140P2021R0018-0010_Att01_RevSpec099713_210512_0010.pdf

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STEEL COATING

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SECTION 09 97 13 - STEEL COATING

GENERAL

1.1 SUMMARY

A. Section Includes:

1. Surface preparation and application of coating system for painting exterior surfaces of steel cranes.

B. Related Sections:

1. Section 00 31 26 - Existing Hazardous Material Information

2. Section 05 04 00 - Miscellaneous Steel

3. Section 08 01 510.91 - Steel Window and Door Restoration

1.2 REFERENCES

A. Definitions:

1. Definitions of Painting Terms: ASTM D16, unless otherwise specified.

2. Dry Film Thickness (DFT): Thickness of a coat of paint in fully cured state measured in mils (1/1000 inch).

3. SSPC Environmental Zones Definitions - SSPC Painting Manual, Volume 2, 2008 Edition.

B. Reference Standards: Latest edition as of Specification date.

1. ASTM International (ASTM):

a. B117/B117M: Standard Practice for Operating Salt Spray (Fog) Apparatus

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

c. D610/D610M: Standard Practice for Evaluating Degree of Rusting on Painted Steel

Surfaces

d. D714/D714M: Standard Test Method for Evaluating Degree of Blistering of Paints

e. D1212/D1212M: Standard Test Methods for Measurement of Wet Film Thickness of

Organic Coatings

f. D2247/D2247M: Standard Practice for Testing Water Resistance of Coatings in

100 % Relative Humidity

g. D3359/D3359M: Standard Test Methods for Rating Adhesion by Tape Test

h. D4060/4060M: Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber Abraser

i. D4541/D4541M: Standard Test Method for Pull-off Strength of Coatings Using

Portable Adhesion Testers.

2. Code of Federal Regulations:

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

3. Military Performance Specification

a. MIL-PRF-23236C: Performance Specification: Coating Systems For Ship Structures

b. MIL-PRF-24635: Performance Specification: Coating Systems, Weather-Resistant, Exterior Use

4. NACE International

a. NACE WJ-2 Waterjet Cleaning of Metals - Very Thorough Cleaning

5. The Society for Protective Coatings (formerly Steel Structures Painting Council, or SSPC):

a. SSPC Painting Manual.

b. SSPC PA 2 - Procedure for Determining Conformance to Dry Coatings Thickness

c. SSPC SP 1 - Solvent Cleaning

d. SSPC-SP 10/NACE 2 - Near-White Blast Cleaning of Steel Joint Standard

e. SSPC-QP 1 - Field Application to Complex Industrial and Marine Structures

f. SSPC-QP 1 - Field Removal of Hazardous Coatings

g. SSPC-VIS 1 - Standard Pictorial Surface Preparation Standards for Painting Steel

Surfaces

1.3 ADMINISTRATIVE REQUIREMENTS

A. Coordinate Work to ensure that adjacent areas are not adversely affected. Coordinate:

1. With the Contracting Officer:

2. With other trades:

a. To ensure that work done by other trades is complete and ready for coating Work.

b. To avoid or minimize work on, or in the immediate vicinity of, coating Work in progress.

c. To ensure that subsequent work will not adversely affect completed coating.

1.4 SUBMITTALS

A. Product Data: Coating manufacturer’s literature including written instructions for evaluating, preparing, and treating substrate; technical data including safety precautions for handling, storing, applying, and disposing of materials; and instructions for protecting surrounding areas from overspray. Include:

1. List of materials to be provided, identified by manufacturer’s name, product name, or stock number, indicating surfaces to which they are to be applied. Maintain a list where work is being performed.

2. Certification by coating manufacturer that products supplied comply with local VOC regulations.

3. Certification that the coating is free of lead, asbestos, barium, and mercury.

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4. Coating manufacturer’s color chart showing full range of colors available.

5. Decoding information to verify the shelf life of materials.

6. Application instructions including environmental limitations.

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

8. Safety Data Sheets (SDS) for information only; safety is the sole responsibility of the

Contractor.

B. Manufacturer’s Information:

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

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

3. Manufacturer’s statement of maximum permissible surface chloride concentration on substrate prior to coating and maximum surface concentration on shop applied primer prior to intermediate coat application, and specific chloride concentration measurement test procedure.

