27QA002_PWS_DWA Skeleton Bay Draft Tube Bulkhead Rehabilitation.pdf

DWORSHAK SKELETON BAY DRAFT TUBE BULKHEAD REHABILITATION W912EF27QA002

BID ITEM LIST

ITEM DESCRIPTION QUANTITY U/M* U/P* AMOUNT

Items 0001 Unit 4 Draft Tube Bulkhead Rehabilitation

Contractor can pick up after November 23, 2026, and return by January 23, 2027

4 EA $_______ $________

0002 Unit 5 Draft Tube Bulkhead Rehabilitation

Contractor can pick up after February 22. 2027 and return by April 19, 2027

4 EA $_______ $________

0003 Unit 6 Draft Tube Bulkhead Rehabilitation

Contractor can pick up after May 10, 2027 and return by July 5, 2027

4 EA $_______ $_______

0004 Supplied Materials – Paint kits

Deliver with Unit 4 Draft Tube Bulkheads by January 23, 2027

1 EA $_______ $________

0005 Weld Repair NTE* 40 LF $_____ $________

SCHEDULE TOTAL $__________

U/M* = Unit of Measure U/P* = Unit Price NTE* = Not To Exceed

Est* = Estimated

TECHNICAL SPECIFICATIONS

1.0 SCOPE

The following specification pertains to the transportation, inspection, and rehabilitation of twelve (12) draft tube bulkheads and associated seal keeper bars. The rehabilitation includes existing coating removal, weld repairs, and new coating application in accordance with the specifications below. The Contractor shall perform all duties assigned in the specification below for all bulkheads.

2.0 GENERAL REQUIREMENTS

2.1 The Scope of work for this project shall not be modified without prior approval from the contracting officer. The Contractor shall not deviate from the specifications listed herein without prior approval from the contracting officer.

2.2 All work conducted in accordance with this contract shall be comply with Federal, State, and local regulations.

2.3 The Government (GOVT) reserves the right to travel to Contractor’s facility for quality assurance inspections at any point during the progression of this contract.

3.0 DRAFT TUBE BULKHEAD TRANSPORTATION

The critical defining elements for the transportation of the draft tube bulkheads (bulkheads) are as defined below:

3.1 The Contractor shall be responsible for transportation from Dworshak Dam to the repair facility and back to Dworshak Dam from the repair facility for the bulkheads. The Contractor shall transport the bulkheads in a manner that does not damage the integrity of any structural members or the newly applied coating upon return.

3.2 GOVT personnel will handle the bulkheads to the contractors desired orientation (from two options below) and will use the bridge crane to load and unload the bulkheads at Dworshak Dam onto and off the contractors’ truck. The bulkheads can be oriented in a manner that they are in the (option 1) flat, horizontal position with the skin plate facing down or (option 2) in the vertical orientation. A coordination meeting should be scheduled ahead of any work being complete to coordinate pickup orientation and bulkhead handling. The lifting eyes on the bulkheads can only be used in the vertical orientation and cannot be used for orienting the bulkhead in any other position. The GOVT will not be responsible for the loading and unloading of the bulkheads at the Contractor’s repair facility. The responsibility of loading and unloading at the Contractor’s repair facility shall be borne entirely by the Contractor.

3.3 All load securement responsibility shall be borne by the Contractor. The GOVT will not be responsible in any manner for load securement.

3.4 Submit a Bulkhead Handling Plan for approval prior to transportation of any bulkheads. In the plan show each orientation to which the bulkheads will be worked on in the contractor’s shop. Different work phases to take into account for bulkhead positioning are blast, NDT inspection, weld repair, and coating application. If the bulkheads are repositioned at any time, be sure to explain how the bulkhead will be repositioned. In the submittal, explain how the bulkheads will be offloaded from the truck and onloaded back onto the truck after coating is complete. Mention any crane or equipment in the shop that will be used to move the bulkheads.

