09_96_20_-_Coatings_Revised_8-20-26_0002.pdf

Webster Dam Spillway Radial Gates Repair

Coatings Revised

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SECTION 09 96 20

COATINGS (Revised)

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Application of a New 3-Coat System

1. Exterior Radial Gates

a. Measurement:

1) Price shall include application on the exterior faces, exterior edges, radial arms structural steel, trunnion blocks, and counterweight frames of (3) radial gates.

2) Price shall include application on (2) floatwell covers and frames.

3) Price shall include the cost of materials for, and application of, the new coating system per this specification.

4) Price shall include the cost of furnishing, preparing, and applying materials for coating operations.

5) Price shall include the cost of removal and reinstallation of bird netting of end trunnion blocks.

6) Price for removal of existing coatings shall be included in Section 02 83 30 – Removal and Disposal of Coatings Containing Heavy Metals.

b. Payment: Lump-sum price offered in the Schedule.

2. Gallery

a. Measurement:

1) Price shall include application to the ladders, pipework, vent work, conduit, and metal fixtures located in the gallery (excluding the floats and float guide rails).

2) Price shall include application on (2) access covers and frames.

3) Price shall include the cost of materials for, and application of, the new coating system per this specification.

4) Price shall include the cost of furnishing, preparing, and applying materials for coating operations.

5) Price for removal of existing coatings shall be included in Section 02 83 30 – Removal and Disposal of Coatings Containing Heavy Metals

b. Payment: Lump-sum price offered in the Schedule.

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B. Spot Repair

1. Interior Radial Gates

a. Measurement:

1) Price shall include application of spot repairs on the interior face of the radial gates.

2) Price shall include the cost of materials for, and application of, the new coating system per this specification.

3) Price shall include the cost of furnishing, preparing, and applying materials for coating operations.

4) Price for removal of existing coatings shall be included in Section 02 83 30 – Removal and Disposal of Coatings Containing Heavy Metals.

b. Payment: Per square foot price offered in the Schedule.

1.02 REFERENCE STANDARDS

A. ASTM International (ASTM)

1. ASTM D 522-13(2008) Mandrel Bend Test of Attached Organic Coatings

2. ASTM D 870-15 Testing Water Resistance of Coatings Using Water Immersion

3. ASTM D 1141-98(2008) Preparation of Substitute Ocean Water

4. ASTM D 1876-08(2013) Standard Test Method for Peel Resistance of Adhesives (T-Peel Test)

5. ASTM D 2244-15 Calculation of Color Differences from Instrumentally Measured Color Coordinates

6. ASTM D 2794-93(2010) Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact)

7. ASTM D 3359-09 Measuring Adhesion by Tape Test

8. ASTM D 3363-(2011) Film Hardness by Pencil Test

9. ASTM D 4060-14 Abrasion Resistance of Organic Coatings by the Taber Abraser

10. ASTM D 4285-83(2012) Indicating Oil or Water in Compressed Air

11. ASTM D 4541-09 Pull-Off Strength of Coatings Using Portable Adhesion Testers

12. ASTM D 4587-11 Conducting Tests on Paint and Related Coatings and Materials Using a Fluorescent UV-Condensation Light- and Water- Exposure Apparatus

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13. ASTM D 5894-10 Cyclic Salt Fog/UV Exposure of painted Metal, (Alternating Exposures in a Fog/Dry Cabinet and a UV/Condensation Cabinet)