4. Provide a letter certifying products are free of, or do not exceed specified limits of, asbestos, lead, chromate, cadmium, and mercury.

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

6. Manufacturer’s qualifications.

7. Manufacturer’s technical representative qualifications.

8. Written approval of contractor by the manufacturer of the specified coatings.

9. List of 5 similar projects using the specified coatings completed in the past 5 years for approval. Similar projects are 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 2A or 2B. 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.

10. Samples for review of coating color and texture.

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

12. Damaged coating repair procedure.

C. Contractor’s Qualifications:

1. Evidence that Contractor’s existing company has a minimum of 10 years of continuous experience on projects of similar size and complexity to this Work applying the specified coatings located in comparable environmental conditions as defined by SSPC

Environmental Zones Definitions. Include:

a. Project names.

b. Owner’s names.

c. Owner’s Representatives names, addresses, and telephone numbers.

d. Description of work.

e. Coatings used.

f. Project supervisor.

g. Total cost of coating work and total cost of project.

h. Completion dates.

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2. Contractor qualifications.

a. Current SSPC- QP1 and QP2 certifications.

3. Supervisor qualifications.

4. Painter qualifications.

5. Quality control representative qualifications

D. Contractor’s safety plan, protection plan, enclosure plan, and inspection plan.

E. Samples: 8-inch square samples, on rigid steel backing, of each coating system, with color and gloss of finish coat to be applied. For review of color and texture only.

1. Provide step samples, defining each separate coat. Use representative colors when preparing samples for review. Resubmit until required color, sheen, and texture are achieved

2. Label each sample for location and application.

3. Provide list of materials and applications for each coat of each sample.

F. Submit repair procedures for damage, defects, or other nonconformances in the coating system for review and approval. Repairs procedures must result in an acceptable, uniform gloss and color on visible surfaces.

1. Pinhole repair procedure

G. Maintenance recommendations for coating system.

H. Sample Warranties:

1. Copy of Contractor’s warranty, stating obligations, remedies, limitations, and exclusions.

Submit with bid.

2. Coating manufacturer’s warranty, stating obligations, remedies, limitations, and exclusions, and obtain from the coating manufacturer a letter of intent to warranty coating before start of work.

1.5 QUALITY ASSURANCE

A. The Contracting Officer reserves the right to periodically observe progress, evaluate quality, and perform tests of the coating.

B. The Contracting Officer may, at his or her discretion, hire a Coating Inspector.

C. All work is subject to review by the Contracting Officer before it is concealed by other work and/or if means of access is removed.

1. Coordinate mandatory reviews with the Contracting Officer prior to the start of Work.

2. Provide reasonable notification to the Contracting Officer to allow for such review as work proceeds.

D. General

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1. Review specifications for requirements affecting Work of this trade. Conflicts 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 steel element.

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

E. 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 including:

a. During the mock-up to establish the quality standard.

b. Periodic inspections for conformance with requirements, including:

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 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 representative shall perform a final inspection of completed work and issue warranty.

F. Contractor Qualifications: Experienced firm that has successfully completed coating work similar in material, design, and extent to that indicated for Project. Must have successful applications of specified materials in local area in use for minimum of 10 years.

1. Employ foreman who is fluent in English, to be on Site at all times during the Work. Do not change foremen during the course of the Project except for reasons beyond control of

Contractor; inform the Contracting Officer in advance of any changes.

2. Contractor shall have current SSPC- QP1 and QP2 certifications.

3. Contractor shall have a dedicated Quality Control Representative during all stages of work, including the mock-up.

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

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

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4. Assure the presence of a qualified technical representation from coating manufacturer.

5. Contractor shall have experience with similar projects for the successful shop application of coating to stainless steel.

6. Approve in writing for application of the coating system by coating manufacturer.

G. Contractor Supervisor Qualifications

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

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

H. Shop Contractor Quality Control Representative

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

2. Shall be NACE Level 3 Certified.

I. Painter Qualifications

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

J. Field Quality Control

1. Do not apply any coatings when measurements, observations, readings, and conditions 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. Inspector’s Name

b. Project Number

c. Location of structure

d. Description of work performed

e. Coatings used

f. Batch numbers of coatings

g. Batch number of thinners

h. Hold point inspections completed

i. Inspection equipment calibrated

j. 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. 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.

c. 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.