3.5 All damage (structural, coating, etc) that is caused to the bulkheads by the Contractor shall be repaired at the Contractor’s expense. A repair procedure detailing the damage and proposed repair must be submitted and approved by the contracting officer before any repairs are made.

3.6 Each top bulkhead (6 total) has an approximate weight of 29000 pounds with approximate dimensions of 9 ft 7 in tall x 27 ft 7 in wide x 3 ft thick. (Please reference attached drawing S-101). Each top leaf bulkhead has an estimated value of $850,000.

3.7 Each bottom bulkhead (6 total) has an approximate weight of 26500 pounds with approximate dimensions of 9 ft 6 in tall x 27 ft 7 in wide x 3 ft thick. (Please reference attached drawing S-101). Each bottom leaf bulkhead has an estimated value of $850,000

3.8 GOVT personnel will remove the seals, springs, and valve from each bulkhead prior to the schedule pick-up date.

3.9 Contractor shall be responsible for complying with all Federal, State, and municipal laws, codes, and regulations applicable to work on this contract. This includes obtaining all necessary licenses and permits related to transportation of equipment and/or contract items, and other areas of work on this contract, as applicable. Licenses and permits shall be obtained without additional expense to the Government. Submit a transportation plan prior to pickup of the first bulkhead detailing how the contractor intends to transport each bulkhead. Include in the submittal how many bulkheads will be transported per truck and the orientation on each truck.

4.0 DRAFT TUBE BULKHEAD REHABILITATION

The critical defining elements for the refurbishment of the bulkheads are as defined below:

4.1 Existing Coatings Removal

4.1.1 The Contractor shall dry-blast clean all surfaces to white metal in accordance with SSPC SP 5/ NACE No. 1. The blast profile must be angular with a minimum profile height of 1.5 mils. Select appropriate abrasive size and equipment operating parameters to limit surface profile to an average of 2.5 mils. Steel shot or other abrasives that do not produce an angular profile shall not be used.

After blast cleaning, and before the first coat of paint, and in any case prior to the deposition of moisture, contaminants, or corrosion, clean all surfaces of dust and abrasive particles by brush, vacuum cleaner, and/or blown down with clean, dry, compressed air.

a. All tapped fastener locations shall be plugged before coatings removal to protect existing threads. The existing lifting point pin locations shall be masked and protected as well. These locations shall remain plugged and masked through the coatings application process.

b. If pinpoint or general rusting appears, the affected areas must be re-blasted and repainted at no additional cost to the government.

Note: No heavy metal-based coatings system was used on the existing bulkheads. The testing results are available upon request.

4.2 Inspection and Reporting

4.2.1 For each bulkhead, inspect one hundred percent (100%) of all welds in accordance with AWS D1.1/D1.1M utilizing Visual Testing (VT) and Magnetic Particle Testing (MT) methods.

a. No Inspections shall be conducted until existing coatings have been fully removed in accordance with Specification Section 4.1 Existing Coatings Removal

b. All inspectors performing structural steel visual inspections must be qualified and certified in conformance with AWS CQ1. All inspectors performing (MT) inspections must be qualified in accordance with ASNT CP-189 NDT Level II. Submit all Weld Inspector Qualifications to Contracting Officer for approval in advance of any inspection.

4.2.2 The Contractor shall visually inspect the entirety of the steel structure and defects such as corrosion or cracks shall be included in the inspection reports. An inspection report must be generated for each of the bulkheads. Include in the inspection report all welded connections that have any indication of cracks, undercuts, craters, porosity, lack of fusion, missing weld, and any areas of corrosion that have removed more than approximately 25 percent of the base metal when compared to the original member thickness.

a. All welded connections included in the inspection report must include a closeup picture showing the defect, a picture or drawing of the connections from a distance to be able to accurately identify its location in the structure, a written description of the defect and written description of the connection. The report shall include approximate length of defect, weld type, and approximate existing size of weld.

b. If corrosion is present, note in the report any areas of corrosion that have removed more than approximately 25 percent of the base metal when compared to the original member thickness.

c. The inspection report shall be provided to the Contracting Officer within five (5) business days of the initial inspection.

d. If any cracks, missing welds, or deficiencies of structural significance are found, the contractor is to notify the GOVT within 24 hours.

