP2, and QP3 http://www.sspc.org/certification/PCCP/PCCPforms.html

b. AISC SPE P1 http://www.aisc.org/find/FindCertifiedCompany.aspx?id=5542.

4. Contractor shall have a field Quality Control Representative on site during all stages of work, including the mockup.

a. Contractor Quality Control Representative is required to document the progress, general quality of work, and any non-compliant work with daily logs, to be submitted within 24 hours.

b. Contractor Quality Control Representative shall submit daily inspection report and any type of deficiency to the Contracting Officer and Contractor simultaneously on a daily basis.

5. Contractor Supervisor shall be on site during all preparation and coating work.

6. Field Contractor Quality Control Representative shall be independent from contractor supervisor and shall perform only Quality Control (that is, not a painter).

Quality Control representative shall be on site at all times during surface preparation and coating.

7. Contractor shall assure the presence of a qualified technical representation from coating manufacturer.

8. Contractor shall have experience with similar projects for the successful field application of coating to structural steel and galvanized structural steel.

F. Contractor Supervisor Qualifications

1. A minimum of 10 years of experience in the preparation and coating of structural steel and hot-dip galvanized structural steel.

2. A minimum of 3 years’ experience in supervising this type of Work. Apprentices shall be under direct supervision of an experienced supervisor.

G. Shop and Field Contractor Quality Control Representative

1. A minimum of 10 years of experience in the quality control of preparation and coating of structural steel and hot-dip galvanized structural steel.

2. Shall be NACE Level 3 Certified.

H. Painter Qualifications

1. A minimum of 5 years’ experience in the preparation and coating of structural steel.

I. Field Quality Control

1. Do not apply any coatings when measurements, observations, readings, etc. are not in conformance to manufacturer’s written instructions.

2. Submit daily inspection reports, which includes day, time, and location of all quality control tests specified:

a. Location of structure

b. Description of work performed

c. Inspector’s Name

d. Project Number

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e. Paint removal method and times of paint removal

f. Coatings used

g. Batch numbers of coatings

h. Batch number of thinners

i. Hold point inspections completed

j. Inspection equipment calibrated

k. Non-conformance and corrective actions

3. Measure and record on daily inspection reports:

a. Pre-surface preparation for obvious defects and contamination to be removed in accordance with the specified preparation.

b. Profile

1) The surface profile shall be measured using replica tape and measured with a spring micrometer, ASTM D4417 Method C, or an electronic depth micrometer with a fine pointed probe, ASTM D4417 Method B.

a) Measure profile of the existing structural steel after mechanical surface treatment.

b) Where steel is pitted, measure profile on ASTM A36 steel coupons

(minimum size) ¼ x 6 x 12 inch temporarily fixed to the structural steel to be abrasive blasted. Blast the coupon along with the structural steel. The profile on the coupons shall meet the requirement for surface profile.

2) Frequency of measuring profile is as follows:

a) At least once at the beginning of each shift by each mechanical surface treatment operator.

b) As required by the Inspector.

c. Evaluate compliance of surface preparation with SSPC SP11 using SSPC-

VIS 3

d. Surface chloride measurements shall be performed on locations where the field applied coating system is to be applied.

1) Beams

a) For the first beam, take one chloride measurement randomly distributed on each of the surfaces listed below:

i. Top of the beam

ii. Bottom of the beam

iii. Web of the beam

iv. Top of the bottom flange

iv. Underside of the top flange

b) For every fifth beam of the remainder of a shipment make a chloride measurement on two of the surfaces, i. – v., listed below. Do not always test the same surface from the list; make assurances that all of the listed surfaces are tested equally through the course of the work.

i. Top of the beam

ii. Bottom of the beam

iii. Web of the beam

iv. Top of the bottom flange

iv. Underside of the top flange

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c) When any 1 chloride measurement is not in compliance with the coating manufacturer’s requirements of the specification, it shall be cause for failure of that member. Apply chloride removal procedures in accordance with coating manufacturer’s requirements. When completed, the surface chloride concentration shall be re‐measured.