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

e. Test compressed air to ensure no moisture or water contamination.

f. Painter shall confirm wet film thickness of intermediate and finish coats taken randomly using a notched gauge at least once every element or at least 20 linear feet in accordance with ASTM D1212/D1212M.

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

h. Conduct pinhole and holiday detection tests after final cure of the finish coating. Use low voltage wet sponge detector or other apparatus approved by the coating manufacturer.

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

a. Primer coat inspection

b. Intermediate coat inspection

c. Finish coat inspection

d. Corrective action

K. Use SSPC-VIS 1: “Standard Pictorial Surface Preparation Standards for Painting Steel Surfaces” to evaluate surface preparation.

L. Adhesion: The Inspector will measure coating adhesion as described in Part 3 and as deemed necessary throughout the project. Use same model pull-off tester (ASTM D4541/D4541M Type

2) for comparison of adhesion data throughout entire project unless directed otherwise by the

Contracting Officer.

M. Preapplication Meeting: Convene a preapplication meeting 2 weeks before start of application of coating systems. Require attendance of parties directly affecting work of this section, including the Contracting Officer, Contractor, Engineer, applicator, and manufacturer’s representative.

Review the following:

1. Environmental requirements.

2. Protection of surfaces not scheduled to be coated.

3. Surface preparation.

4. Application methods.

5. Repair.

6. Field quality control.

7. Cleaning.

8. Protection of coating systems.

9. One-year inspection.

10. Coordination with other work.

1.6 MOCK-UPS

A. Mock-Ups: Prepare mock-up for each coating system specified using same materials, tools, equipment, and procedures intended for actual surface preparation and application.

1. Perform separate mock-ups at boom, house, and frame.

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2. Size and location of the mock-ups shall be determined by the Contracting Officer and shall not be less than 4 square feet.

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

4. Perform specified coating application such that a portion of each coating layer is exposed to view. Each coating layer shall have a distinguishably different color

5. Blasting coupons shall be used during mockups to verify surface preparation techniques and profile.

B. Additional mock-ups 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 Contracting Officer’s approval.

C. Mock-ups will cure 21 days prior to testing and evaluation by the Contracting Officer.

D. Permit Contracting Officer, Inspector, and Coating Manufacturer to perform field adhesion testing of coatings on mock-ups prior to proceeding with overall work. Adhesion tests will be performed in accordance with ASTM D4541/D4541M. Results of tests will be evaluated by the

Contracting Officer.

E. Coating manufacturer shall review surface preparation and coating mock-ups on site during installation.

F. Coordinate the mock-up schedule with the Contracting Officer.

1.7 DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, and handle materials according to manufacturer’s recommendations and in such a manner to prevent damage to materials or structure.

B. Delivery: Deliver materials to Site in manufacturer's original, unopened containers and packaging, with labels clearly identifying:

1. Coating or material name.

2. Manufacturer.

3. Color name and number.

4. VOC content.

5. Batch or lot number.

6. Date of manufacture.

7. Directions for storing, handling, mixing with other components, and application, including precautions.

8. Thinning instructions, if applicable.

C. Acceptance at Site: Damaged or deteriorated materials shall be clearly identified and not used on this Project. Promptly remove rejected and non-complying materials from the premises.

D. Store materials in original, undamaged containers and, if permitted, partially-used materials in tightly-covered containers in clean, dry, well-ventilated, protected location on raised platforms with weather-protective coverings, within temperature range required by manufacturer Store to

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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.

E. Limit stored materials on structures to safe loading capacity of structure at time materials are stored, and to avoid damage or permanent structure deflection.

F. Conspicuously mark damaged or opened containers or containers with contaminated materials and remove from Site as soon as possible.

G. Remove and replaced materials that cannot be applied within the stated shelf life.

H. Waste Management and Disposal: Comply with applicable safety codes and regulations that govern the work, including all Federal, State, Local, OSHA, and EPA regulations covering waste and wastewater disposal.

1.8 PROJECT CONDITIONS

A. Verify existing dimensions and details prior to the start of coating Work. Notify the Contracting

Officer of conditions found to be different than those indicated in the Contract Documents. the

Contracting Officer will review condition and inform Contractor of required remedy.

B. Comply with the Government’s limitations and restrictions for Site use and accessibility.

C. Environmental Limitations: Prepare surfaces and apply and cure coating only:

1. When existing and forecast weather conditions permit coating to be applied according to the coating manufacturer’s written instructions.