4.2.3 The GOVT intends to travel to the Contractor’s facility to conduct internal inspections of each bulkhead in conjunction with other inspections. These inspections will be conducted after the existing coatings systems have been completely removed. A minimum of four (4) Bulkheads shall be available for inspection at a time by the GOVT. The Contractor shall inform the Contracting Officer a minimum of two (2) weeks in advance of the coatings systems being removed. The GOVT will coordinate with the Contractor a minimum of five (5) business days in advance the inspection. The Contractor is to provide adequate means of egress and access for the internal GOVT inspection at the Contractor’s facility.

4.2.4 Additional shop visits and witness point inspections may occur at the sole discretion of the GOVT at any time during the length of the contract. Typical witness points to coordinate with the government for inspection are to verify blast profile, check primer coating thickness, and a final inspection before shipping. Witness points associated with weld repairs will be discussed as weld repairs are identified.

4.2.5 The GOVT will inspect weld repairs after welding is completed on each set of four (4) bulkheads.

Weld repair inspection by the GOVT must be complete before any coatings have been applied to the bulkheads.

4.3 Weld Repairs

4.3.1 The Contractor shall be required to repair no more than forty (40) linear feet of weld, if defects are discovered and deemed necessary for repair by the GOVT. The Contractor’s weld repair shall conform to AWS D1.1 standards using a 70KSI electrode and pre-qualified process. The Contractor will be responsible for all weld repair preparation and welding processes. The Contractor will be required to submit a Weld Repair procedure in accordance with AWS D1.1. This procedure will be subject to GOVT Review and Approval.

4.3.2 The weld operator must be qualified under AWS D1.1 prior to performing any weld repair on this project. Submit Qualification of Welders and Welding Operators for approval in accordance with AWS D1.1 for each welder stating the type of welding and position qualified for, the code and procedure qualified under, date qualified, and the firm and individual certifying the qualification of the tests.

4.3.3 The Contractor shall be responsible for inspecting all weld repairs completed in accordance with Section 4.2.1 and the approved Weld Repair Procedure. Inspection reports shall be submitted for approval to the GOVT prior to the initiation of coatings application. The contractor shall allow the GOVT one (1) business day to review the inspection report before proceeding with coatings application.

4.4 Coating System

The Contractor shall utilize US Army Corps of Engineers (USACE) coating system No. 5-E-Z for this contract in accordance with 09 97 02 (see attached spec). This coating system is available from various commercial paint suppliers.

4.5 Coating Application

The attached 09 97 02 spec provides more in-depth information on the coating application requirements. The contractor shall comply will all requirements outlined in the attached specification. These are the highlights:

4.5.1 The painting Contractor must be a certified SSPC QP 3 painting Contractor or hold an AISC Complex Coatings (CC-1, CC-2, CC-3) Endorsement for all surface preparation and coatings application.

4.5.2 The Contractor shall have all paint materials certified by CERL lab.

4.5.3 Submit records of qualification tests for each Qualified Coating Applicator.

4.5.4 Only conventional spray equipment will be permitted for use under this contract

4.5.5 Prior to coatings application and after the NDE inspections have been completed, the bulkheads are to be “sweep blasted” in accordance with SSPC SP7 to clean the bulkheads. The first coat of paint shall be applied within eight hours after blast cleaning and in any case prior to the deposition of any detectable moisture, contaminants, or corrosion.

4.5.6 The Contractor shall perform dry film measurements on all areas of the structure being coated in accordance with SSPC PA 2 with level 1 thickness restrictions. The Contractor shall perform enough thickness measurements to ensure that every area on every member in compliance with the requirements of this contract.