14. ASTM G 8-96(2010) Cathodic Disbonding of Pipeline Coatings

15. ASTM G 154-12 Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials

B. Federal Standards (Fed Std)

1. Fed Std 595C(1)-08 Colors Used in Government Procurement

C. International Organization For Standardization (ISO)

1. ISO 8502-3-1992 Assessment of Dust on Steel Surface Prepared for Painting (Pressure-Sensitive Tape Method)

D. The Society for Protective Coatings (SSPC)/NACE International (NACE)

1. SSPC-AB1-15 Mineral and Slag Abrasives

2. SSPC-AB2-15 Cleanliness of Recycled Ferrous Metallic Abrasives

3. SSPC-AB3-04 Newly Manufactured or Re-Manufactured Steel Abrasives

4. SSPC-PA1-04 Shop, Field, and Maintenance Painting of Steel

5. SSPC-PA2-15 Measurement of Dry Paint Thickness with Magnetic Gages

6. SSPC-QP1-15 Evaluating Painting Contractors (Field Application to Complex Industrial Structures)

7. SSPC-SP1-15 Solvent Cleaning

8. SSPC-SP10/NACE 2-07 Near-White Blast Cleaning

9. SSPC-SP11-13 Power Tool Cleaning to Bare Metal

10. SSPC-VIS1-02 Guide and Reference Photographs for Steel Surfaces Prepared by Abrasive Blast Cleaning

11. SSPC-VIS3-04 Visual Standard for Power- and Hand-Tool Cleaned Steel

12. NACE RP 0287-02 Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel Surfaces Using a Replica Tape

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1.03 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 - Submittals.

1. Include the following information with each set of data or certification:

a. Applicable Tabulation Number and Option from Coating Tabulations.

b. Identification of “Items to be coated” including sub-letter and sub-number listed in Coating Tabulations.

B. RSN 09 96 20-1, Approval Data:

1. For each coating material:

a. Manufacturer’s product data, application, and SDS sheets.

b. Include the following information:

1) Supplier’s name, address, and phone number.

2) Manufacturer’s designated product name.

3) Applicable tabulation number from Coating Tabulations.

4) Identification of “Items to be coated” including sub-letter and sub-number listed in Coating Tabulations.

2. For each substituted coating material “equal” to specified product in Coating Tabulation:

a. List of not less than 3 similar successful material applications:

1) Project name, location, type of structure, and application dates.

2) Owner’s name, address, and telephone number.

b. Certification that material meets or exceeds specified requirements:

1) Manufacturer’s certification including technical representative’s signature and date of signature.

2) Independent laboratory’s certified test reports.

D. RSN 09 96 20-2, Final Approval Data:

1. For each coating material [and thinner]:

a. Purchase orders including order number, date, manufacturer’s designated product name, batch number(s), and quantity purchased.

E. RSN 09 96 20-3, Qualifications:

1. Coating contractor:

a. Current SSPC-QP1 certification.

2. Coating applicator:

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a. Current Coating Application Specialist (CAS) or Plural Component Application Certification (PCAC).

b. List of not less than 3 comparable jobs for each coating type including owner’s name, address, and telephone number.

3. Coating inspector:

a. Current Level 3 certification for NACE Certified Coatings Inspector (CIP) or SSPC Protective Coatings Inspector (PCI).

b. List of not less than 5 years of comparable jobs including project description, location, and owner’s name, address, and telephone number.

F. RSN 09 96 20-4, Quality Control Plan:

1. Quality Control Manager:

a. Name and title.

2. Quality Control Procedure:

a. Quality control plan.

b. Procedure for addressing identified non-conformities.

G. RSN 09 96 20-5, Contractor Quality Testing Report:

1. Comprehensive report of daily quality control test reports.

1.06 DELIVERY, STORAGE, HANDLING

A. Deliver materials to jobsite in original, undamaged, unopened containers labeled with manufacturer’s name, designated product name, batch number, date of manufacture, and any special instructions.

B. Deliver materials in containers not larger than 5 gallons as packaged by manufacturer unless suitable equipment is provided at jobsite to handle and thoroughly mix materials in larger containers.

C. Store coating materials and thinners in accordance with the manufacturer's recommendations, and as a minimum, store off the ground, under cover, and at 50 to 95 degrees F.

D. Do not use coating material which has exceeded manufacturer’s specified storage stability period (shelf life).

1.07 AMBIENT CONDITIONS

A. Maintain environmental conditions to meet coating manufacturer’s requirements during surface preparation, coating application, and curing period. Provide heating or cooling, and dehumidification as needed. Complete curing before placing the coating systems into service.