2. Ambient Temperature: Between 50 degrees F and 95 degrees F, and within air temperature range in accordance with manufacturer’s instructions.

3. Surface Temperature: Minimum of 5 degrees F (3 degrees C) above dew point.

4. Relative Humidity: Prepare surfaces and apply and cure coatings within relative humidity range in accordance with manufacturer’s instructions.

5. Precipitation: Do not prepare surfaces or apply coatings in rain, snow, fog, or mist or to damp or wet substrates.

6. Wind: Do not spray coatings if wind velocity is above manufacturer’s limit.

D. Dust and Contaminants:

1. Schedule coating work to avoid excessive dust and airborne contaminants.

2. Protect work areas from excessive dust and airborne contaminants during coating application and curing

E. Handle and install materials in strict accordance with safety requirements required by coating manufacturer; Safety Data Sheets (SDS); and local, state, and federal rules and regulations.

Maintains Safety Data Sheets (SDS) with materials in storage area and available for ready reference on site.

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F. Maintain required ventilation during preparation and application of coating materials.

1.9 CHANGES IN WORK

A. During rehabilitation work, existing conditions may be encountered which are not known or are at variance with the Contract Documents. Such conditions may interfere with the Work and may consist of damage or deterioration of the substrate or surrounding materials that could jeopardize the integrity or performance of the Work.

1. Notify the Contracting Officer of conditions that may interfere with the proper execution of the Work or jeopardize the performance of the Work prior to proceeding with the Work.

1.10 WARRANTY

A. General

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

Government.

B. For a period of 5 years, all manufacturer(s) and Contractor shall jointly warrant the coating 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/D714M.

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 10 (Less than or equal to

0.001 percent) of the surface area being coated as measured in accordance with ASTM D

610/D610M.

C. For a period of 10 years, all manufacturer(s) shall warrant that 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/D714M.

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 (Greater than 0.03 percent and up to 0.1 percent) of the surface area being coated as measured in accordance with

ASTM D610/D610M.

PART 2 - PRODUCTS

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2.1 MATERIALS FOR PREPARATION AND COATING OF STEEL:

A. Acid-based Surface Chloride Removal Product (Salt Remover)

B. Surface CSN Test Kit

C. Chloride ion Test Kit for Water

D. Chloride Ion Test Kit for Abrasive.

E. Alkaline cleaner/degreaser designed to remove dirt, oils, and grease as recommended by the coating manufacturer.

2.2 STEEL COATING, GENERAL

A. Source Limitations: Obtain materials through one source (from single coating manufacturer), or from sources approved by coating manufacturer.

B. Material Compatibility: Provide primers, intermediate coats, finish coats, and related materials that are compatible with one another and substrates indicated under conditions of application and service, as demonstrated by manufacturer based on testing and field experience.

C. Material Quality: Provide manufacturer’s best-quality coating materials that are factory formulated and are recommended by manufacturer for application indicated. Material containers not displaying manufacturer’s product identification are not acceptable.

D. Color:

1. Primer and Stripe Coats

a. Use contrasting colors as recommended by the coating manufacturer to distinguish from Intermediate Coat.

2. Intermediate and Finish Coat Color: As selected by Contracting Officer with approval by

Coating Manufacturer in advance of sales order for coatings and application.

3. Gloss and Finish as selected by Contracting Officer with approval by Coating

Manufacturer in advance of sales order for coatings and application.

2.3 SEALER (AT CREVICES)

A. Amerlock sealer, manufactured by PPG Industries, Inc.

1. Two-component, penetrating epoxy primer sealer.

2. 100 percent solids by volume.

3. Color: Clear.

2.4 STEEL COATINGS

A. Paint System:

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1. Primer: Dimetcote 302H Reinforced inorganic zinc-rich primer, manufactured by PPG

Industries, Inc.

a. 3.0 - 4.0 mils DFT

b. 78 percent solids by volume

2. Stripe Coat (corners and edges): Dimetcote 302H Reinforced inorganic zinc-rich primer, manufactured by PPG Industries, Inc.

a. 2.0 - 4.0 mils DFT

b. 78 percent solids by volume

3. Intermediate: Amercoat 240, two-component phenalkamine epoxy, manufactured by PPG

Industries, Inc.