4.5.7 Apply paint by spray, unless access is limited for spray operations, to an average dry film thickness of a minimum of 7.0 mils for the completed system, with the thickness at any spot not being less than 6.0 mils. The dry film thickness of the zinc rich primer must be approximately 2.5 mils with the thickness at any spot being not less than 2.0 mils. The above specified film thickness must be attained in any event, and any extra coats needed to attain the specified thickness must be applied at no additional cost to the GOVT.

4.6 Coating Inspection

4.6.1 The Contractor shall provide a third-party certified coatings inspector, who is listed as either SSPC- PCI Level 2 or NACE CIP Level 2 for all surface preparation and painting activities. The third-party inspector is to provide a calibration report for the coating’s thickness gauge.

4.6.2 The Contractor’s inspector shall inspect, and document all work phases and operations during the project. See the attached 09 97 02 spec for inspection report requirements.

4.7 Supplied Materials

The Contractor is required to supply the following paint kits as part of this contract. Each paint kit shall have no less than 75% of their shelf life remaining upon delivery.

a. The Contractor shall Provide one (1) Kit of the Formula VZ-108D that when combined has a total volume of 5 gallons. All components of the kit shall be new and unopened.

b. The Contractor shall provide one (1) 5-gallon container of the Formula V-766E in the gray color. The container shall be new and unopened.

c. The Contractor shall provide one (1) 5-gallon container of the Formula V-766E in the White color. The container shall be new and unopened.

5.0 SECURITY REQUIREMENTS

5.1 General security requirements and guidance

The security requirements described below apply to all contract personnel (including employees of the prime Contractor (“Contractor”) and all sub Contractor employees) supporting the performance requirements of this contract. The Contractor is responsible for compliance with these security requirements. Questions regarding security matters shall be addressed to the designated Government representative (e.g., Contracting Officer Representative (COR), Requiring Activity (RA) representative, or Contracting Officer (if a COR or other RA representative is not appointed). Contract personnel are critical to the overall security and safety of US Army Corps of Engineers installations, facilities and activities, and security awareness training contributes to those efforts. The Department of War (DoW) and Army security training requirements specified below, if applicable, are performance requirements; all applicable contract personnel shall complete initial training within 15 days of notice to proceed (NTP) or the date new contract personnel begin performance on the contract. Within five business days from the completion of training, the Contractor shall provide written documentation (e.g., email or memorandum) to the Government representative. The documentation shall include the names of contract personnel trained and which training they completed; the Contractor shall maintain training records as part of their contract files and be prepared to provide copies of training certificates to the Government representative.

Contractor personnel and vehicles are subject to search when entering federal installations. Additionally, all contract personnel shall comply with Force Protection Condition (FPCON) measures, Random Antiterrorism Measures (commonly referred to as “RAMs”), and Health Protection Condition (HPCON) measures. The Contractor is responsible for meeting performance requirements during elevated FPCON and/or HPCON levels in accordance with applicable RA plans and procedures—this includes identifying mission essential and non-mission essential personnel. In addition to the changes otherwise authorized by the changes clause of this contract, should the FPCON or HPCON levels at any individual facility or installation change, the Government may implement security changes that affect contract personnel. The Contractor shall ensure all contract personnel are aware of their security responsibilities, including any site-specific requirements identified in local policies or procedures.

5.2 Physical security and access control requirements

All contract personnel requiring physical access to a federal installation or facility shall comply with the access control procedures of that location. Contract personnel requiring unescorted access to meet contract performance requirements on a DoW installation in the US shall be vetted by the installation/facility Provost Marshal/Directorate of Emergency Services/Security Office using the National Crime Information Center- Interstate Identification Index (commonly referred to as “NCIC-III”) and Terrorist Screening Database (commonly referred to as “TSDB”). Contract personnel shall comply with all personal identity verification requirements specified in installation/facility policies and procedures. Contract personnel who do not meet requirements for unescorted access to USACE facilities shall coordinate escorted access with the Government representative, as needed. Contract personnel who receive keys, access cards, or lock combinations that provide access to government-owned property shall comply with key and lock control procedures of the RA.