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B. Coatings shall be applied when the substrate surface temperature is 5 degrees F or more above the dew point temperature and for at least 8 hours after application.

PART 2 PRODUCTS

2.01 EQUIPMENT

A. Surface preparation and spray application equipment:

1. Sized in accordance with coating manufacturer’s recommendations.

2. Provide:

a. Pressure gauges and pressure regulators.

b. Air supply lines free from oil and moisture.

2.02 ABRASIVES

A. Mineral and slag abrasives: Meets SSPC-AB1, type I (natural minerals) and type II (slags), class A.

B. SSPC-AB2 for recycled cleanliness.

C. SSPC-AB3 Class I (steel) or II (iron) for angular shaped grit. Shot abrasives are not acceptable.

D. Commercially available products or processes to render the hazardous waste stream non-hazardous and not exceeding toxicity threshold limits.

2.03 COATINGS

A. Specified in Coating Tabulations:

1. Apply only one coating system per option in Coating Tabulations.

2. Apply compatible products of same manufacturer for coating system components.

B. Volatile Organic Compounds (VOC): Do not exceed maximum permitted by Federal, State, and local air pollution control regulations as supplied in container or by addition of thinner material.

C. Factory color or tint only. Do not color or tint at jobsite.

D. Use manufacturer’s recommended thinners for coating materials.

E. Do not use accelerator products unless approved by COR.

2.04 FILLERS AND CAULKS

A. Caulks:

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1. Coating manufacturer’s standard or compatible caulk material.

2. Polyurethane, silicone, or silicone acrylic caulk material: Meets or exceeds ASTM C 920 type S or M, grade NS, class 25, suitable for water immersion service.

B. Fillers:

1. Carboguard 501, as manufactured by Carboline, www.carboline.com.

2. Devmat 142HB, as manufactured by International Paint, www.international-pc.com.

3. PPG Amercoat 114 A, as manufactured by PPG, www.ppgpmc.com.

4. Steel Seam FT910, as manufactured by Sherwin Williams, www.sherwin-williams.com.

5. Surfacing Epoxy Series 215, was manufactured by Tnemec, www.tnemec.com.

6. Provide one of the above fillers, or equal with following essential characteristics:

a. Coating manufacturer’s standard filler material.

7. Approved use by manufacturer.

PART 3 EXECUTION

3.01 PROTECTION OF ADJACENT SURFACES, EQUIPMENT AND NEWLY

COATED SURFACES

A. Remove, mask, or otherwise protect items or surfaces not coated from contamination and damage during cleaning and coating operations.

B. Examples include protecting mating and machined surfaces, mechanical and electrical equipment (open or enclosed), instruction and similar plates, and wet and newly coated surfaces.

3.02 COATING OF METALWORK EMBEDDED IN CONCRETE

A. For ferrous surfaces embedded in concrete:

1. For atmospheric exposure on both sides of embedded concrete:

a. Extend primer coats 6 inches, minimum, into concrete embedment measured from face of concrete and along surface of embedded of concrete faces.

b. Examples include: above ground thrust or anchor blocks, floors, and walls with pipe or metal passing through the concrete.

2. For burial or immersion service exposure on either side of concrete faces:

a. Extend primer coat continuously through solid concrete structure.

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b. Examples include: sill plates, anchor plates.

B. Caulk the concrete/steel interface to seal gaps at exposed faces in accordance with manufacturer’s instructions with maximum thickness of 1/2-inch.

3.03 SURFACE PREPARATION

A. Remove or repair surface irregularities and impart profile as specified:

1. Welds:

a. Welds: Smooth and continuous.

b. Weld spatter, slag, buckshot, laminations, and slivers: remove and grind smooth.

c. Undercuts and porosity: Fill with weld material and grind smooth.

d. Projections, sharp edges, high points, fillets, and corners: Grind smooth to a radius of at least 1/16-inch.