a. 4.0 - 8.0 mils DFT

b. MIL-PRF-23236 (C): Greater than 70 percent edge retention

1) Type VII Edge retention

c. MIL-PRF-24647

d. ASTM B117/117M: 14,000 hours with no blistering, rusting, or flaking

e. ASTM D2247/D2247M: 3,500 hours with no blistering, rusting, or cracking on panel face

f. ASTM D4060/D4060M: No more than 100mg average loss after 1,000 cycles (cs-17 wheel, 1 kg)

4. Finish: PSX 700(SG), two-component polysiloxane, manufactured by PPG Industries, Inc.

a. 4.0 to 7.0 mils DFT

b. MIL-PRF-24635 Type VI

c. 90 percent solids by volume

d. Very Low VOC

e. Isocyanate free

2.5 SUBSTITUTIONS

A. Coatings

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

Officer in accordance with General Conditions and must include the following documentation:

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

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

c. Field test and service data for similar service conditions

PART 3 - EXECUTION

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3.1 EXAMINATION

A. Examine substrate surfaces and conditions under which coating systems are to be applied with

Contractor and Coating Manufacturer’s Technical Representative for compliance with requirements and other conditions affecting application or performance of coating.

1. Ensure that work done by other trades is complete and conditions are ready for coating

Work.

2. Do not begin surface preparation or application until unacceptable areas or conditions have been corrected.

3. Verify that areas and conditions under which coating Work is to be performed permit proper and timely completion of the work.

4. Verify compatibility with and suitability of substrates, including existing coatings.

5. Notify the Contracting Officer in writing of conditions which may adversely affect application or performance of the coating and recommend corrections.

6. Do not proceed with coating Work until adverse conditions have been corrected and reviewed by the Contracting Office.

7. Commencing coating Work constitutes acceptance of Work surfaces and conditions.

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

3.2 PROTECTION OF SURFACES NOT SCHEDULED TO BE COATED

A. Protect full length of all wire ropes during preparation and coating work.

B. Take precautions to ensure safety of people, including building users, passers-by, and workers, and animals, and protection of property, including adjacent building elements, landscaping, and motor vehicles.

C. Prevent construction debris, coatings, and other materials from coming into contact with pedestrians, motor vehicles, landscaping, buildings, and other surfaces that could be harmed by such contact.

D. Protect paving and sidewalks, and adjacent building areas from mechanical damage due to containment structures and other equipment.

E. Limit access to Work areas. Provide “Wet Paint” signs to protect newly coated surfaces.

F. Erect temporary protective canopies, as necessary, over walkways and at points of pedestrian and vehicular access that must remain in service during Work.

G. Take precautions to protect against air-borne materials and runoff.

H. Masking and Preparation:

1. Comply with coating manufacturer’s written instructions for protecting structure and other surfaces against damage from exposure to its products.

2. Cover adjacent surfaces with materials that are proven to resist coating system.

3. Mask off or protect from spatter, overspray, or other damage surfaces not scheduled to receive coating.

4. Remove masking and other protective measures at completion of coating Work.

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I. Assume responsibility for injury to persons or damage to property due to Work, and remedy at no cost to the Government.

3.3 PREPARATION - GENERAL

A. Repair steel prior to preparation and coating work.

1. See Section 05 04 00.

B. Remove glazing from windows, louver blades, and remove doors and hardware prior to preparation and coating work.

1. See Section 08 01 51.91.

C. All surface preparation and coating application shall be within an enclosure system that will contain all water, abrasive, paint, dust and debris resulting from surface preparation and coating application procedures.

1. See Section 00 31 26.

2. Surface Preparation Water:

a. Water source shall be clean, potable water compliant with SSPC SP WJ-2.

b. Do not use water sources with chloride content that increase surface chloride contamination of prepared surfaces. Chloride content of the water shall be less than

100 ppm. Retest water whenever the source changes; this includes each delivery if the water is delivered to the site. Test source water more frequently when required by the Contracting Officer.

D. Clean substrates of substances that could impair bond of coatings, including dirt, oil, grease, and incompatible paints and coatings.

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

1. SSPC-Vis-1 shall be used as a guide to judge compliance of surfaces prepared by abrasive blasting in accordance with SSPC SP10.