5.3 Suspicious Activity Reporting Training (e.g. iWATCH, CorpsWatch, or See Something, Say Something

All onsite contractor personnel shall receive initial and annual refresher training on the local suspicious activity reporting program using the website: https://www.nww.usace.army.mil/Business-With-Us/Contracting/AT- OPSEC-for-Contractors/. This locally developed training provides contractor personnel with general information on suspicious behavior, and guidance on reporting suspicious activity to the project manager, security representative or law enforcement entity. Submit report of training to the Contracting Officer.

5.4 Escorting In Classified and/or Sensitive Areas

In accordance with applicable regulations, all contractor personnel who do not possess the appropriate security clearance or access privileges will be escorted in areas where they may be exposed to classified information or operations, sensitive information or activities, or restricted areas.

5.5 Pre-screen candidates using E-Verify Program

Contractors shall comply with the requirements set forth in FAR clause 52.222-54 Employment Eligibility Verification and FAR Subpart 22.18 in using the E-Verify Program at (https://www.e-verify.gov/) (website subject to change) to meet the contract employment eligibility requirements. Contractors are encouraged to cooperate with Federal and State agencies responsible for enforcing labor requirements to include eligibility for employment under United States immigration laws in accordance with FAR 22.102-1(i). An initial list of verified/eligible candidates shall be provided to the COR no later than three business days after the initial contract award. When contracts are with individuals, the individuals will be required to complete a Form I-9, Employment Eligibility Verification, and submit it to the Contracting Officer to become part of the official contract file.

6.0 SUBMITTALS

6.1 Pre-Award Submittals

The Offeror shall submit the following at the time of bid. Failure to submit the following documents can be deemed a technically unacceptable bid.

Descriptive Materials:

a. Paint Product Datasheets for System 5-E-Z

b. Manufacturer’s Warranty Information

Higher-Level Contract Quality Requirements (see clause 52.246-11):

a. SSPC QP 3 Certification or AISC Complex Coating Endorsement

b. Qualification of Welders and Welding Operators (AWS D1.1/D1.1M or equivalent)

c. Weld Inspector Qualifications (ASNT CP-189 NDT Level II)

6.2 Post-Award Submittals

For all submittals allow for up to 30 days for submittal review and approval by the government. The government will consider expedited review upon contractor request and schedule justification. Submittals specified as required prior to starting work must be approved before that work can start. The following shall be submitted to the Contracting Officer or designated representative for review and approval after contract award but before the start of any related physical work:

a. Weld Repair Procedures, as needed

b. Army Security Training Certificates

c. Transportation Plan

d. Bulkhead handling plan

Paint spec (09 97 02, attached) related post award submittals:

e. Product samples

f. Special Paint Formulas

g. Solvent and Thinners

h. Coating Thickness Gauge Calibration Report

i. Qualified Coating Applicator

j. Certified Coating Inspector

6.3 Delivery Submittals – Comprehensive Reports

The Contractor shall provide one complete digital copy of a comprehensive inspection report for each bulkhead.

The reports shall include the following sections:

a. Complete Weld Inspection Report

b. Complete Coatings Inspection Reports

c. Complete Warranty Information

Inspection reports (both weld and coating) for each bulkhead will need the name of the structure following the following naming convention. PH – Powerhouse. DT – Draft Tube. # - Unit number. A or B – Draft tube slot A or B. T or B – Top or Bottom bulkhead. The GOVT will provide the contractor with numbers for each bulkhead. The contractor will need to track the number through the contract to ensure weld inspection reports are consistent and on the same structure as coating inspection reports. The number will need to be present in each weld inspection report and coating inspection report that is relevant to that structure.