2. Substrate defects:

a. Pitting, gouges, scratches, porosity, and similar:

1) Grind smooth.

2) Defects exceeding 20 percent reduction in wall thickness require weld repairs.

3. Grind full length of edges and corners smooth to a radius of at least 1/16-inch.

B. Surface preparation method:

1. See Coating Tabulations.

a. Method A: SSPC-SP1

b. Method C: SSPC-SP10/NACE 2.

c. Method C-1: Repair of defective or damaged coated areas.

1) For metal substrate:

a) SSPC-SP11

2) For surrounding intact coating (nominal 2 to 4 inch margin):

a) SSPC-SP1

b) Feather abrupt edges and around repair area by hand or power tool with non-woven pad into adjacent tightly bonded coatings.

c) Roughen or abrade surface in accordance with manufacturer’s recommendations to achieve matted or lusterless finish.

d) SSPC-SP1

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d. Method H: SSPC-SP5/NACE 1.

4.2. Compare prepared steel surfaces to following visual reference photographs for allowable visible contaminants and stains:

a. SSPC-VIS1 for abrasive blast cleaning.

b. SSPC-VIS3 for power and hand tool cleaning.

5.3. Assessment of dust contaminants:

a. Perform clear tape test method in accordance with ISO 8502-3.

b. Perform three tests per shift.

C. Acceptance Criteria: Degree of cleanliness shall meet Class 3. Surface profile:

1. Prepare as specified in Coating Tabulations.

2. Where not specified, prepare in accordance with manufacturer’s instructions for metallic substrates or existing coating surfaces and service environment.

3. Where manufacturer’s instructions do not specify a surface profile, prepare blasted surfaces to following profile:

a. Atmospheric Service Environments: 1 mil or greater angular profile and less than specified millage of first applied coat.

b. Burial and Immersion Service Environments: Angular profile 2 mil or greater and less than specified millage of first applied coat.

4. Inspect surface profile in accordance with NACE RP 0287:

a. Use replica tape suitable for surface profile depth range.

b. Perform at least two tests per 1,000 square feet.

D. Re-clean or perform additional surface preparation of contaminated surfaces before coating application.

3.04 COMPRESSED AIR EQUIPMENT

A. Keep air compressor and spray application equipment lines free of oil and moisture during work.

B. Compressed air quality:

1. Perform tests in accordance with ASTM D4285.

2. Perform test at the beginning of every shift.

3.05 FILLERS AND CAULK APPLICATION

A. Caulk areas including crevices, gaps, plate seams, skip welds, and conduit penetrations.

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B. Fill areas including prepared pits, plate seams, and gaps at bolts and rivets.

C. Apply in a uniform texture, neatness, and color matched appearance.

D. Apply in accordance with manufacturer’s instructions and achieve tight bond to substrate or previous coats.

3.06 COATING APPLICATION

A. Stripe coat:

1. Brush apply stripe coat.

2. Apply stripe coat prior to spray application of the primer, when practical.

3. Apply to edges, corners, interior angles, pits, plate seams, crevices, rivets, nuts, threads, bolts, washers, welds, and similar features.

B. Apply number of coats and coating thickness specified in Coating Tabulations.

1. Alternate coat colors to differentiate between coats.

2. Apply in accordance with manufacturer’s instructions.

3. Apply in accordance with SSPC PA1.

C. Prevent overspray or dry spray. When such conditions occur, clean surfaces prior to application of subsequent coats.

D. Re-clean contaminated surfaces between coats.

E. Dry Film Thickness (DFT):

1. After each coat, inspect hardened coating system for DFT compliance in accordance with SSPC PA2.

2. Acceptance Criteria: no single spot measurement less than 80 percent of specified minimum.

F. Coating Adhesion:

1. Test in accordance with ASTM D4541 at the direction of the COR.

3.07 CONTRACTOR FIELD QUALITY TESTING

A. Inspection Equipment:

1. Calibrate inspection devices and equipment in accordance with the manufacturer’s instructions.

2. Verify calibration prior to every use.

B. Qualified personnel shall conduct tests and sign reports.

1. Perform tests in presence of the COR:

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2. Provide rigging for COR to observe inspections.