F. Clean using methods recommended in writing by coating manufacturer.

G. Sufficiently remove any corrosion or damaged coating impeding access to CSN salts. This step is not meant to provide final preparation, the purpose is to sufficiently remove any corrosion or damaged coating that may otherwise impede access to the CSN salts and their removal.

H. Use Surface CSN Test Kit in accordance with the manufacturer’s directions to determine chloride, sulfate, and nitrate concentration on prepared surfaces.

1. Chloride, sulfate, and nitrate content on the surface shall be equal to or less than the manufacturer’s maximum permissible surface CSN concentration.

2. Notify the Contracting Officer of any surfaces where the Surface CSN Test Kit cannot be properly and adequately applied. The Contracting Officer will provide an alternate procedure with an appropriate factor (multiplier) to be used for the different test method(s).

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I. Soluble Salts Removal Procedure: Add Salt Remover to clean potable water in accordance with the manufacturer’s directions and thoroughly pressure wash surfaces as recommended by the Salt

Remover manufacturer and approved by the Contracting Officer. Force-dry all surfaces, including ponded areas, using clean, dry, oil free, and compressed air. Whether or not crevices, joints, and connections appear dry, force any residual moisture from these areas and blow-dry using clean, dry, oil free, compressed air.

1. Determine surface CSN concentration on prepared and reprepared surfaces. If CSN concentration is greater than manufacturer's maximum surface permissible CSN concentration repeat the soluble salts removal procedure. If surfaces remain noncompliant notify Contracting Officer.

J. Surface preparation of Limited/Difficult Access Surfaces shall be carried out to the maximum extent practical based on reasonable effort demonstrated in the mockups and found to be acceptable by the Contracting Officer.

1. Prepare surfaces using tool(s) and procedure(s) approved in mock-up.

K. Abrasives shall have a gradation that the abrasive will produce a uniform profile.

1. 1.5 - 2.0 mil surface profile

2. Chloride content shall be less than 100 ppm

3.4 SURFACE PREPARATION

A. Prepare steel surfaces in accordance with manufacturer’s instructions.

B. Preparation: Remove rust and loose mill scale.

1. Fabrication defects:

a. Correct steel and fabrication defects revealed by the effects of surface preparation.

b. Remove weld spatter, flux, and slag.

c. Round sharp edges and corners of welds to a smooth contour.

d. Smooth weld undercuts and recesses.

e. Grind down porous welds to pinhole-free metal.

f. Remove weld flux from surface.

C. Initial Preparation:

1. Substrate: steel with existing coating, or where present, areas of bare metal or rusted bare metal. Clean and prepare substrate surfaces according to coating manufacturer’s written instructions and abate any hazardous materials. Provide clean, dust-free, dry, and sound substrate for coating application.

a. Prepare all surfaces to be coated in accordance with SSPC-SP1 and remove salts:

1) Remove all visible oil, grease, drawing and cutting compounds, wax, fatty acids, dirt, dust, loose particles, soil, salts, animal wastes, bolt lubricants, dyes, and other contaminants from surfaces in accordance with SSPC-SP1 Section 4.4

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Contracting Officer before use.

a) Apply cleaner/degreaser solution to surfaces and allow to dwell as recommended by the manufacturer.

b) Mist surfaces with water as needed to maintain cleaner/degreaser in a wet condition during the dwell period.

c) Vigorously scrub areas with stubborn deposits of contaminants with the cleaner/degreaser as recommended by the coating manufacturer.

b. Before the cleaning solution dries on the surface, remove contaminants, cleaner/degreaser solution, all loose mill scale, loose rust and other corrosion products, and loose coating by thoroughly pressure washing and preparing surfaces in accordance with SSPC SP WJ-2 using Surface Preparation Water at a stand-off distance and pressure range established in mock-up testing.

1) Pressure wash 3,000 to 5,000 PSI (at gauge)

2) Check surfaces for pH at a minimum of 5 locations every 100 square feet with pH paper to confirm surfaces, including crevices, are neutral, pH 6 to 8, and that all alkaline cleaner/degreaser has been removed. If surfaces are still alkaline continue pressure washing until surfaces have been neutralized.

3) The cleaned, treated surfaces shall be free of oil, grease, drawing and cutting compounds, wax, fatty acids, dirt, dust, loose particles, soil, salts, animal wastes, bolt lubricant, dyes, and other contaminants. Contaminants not removed by the alkaline cleaner/degreaser shall be removed by other methods of SSPC-SP1

c. Before continuing with surface preparation, allow surfaces to completely dry, including crevices. Whether or not crevices, joints, and connections appear dry, force any residual moisture from these areas and blow-dry using clean, dry, oil free, compressed air.