2) Smaller steel components

a) For the first smaller steel components, such as angle bracing of anchorages, the frequency of surface chloride measurements using Surface Chloride Test Kit shall be as follows:

b) Take two chloride measurements distributed randomly on the component.

c) For every fifth smaller steel components the frequency of surface chloride measurements using Surface Chloride Test Kit shall be as follows:

d) Take one chloride measurements distributed randomly on the component.

e) When any 1 chloride measurement is not in compliance with the coating manufacturer’s requirements of the specification, it shall be cause for failure of that component. Apply chloride removal procedures in accordance with coating manufacturer’s requirements. When completed, the surface chloride concentration shall be re‐measured.

3) The specific location of tests taken to satisfy this requirement shall be recorded and included in field reports distributed to the Contracting

Officer.

e. Measure surface temperature using a surface thermometer prior to the application of any coating and at least once every 2 hours during application.

No coating shall be conducted if temperature is outside the range provided in the manufacturer’s written instructions.

f. Air temp, relative humidity and dew point recorded before application of any coating and at least once every 2 hours during application if readings are not in conformance to manufacturer’s written instruction, no coating shall be conducted.

g. Observation of coating mixing and application for conformance to manufacturer’s instructions and mockup(s).

h. Painter shall confirm wet film thickness of coating taken randomly using a notched gauge at least once every element or at least 15 linear feet in accordance with ASTM D1212.

i. Measure dry film thickness in accordance with SSPC PA-2.

4. Schedule hold points between all major operations for inspection. Document the following in daily inspection reports:

a. Surface preparation inspection

b. Protective coating inspection

c. Corrective action

J. Use SSPC-VIS 3 - “Guide and Reference Photographs for Steel Surfaces Prepared by

Power and Hand Tool Cleaning” to evaluate surface preparation (SSPC-SP11).

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K. Adhesion - The Contracting Officer or the Inspector will measure coating adhesion as deemed necessary throughout the project. Use same model pull-off tester (ASTM D4541

Type 2) for comparison of adhesion data throughout entire project unless directed otherwise by the Contracting Officer.

L. Attend weekly progress meetings. Attendance shall include the contractor’s project manager, site foreman, contractor’s quality control representative, and the independent coating inspector.

1.7 MOCKUPS

A. Prepare mockups of the specified surface preparations and coating application

1. Install the following mockups

a. Mockup of Existing Structural Steel, Field Painting

1) Beam

a) Prepare coating mockup at (1) 6-inch wide full perimeter beam end, and (2) 6-inch wide full perimeter middle beam section.

2. Size and location of the mockups shall be determined by the Contracting Officer and shall not be less than one beam end area, one beam center area, and one bolt interface surface area. Duplicate mockups are to be established and evaluated, so as to be conducted at both top and bottom elevator shaft locations.

3. Conduct quality control testing prior to, during, and after surface preparation and coating application.

4. Permit Contracting Officer, Inspector, and Coating Manufacturer to perform surface chloride measurements on mockups prior to proceeding with overall work.

Results of tests will be evaluated by the Contracting Officer.

5. Surface Chloride Measurements

a. Existing Structural Steel Mockups - Measure surface chloride concentration prior to and after surface preparation. Perform surface chloride tests on pitted areas, as well as adjacent to welds; otherwise, test locations shall be selected that are representative of the surface as a whole.

1) For beams and similar structural components, take one chloride measurement randomly distributed on each of the surfaces listed below:

a) Top of the beam

b) Bottom of the beam

c) Top of the bottom flange

d) Web of the beam

e) Underside of the top flange

2) For smaller structural steel components, such as angle bracing of anchorages, the frequency of surface chloride measurements using

Surface Chloride Test Kit shall be as follows:

a) Take two chloride measurements distributed randomly at each anchorage.

b. If chloride contamination exceeds manufacturer’s recommendation perform chloride removal procedure.

6. Apply required coating system to each surface preparation mockup.

B. Additional mockups shall be made until acceptable results are achieved. Adjustments to application of products shall be made in accordance with limits defined in manufacturer's recommendations upon approval of the Contracting Officer.

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C. Mockups will cure 7 days prior to testing and evaluation by Contracting Officer, in an engineered controlled environment work space, but could be longer cure period if no engineered controlled enclosure is in place.

D. Permit Contracting Officer, Inspector, and Coating Manufacturer to perform field adhesion testing of coatings on mockups prior to proceeding with overall work. Adhesion tests will be performed in accordance with ASTM D4541 Standard Test Method for Pull-

Off Strength of Coatings Using Portable Adhesion Testers. Results of tests will be evaluated by the Contracting Officer.