C. Make daily reports for review by the COR, including:

1. Date of work.

2. Description of areas and work performed.

3. Environmental conditions.

4. Results from the following quality control tests:

a. Surface profile.

b. Visual comparison of prepared surfaces.

c. Assessment of dust contaminants.

d. Compressed air quality.

e. Dry film thickness (DFT).

f. Discontinuity (Holiday) testing.

g. Coating adhesion testing (when determined by the COR).

D. Final inspection will take place after repairs, but before placing into service.

3.08 REPAIR AND REMEDIAL WORK

A. Repair defective or damaged areas of coatings in accordance with coating manufacturer’s recommendations.

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3.09 COATING TABULATIONS

Tabulation No. IE-19

Items to be coated or repaired:

a. Radial Gates

b. Gallery

c. Floatwell / Access Covers

Notes:

1. Do not coat stainless steel, bronze, or non-metallic surfaces.

2. Coat all fasteners to include nuts, bolts, washers, and exposed anchors.

3. Fast dry curing agents are allowed as a substitute.

Coating materials – Option 1 Epoxy/ polysiloxane topcoat

Number and thickness of coats

Surface preparation method

PPG: Amerlock 400/ PSX

PPG Sigmashield 880/ PSX

Sherwin Williams Duraplate 235/ Sherloxane 800

Color: Manufacturer’s standard light color and gloss

2 base coat apply at 4-8 mils DFT per coat, plus stripe coats.

1 or more topcoats, apply at 3-7 mils DFT per coat

Total system measured to steel substrate:

11-mil DFT, minimum 23-mil DFT, maximum

Method A followed by:

Method C / Method H (Per manufacturer’s guidelines)

Method C-1 (Interior of Gates) (Per manufacture’s guidelines)

Follow manufacturer’s surface preparation and application instructions to apply subsequent coats

PERFORMANCE REQUIREMENTS:

Testing Protocol Acceptance Criteria

Fresh/deionized water immersion test, ASTM D870:

passes, 2 years test with aerated water held at ambient temperature with no blisters evident on either scribed or unscribed sides.

Dilute Harrison immersion test, Modified

ASTM D870:

passes, 2 years test with aerated water held at ambient temperature with no blisters evident on either scribed or unscribed sides.

Abrasion resistance, ASTM D4060, CS-17 wheel, 1,000 cycles, 1-kg load:

Polysiloxane: 80 milligram or less

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Tabulation No. IE-19

Direct impact, ASTM D2794: 40 inch-pounds

Pulloff adhesion, ASTM D4541, annex A2, type II tester:

1500 psi or greater

Cyclic testing salt fog/UV, ASTM D5894: 1/4 inch or less undercutting at 3000 hrs.

Cathodic disbondment, ASTM G8: 1/4 inch or less disbondment 120 day test

Tabulation No. 1

PERFORMANCE REQUIREMENTS:

Testing Protocol Acceptance Criteria

Abrasion resistance, ASTM D 4060, CS-17 wheel, 1,000 cycles, 1-kg load:

Direct impact, ASTM D 2794:

Pulloff adhesion, ASTM D 4541, annex A2, type II tester:

Cyclic testing salt fog/UV, ASTM D 5894:

QUV accelerated weathering test, ASTM D 4587:

Epoxy/polyurethane:100 milligram loss or less MC urethanes: 100 milligram loss or less

Epoxy/polyurethane: 30 inch-pounds MC Urethanes: 100 inch-pounds

Epoxy/polyurethane and MC urethane:

800 psi or greater

1/4 inch or less undercutting at 3000 hrs.

Passes 3,000 hour test with no blisters evident on either scribed or unscribed sides, or color difference ASTM D 2244.

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END OF SECTION