D. SSPC-SP 10/NACE 2 Near White Blast Cleaning, with minimum 1.5 to 2.0 mil anchor profile.

1. Prepare surfaces including welds in accordance with SSPC-SP10:

a. Remove existing coatings by preparing the surface, including welds, in accordance with SSPC-SP10. Thoroughly clean any pitted areas; maintain blast angle at 90 degrees to the surface for maximum cleaning efficiency.

b. Provide a surface profile of 1.5 to 2.0 mils where new coating system will be applied to prepared steel substrates. Blasting coupons shall be used during mockups to verify surface preparation techniques and profile.

c. Determine surface CSN concentration on prepared surfaces. If CSN contamination is greater than the manufacturer’s maximum permissible surface CSN concentration, remove soluble salts in accordance with the Soluble Salts Removal Procedure as necessary to meet the required chloride, sulfate, or nitrate surface concentration levels.

d. Upon completion of the Soluble Salts Removal Procedures, re-prepare surfaces as required for compliance with SSPC-SP10 as required.

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2. Prior to application of coating system:

a. Remove all abrasive, dust, and paint residue from steel surfaces with an industrial

HEPA grade vacuum cleaner with a brush-type cleaning tool. Surfaces shall be compliant with ISO 8502-3 Level 1 or better.

E. Contractor’s Quality Control Representative’s shall examine substrate to ensure that it is prepared as required and ready to receive coating.

1. Allow Coating Manufacturer’s Technical Representative to review substrate.

Manufacturer’s representative shall report in writing to Contractor and Contracting Officer conditions which may adversely affect coating system application or performance and recommend corrections.

2. Do not proceed with coating application until unsatisfactory conditions have been corrected. Allow for review by Contracting Officer.

3. Re-prepare non-compliant surfaces.

4. Prime surfaces after examination and before oxidation of the surface occur. Only prepare enough surface area that can meet the surface preparation requirements and be coated in the same 8-hour shift.

5. Commencing coating application constitutes acceptance of Work surfaces and conditions.

3.5 APPLICATION

A. General: Prepare and apply materials according to coating manufacturer’s written instructions, at recommended rates and coverages.

B. Test prepared surfaces for moisture and other conditions as recommended by coating manufacturer. Verify that ambient air and substrate surface temperatures, relative humidity, and dew point are within ranges recommended by coating manufacturer and are forecast to remain within these ranges during coating curing period.

C. Mix materials thoroughly to uniform, smooth consistency in accordance with manufacturer’s instructions. Do not thin or dilute unless permitted by coating manufacturer; use recommended thinners within recommended limits.

1. Stir as required during application.

2. If surface film forms, do not stir film into material. Remove film and strain coating material before using if acceptable to coating manufacturer.

3. Maintain containers used for mixing and applying coating in clean condition, free of foreign materials and residue. Keep containers closed when not in use to avoid contamination.

D. Apply coating by roller, spray, or brush as recommended by manufacturer. Use applicator and technique best suited for substrate and type of material being applied.

1. Extend application on interior surfaces minimum 4 inches at all openings.

2. Apply materials as soon as practicable after completion of surface preparation or full curing of previous material application.

3. Do not coat over conditions detrimental to formation of durable coating film, such as dirt, rust, scale, grease, or moist or scuffed surfaces.

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E. Penetrating sealer

1. Install penetrating sealer at all crevices and joints.

2. Install in accordance with manufacture’s recommendations.

F. Doors

1. Prepare and coat all sides of doors prior to reinstalling.

G. Louvers

1. Prepare and coat all sides of blades prior to reinstalling.

H. Attic-Stock Items

1. Prepare and coat all sides of ladders, track guards, and block and hook assembly prior to installing.

3.6 REPAIR

A. Damaged Materials: Repair or replace damaged materials and surfaces not scheduled to be coated.

B. Damaged Coatings: Touch-up or repair damaged coatings (including destructive test sites) in accordance with the coating manufacturer’s approved Damaged Coating Repair Procedure.