E. Coating manufacturer shall review surface preparation and coating mockups on site.

F. Coordinate the mockup schedule with the Contracting Officer. Mockups shall not be conducted until all of the environmental and operational controls are in place. The mockups may be the initiation of painting. However, the mockups(s) shall be approved by Contracting Officer before commencement of the overall preparation and coating work. Sample shall be protected and retained during the Work to serve as a standard for full-scale work. Upon completion of Work, the sample may be incorporated into the full-scale work.

1.8 DELIVERY, STORAGE, AND HANDLING

A. Packing, Shipping, Handling, and Unloading: Deliver materials to job site in original, new, and unopened packages and containers bearing the manufacturer’s name and label and batch numbers. Gallon Kit (20 lb.) containers of types suitable to prevent leakage of contents.

B. Acceptance at Site: Materials shall be accepted at site providing no damage deleterious to product’s function is visible and applicable safety data sheets are present. Promptly remove rejected and non-complying materials from the premises.

C. Storage and Protection: Store materials in tightly closed containers in well-ventilated areas with ambient temperatures continuously maintained at not less than 35 degrees

Fahrenheit and not more than 100 degrees Fahrenheit, unless required otherwise by manufacturer’s instructions. Storage area shall be protected from exposure to direct sunlight, heat, sparks, flames, and weather.

1. Maintain containers in clean condition, free of foreign materials and residue.

2. Store containers so manufacturer’s labels are clearly displayed.

3. Remove rags and waste from storage areas daily.

D. Waste Management and Disposal: Comply with applicable safety codes and regulations that govern the work, including Occupational Safety and Health Administration (OSHA), State OSHL (Occupational Safety and Health Law), and Environmental Protection

Agency (EPA) regulations covering waste and wastewater disposal and VOC content.

E. Handling and storage of Shop-Coated Galvanized Steel

1. Galvanized steel members shall be handled and stored with care to minimize damage to, or contamination of, the coating according to the Transportation, Storage, and Installation Protection Plan.

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1.9 PROJECT / SITE CONDITIONS

A. Equipment, material, and appliances required for completion of Work, shall be so located and operated as to provide for maximum efficiency, public safety, persons employed at the site, and to prevent damage to new and existing construction, in accordance with the

Contractor’s safety plan, OSHA, and applicable safety codes and regulations.

B. Confine operations at Project site to areas permitted by laws, permits, contract, the

Contracting Officer, and Contractor’s safety plan.

C. Assume full responsibility for protection and safekeeping of products stored on premises, and for their proper use.

D. Provide Contracting Officer, Inspector, and Manufacturer with access to the Work, daily if so desired by any of the vested parties.

E. Where conditions are uncovered that are not anticipated by the specifications, notify

Contracting Officer in writing immediately, before work is initiated.

F. Do not prepare substrate when the surface temperature is less than 5 degrees Fahrenheit above the dew point, or when relative humidity exceeds 90 percent. Surface areas exposed to condensation or moisture prior to receiving primer coat shall be re-prepared.

G. Drying time of coating is dependent upon temperatures, but product shall not be applied at temperatures below 50 degrees Fahrenheit.

H. No coating shall be applied if relative humidity and the air and surface temperatures are outside the range provided below or the manufacturer’s written instructions, whichever are more stringent.

1. Field Coating - Do not apply coatings to damp or wet surfaces, and at air and surface temperatures less than 5 degrees Fahrenheit above the dew point, to avoid condensation.

2. Repair Coating - Do not apply coatings to damp or wet surfaces, and at air and surface temperatures less than 5 degrees Fahrenheit above the dew point.

3. Ambient humidity shall be less than 85 percent relative humidity.

1.10 JOB SITE REFERENCES

A. Maintain at least 1 copy of each referenced standard and this Specification at the job site and make available to Contracting Officer prior to surface preparation or coating application work.

B. Maintain on site and within the shop a complete file of MSDS and manufacturer’s product and application data sheets for each coating material, keeping in mind that this is a zero-

VOC coating product intended to minimize likelihood of use of organic solvents in the work place shaft.

1.11 COORDINATION AND SCHEDULING

A. Schedule application of coatings so that Work performed by other trades or on surfaces adjacent to area of Work of this Section is complete. Assure that this Work does not affect the performance or final appearance of Work in this Section.

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B. Complete painting work on existing and new steel prior to concealing steel elements with grout or similar materials.