Touch-up of minor damage shall be acceptable where result is not visibly different from adjacent surfaces. Recoat entire surface where touch-up result is visibly different, either in sheen, texture, or color.

C. Coatings Defects: Repair in accordance with manufacturer’s instructions coatings that exhibit film characteristics or defects that would adversely affect performance or appearance of coating systems.

D. Coating Pinholes: Coating shall be free of pinholes and other defects. Repair pinholes in accordance with the approved manufacturer’s Pinhole Repair Procedure.

3.7 FIELD QUALITY CONTROL

A. Material Coverage Rates.

1. At beginning of application, calibrate material coverage rate with wet-mil thickness equivalent to minimum specified dry-mil thickness. Measure wet-mil thickness with thickness gauge.

2. Measure wet-mil thickness at least once for every 10 square feet of surface coated. Adjust coverage rate to maintain minimum thickness.

3. Record measurements, locations, and dates and provide to Contracting Officer weekly for review.

B. Measure surface chloride contamination twice for every 150 square feet of surface prepared.

Surface chloride contamination shall be no more than 2 micrograms per square centimeter.

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1. Record measurements, locations, and dates and provide to Contracting Officer daily for review.

C. Allow the Contracting Officer access to observe progress and quality of portion of completed

Work.

D. The following tests shall be performed by Third Party Inspector at the Contractor’s expense.

Contractor shall provide access to test locations determined by the Contracting Officer.

1. Verify coatings and other materials are as specified.

2. Verify surface preparation and application are as specified.

3. Measure dry-film thickness of each coat and total DFT of coating. Coating thicknesses are acceptable if within specified ranges.

4. Coating Defects: Check coatings for film characteristics or defects that would adversely affect performance or appearance of coating systems.

a. Conduct pinhole and holiday detection tests after final cure of the finish coating. Use low voltage wet sponge detector or other apparatus approved by the coating manufacturer.

5. Perform adhesion tests per ASTM D3359, Test Method A, after coating has cured. Coating adhesion is not acceptable if removal occurs (rating below 5A).

a. Perform 1 test for every 25 to 50 SF of installed coating as directed by Third Party

Inspector and Contracting Officer.

6. Perform pull-off tests per ASTM D4541, after coating has cured.

a. Perform 1 test for every 50 to 100 SF of installed coating as directed by Third Party

Inspector and Contracting Officer.

7. If coating application is acceptable, the Government will pay Contractor to repair substrate and coating as necessary at test locations.

8. If coating application is unacceptable, Contracting Officer will determine remedy.

Contractor shall remove and replace unacceptable coating or perform other remedial actions at no cost to the Government. Contractor shall also repair substrate and coating at test locations with unacceptable results at no cost to the Government. Contractor may, at own expense, perform additional measurements and testing to determine limits of areas with unacceptable coating.

9. Provide test reports to Contracting Officer.

E. Contracting Officer may direct that coating application stop if test results show that materials being used do not comply with specified requirements. Recoat and tint rejected work at no additional cost. If new coating application is incompatible with rejected coated surfaces, preparation procedures specified in this Section will be performed again at no additional cost to the Government.

F. Completed Work shall match approved mockup for color, texture, and coverage, in opinion of the

Contracting Officer, and shall be free from flow-lines, streaks, blisters, and other surface imperfections. Remove, refinish, or recoat Work not complying with specified requirements.

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G. Manufacturer’s Field Services: Manufacturer’s representative shall provide technical assistance and guidance for surface preparation and application of coating systems.

3.8 CLEANING

A. At the end of each workday, clean Site and Work areas and place rubbish, empty cans, rags, and other discarded materials in appropriate containers.

B. After completing coating Work:

1. Clean spillage, overspray, and spatter from adjacent surfaces using cleaning agents and procedures recommended by manufacturer of affected surface. Exercise care to avoid scratching or damage to surfaces.

2. Repair surfaces stained, marred, or otherwise damaged during coating Work.

3. Clean up debris and surplus materials and remove from Site.

C. Remove temporary coverings and protection of surrounding areas and surfaces.

3.9 ONE YEAR INSPECTION

A. Government will set date for 10 month inspection of coating systems.

B. Inspection shall be attended by the Contracting Officer, Contractor, Architect/Engineer and manufacturer’s representative.

C. Repair deficiencies in coating systems as determined by the Contracting Officer in accordance with manufacturer’s instructions.

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