C. Schedule steel and galvanized steel preparation and painting so that dust and other contaminants from the preparation process will not fall onto uncured, newly painted surfaces.

D. Protect areas not to be coated.

E. Protect surface from salt and other contamination.

1.12 WARRANTY

A. General

1. Coating failures shall be repaired/corrected within the warranty period at no cost to the Owner.

B. For a period of 10 years, coating manufacturer and Contractor shall jointly warrant the coating system and labor with no dollar limit so as the coating:

1. Will not check, crack, blister, peel, delaminate or allow exterior water to penetrate the coating

a. Blisters will be evaluated using ASTM D714

1) Blisters less than a rating of No. 10 shall be considered a defect and must be repaired.

2. Will not allow the substrate to corrode in excess of Rust Grade 8 (Less than or equal to 0.001 percent) of the surface area being coated as measured in accordance with

ASTM D 610.

PART 2 - PRODUCTS

2.1 COATINGS

A. Material Compatibility:

1. Provide materials for use within each coating system that are compatible with one another and substrates indicated, under conditions of service and application as demonstrated by manufacturer, based on testing and field experience.

2. Provide products of same manufacturer for each product in coating system or provide written approval by all manufacturers for the system.

2.2 SURFACE CHLORIDE TEST KIT

A. Surface Chloride Test Kit:

1. Chlor*Test, manufactured by Chlor*Rid International, Inc. PO Box 908, Chandler

Arizona (800)422-3217 www.chlor-rid.com, or approved equal.

2. DeFelsko PosiTector Soluble Salt Tester (in accordance with ASTM D4940), DeFelsko Corporation, 800 Proctor Avenue, Ogdensburg, New York, 13669. Tel

No. 800-448-3835. www.defelsko.com

3. Approved equal shall demonstrate a retrieval efficiency of at least as 70 percent, as tested by an independent laboratory retained by and paid for by the manufacturer.

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2.3 FIELD COATING AND FIELD REPAIR COATING

A. Manufacturer: ZRC Worldwide, 145 Enterprise Drive, Marshfield, Massachusetts, 02050. Tel. No. 781-319-0400. Toll Free No. 800-831-3275. Email:

info@zrcworldwide.com. www.zrcworldwide.com.

B. Product Name: ZRC Zero-VOC Water-Based Cold Galvanizing Compound

C. Materials Specifications:

1. Type – Two-component liquid inorganic zinc compound.

2. Finish – Flat light gray.

3. Metallic zinc content – 93 percent by weight in dry film.

4. Flash point – none.

5. Solids content – 43.5 percent by volume (ASTM D2832).

6. VOC content – 0 g/l (0 lbs./gal) (ASTM D1475).

7. Viscosity – 525 cps. – Brookfield spindle #5 at 100 RPM at 25 degrees C (ASTM

D2196)

8. Maximum service temperature – 1700 degrees Fahrenheit (ASTM D2485).

9. Specific gravity – 3.02 (ASTM D1963).

10. Electrical conductivity – 73 million ohms per 3 mil dry (Resistivity).

11. Pot life – At least 8 hours.

12. Shelf life – 2 years minimum.

13. Dry time – (Set to touch) When ambient air dried, 15 to 20 minutes (ASTM D1640).

14. Recoat time – (Second coat) After 24 hours. The maximum total DFT is recommended to be 6.0 mils. Under certain conditions, recoat time can be reduced.

Contact manufacturer for specifics.

15. Substrate acceptable for coating – Substrates shall be of iron, steel, or aluminum.

D. Equipment

1. Brush or roller applied.

E. Mixes

1. Coating herein specified is a two-component compound.

2. Mix Ratio: 1-part Liquide + 3.1 parts Powder (by weight). Contents shall be mixed together well by adding the Powder to the Liquid. Constant agitation or mixing during application is recommended to ensure a homogenous mix.

2.4 MATERIALS FOR PREPARING EXISTING STEEL AND DAMAGED GALVANIZED

STEEL

A. 3M Corporation, 3M Center, St. Paul, MN, www.3m.com

1. Scotch-Brite Clean and Strip

2. Or approved equal

2.5 COATING SUBSTITUTIONS

A. “As Equal” proprietary coatings systems for consideration may be submitted to

Contracting Officer and must include the following documentation:

1. Manufacturer’s certification that coating is of same generic type as specified system.

2. Performance of formulation showing that it meets or exceeds performance of specified coating system and is suitable for the anticipated service conditions.

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3. Field test and service data for similar service conditions.

4. The listed products signify only that at the time of inspection and test the manufacturer could make a product that met specification requirements.

5. Conform to performance and test parameters established herein in specification.

PART 3 - EXECUTION

003.1 OVERALL SEQUENCE OF WORK

A. General

1. Prepare surfaces and mitigate hazardous materials.

a. Conduct necessary quality control tests and inspections at hold points.

b. Document preparation of surface in daily inspection log.

2. Apply coating as required.

a. Conduct necessary quality control tests and inspections at hold points.

b. Document coating application in daily inspection log.

B. Existing Steel Components

1. Prepare and paint existing steel components designated to remain in the shaft as specified.

C. Galvanized Components

1. Field Painting: Repair localized damaged galvanized structural steel and elevator components with specified coating system.

2. Not to be painted – Elevator assemblies and components received on-site with galvanizing finish, other than localized repairs at damaged areas.

003.2 EXAMINATION

A. Steel surfaces to be coated shall be clean, that is, devoid of grease, oil, mill scale, oxidation, loosely adherent rust, etc.

B. Coating shall be applied directly to metal surface so as to be galvanically active.

C. Examine substrates and conditions, with Inspector for compliance with requirements and conditions affecting performance of work.

1. Atmospheric Conditions: Follow manufacturer’s directions for allowable atmospheric conditions. Do not apply coatings if the following variables are likely to exceed or fall short of manufacturer’s parameters.

a. Measure dew point with a psychrometer or other suitable instrument prior to application. Minimum accuracy of instrument (at nominally 68°F, 90 to

100% RH) shall be ±2%.

b. Perform surface temperature readings on substrate to receive coating prior to application. Do not apply if surface temperature of steel is outside specification requirements. Minimum accuracy of instrument shall be ± 1°F.

c. Measure ambient air temperature (Minimum accuracy of instrument shall be

± 1°F) and relative humidity (Minimum accuracy of instrument (at nominally 68°F, 90 to 100% RH) shall be ±2%) in area of work prior to coating application. Do not apply if ambient air temperature and relative humidity is outside manufacturer’s parameters.

2. Do not proceed with work prior to written approval of test samples.

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3. Begin coating application only after unsatisfactory conditions have been corrected and surfaces are dry.

4. Coating application indicates acceptance of surfaces and conditions by the contractor.

5. Final Acceptance

a. After all existing steel and damaged galvanizing coatings have been applied, repaired as required, and cured, the Contracting Officer will give final coating acceptance at the jobsite.

b. After galvanized steel is erected, damaged field coatings and galvanizing are repaired, and required field bolted connections are fully coated, assessment of the field applied coating systems for specification compliance will be performed.

003.3 PREPARATION - FIELD COATING

A. Protection

1. Protect existing construction and work in place from damage resulting from operations related to the Work including removals, reinstallation, and the storage, preparation, handling, and application of coating materials.

2. Exercise caution in performing Work so as not to damage other building and site elements. Protect the building and site elements from damage.

3. In areas where coating systems are to be applied, protect surrounding construction and property from drippage or other effects of coatings.

4. Materials damaged by coating process shall be repaired to the satisfaction of the

Contracting Officer without additional cost to the Government.

5. Protection materials shall be carefully and thoroughly removed upon completion of

Work.

6. Workers, pedestrians, animals, plants, vehicles, other property, etc.

a. Work required in this Section includes use of chemicals that can harm workers, pedestrians and other persons, animals, plants, and damage vehicles, other property and other persons and objects that are vulnerable to damage by coating operations.

7. Damage to adjacent property, buildings, vehicles, site features, etc., caused by coating operations shall result in no additional cost to the Owner.

B. General:

1. Remove items already in place that are not to be coated. If removal is impractical or impossible because of size or weight of item, provide surface-applied protection before proceeding with surface preparation and coating.

2. After completing coating operations, reinstall items that were removed; use workers skilled in the trades involved.

3. Protect existing components and areas that are not to receive protective coatings.

Use suitable rigid materials adequate to tightly cover and otherwise protect existing coatings and surfaces.

4. Clean substrates of substances that could impair bond of coatings, including dirt, oil, grease, and incompatible paints, coatings, and bond-inhibiting compounds.

5. Prior to painting remove all abrasive, dust, and paint residue from surfaces with commercial grade vacuum cleaner with a brush-type cleaning tool.

6. Existing steel: SSPC-VIS-3 shall be used as a guide to judge power tool treated surfaces.

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C. Surface Preparation - Field Painting

1. Existing Structural Steel

a. Surface preparation is dependent upon substrate condition. Since work areas shall already been abated prior to coating operations in an engineered controlled environment and containment, maintain such controls and containment during surface preparation, coating application, and subsequent cure.

b. Remove grease, oil, dirt, and other surface contaminants from areas to be painted, in accordance with SSPC-SP 1, prior to abrasive blast cleaning.

c. Remove existing coatings by preparing the surface, including welds and crevices, in accordance with SSPC-SP11. Thoroughly clean any pitted areas.

d. Remove all dust and debris from surfaces to be painted.

e. Determine chloride content on prepared surfaces and on prepared welds if determined necessary from mockup testing and evaluation, if chloride contamination is greater than manufacturer’s recommendations, remove chloride salts according to the chloride removal procedure for Existing

Steel.

f. Coat surfaces after the Inspector’s examination and before oxidation of the surface occur. Re-prepare non-compliant surfaces.

2. Surface preparation for damaged galvanizing of Shop Coated Galvanized Steel

a. Damage constitutes the following:

1) Areas of galvanizing where the steel substrate has become exposed due to damage

2) Areas of galvanizing where thickness of the galvanized layer has been reduced to 3 mils or less due to damage

3) Areas of galvanizing that have disbonded from the steel substrate

b. Visually identify physically damaged and deteriorated areas including, but is not limited to:

1) Physical damage from handling and installation, weld-through

2) Rusting of steel substrate

3) Disbondment of, or other defects in, the galvanized layer.

c. Excessive damage to the galvanizing constitutes rejection.

d. Remove grease, oil, dirt, and other surface contaminants in accordance with

SSPC SP1 from areas with damage or imperfections, and from the exiting intact coating within a minimum of two inches and to the extent that the repair coating overlaps.

e. Remove any debonded galvanizing and feather-back edges to firm intact galvanizing

f. Prepare damaged surfaces in accordance with SSPC SP11 using 3M Scotch-

Brite Clean and Strip and transition the surface preparation from steel to galvanized steel allowing a minimum of two inches of overlap onto the galvanized surface.

g. Feather edges to provide a smooth transition between new remedial protective coating finish and existing galvanizing so that the recoated surface will have a smooth, continuous appearance.

h. Apply the coating in a manner as to achieve complete and thorough coverage of the surface and all irregularities.

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i. All remedial protective coating work herein specified shall be done under controlled environmental conditions and enclosures whereupon coatings are applied before oxidation of metal surface occurs that could limit adhesion.

Re-prepare non-compliant surfaces.

003.4 APPLICATION

A. General Application Information

1. Apply coatings according to manufacturer’s written instructions and in strict accordance with the specification to a dry film thickness of 2.5 to 3.5 mils, but anomalies no greater than 5.0 mils.

2. Use applicators and techniques suited for coating and substrate indicated.

3. Remove fixed items such as lights, conduits, etc. to prepare and coat underlying surfaces. Move movable equipment and coat surfaces behind movable equipment with the required coating system.

4. Do not install fixed equipment and appurtenances until surfaces that will ultimately be behind fixed equipment and appurtenances are coated with the required coating system.

5. The coating system has good brushing properties.

6. The coating shall be well stirred before use so that it is completely homogeneous to ensure the continuous application of a completely homogenous material at all times.

7. The coating may be proportioned and mixed topside (above ground) so as to limit any likelihood of spills and contamination of surround cave ecosystem during remedial coating operations in tight-working elevator-shaft working quarters.

8. Material partially used at the end of any day shall be protected from skinning by placing thin blanket of water over the remaining coating followed by careful closing of vented containers. Coating may be reused on the following day after total homogenization.

9. Brush apply coatings in wet coat fashion.

10. Follow manufacturer’s written instructions for recoat times for all coatings.

B. Specific Application Information

1. Apply by brush or roller.

2. Ensure that protective coating film is uniform at specified dry film thickness.

3. Apply coatings to produce surface films without spotting, holidays, laps, brush marks, runs, sags, ropiness, bubbles, or any other…