PH-DT-4A-T

PH-DT-4A-B

PH-DT-4B-T

PH-DT-4B-B

PH-DT-5A-T

PH-DT-5A-B

PH-DT-5B-T

PH-DT-5B-B

PH-DT-6A-T

PH-DT-6A-B

PH-DT-6B-T

PH-DT-6B-B

7.0 SHIPPING

The bulkheads shall be retrieved from the Dworshak Project in three different phases. Each phase will align with the CLIN structure and include two (2) top and two (2) bottom bulkheads. The bulkheads will be oriented in one of the options mentioned in paragraph 3.2.

The three phases are as follows:

Phase 1: Bulkheads can be picked up after November 23rd, 2026, and must be returned by January 23rd, Phase 2: Bulkheads can be picked up after February 22nd, 2027, and must be returned by April 19th, 2027 Phase 3: Bulkheads can be picked up after May 10th, 2027, and must be returned by July 5th, 2027

The Contractor shall be responsible for packing and shipping the bulkheads in a manner that will ensure undamaged and complete arrival to Dworshak Project. Retrievals and deliveries shall only be conducted Monday–Thursday during the hours of 7:30 a.m. – 2:30 p.m., excluding federal holidays. All transportation activities shall be coordinated with the Contracting Officer a minimum of fifteen (15)calendar days in advance.

All other shipments shall be delivered to:

USACE Dworshak Project Attn: Contract Performance Specialist 1428 Northfork Drive Ahsahka, ID 83520

8.0 MANUFACTURER’S WARRANTY

8.1 General Warranty

The Contractor shall warrant the complete coating system on each rehabilitated bulkhead against failure for a period of one (1) year. The warranty period for each bulkhead shall commence upon the date of formal written acceptance of that bulkhead by the Government.

This warranty covers all materials, labor, workmanship, and transportation (including travel and on-site work) necessary to remedy any failures as defined herein. All warranty work shall be performed at no additional cost to the Government.

8.2 Definition of Coating Failure

For the purposes of this warranty, "failure" shall be defined as the presence of any of the following conditions on the coated surfaces of a single bulkhead:

a. Rusting: Visible rust or corrosion (other than from mechanical damage) that exceeds ASTM D610, Grade 8 on more than 1% of the total coated surface area of the bulkhead.

b. Blistering: Any blistering of the coating that exceeds ASTM D714, Size No. 8 in density on any portion of the surface.

c. Flaking or Delamination: Any flaking, peeling, or delamination of the coating from the substrate or between coats.

d. Cracking: Any cracking of the coating that exposes the underlying substrate.

8.3 Warranty Execution

Upon notification of a suspected failure by the Government, the Contractor shall, within 30 calendar days, inspect the bulkhead in coordination with the Contracting Officer. If the condition is determined to be a "failure" as defined in Section 8.2, the Contractor shall submit a complete repair procedure to the Contracting Officer for approval.

The repair procedure shall be consistent with the surface preparation and coating application requirements of the original contract specification. Upon approval, the Contractor shall execute the repairs within a timeframe agreed upon by the Contracting Officer. All repaired areas shall be warranted for the remainder of the original warranty period or for one (1) year, whichever is longer.

8.4 Exclusions

This warranty does not cover coating damage resulting from:

1. Mechanical abuse or impact damage incurred after Government acceptance.

2. Chemical exposure not specified or anticipated in the service environment.

3. Modifications to the bulkheads performed by the Government or other parties after acceptance.

8.5 Manufacturer's Warranty

Any pass-through warranties from the coating manufacturer that extend beyond the one-year period defined herein shall be transferred to the Government. The Contractor shall provide all necessary documentation for the Government to be able to make a claim under such a warranty.

TECHNICAL EXHIBIT 1

PERFORMANCE REQUIREMENTS SUMMARY

DWORSHAK DRAFT TUBE BULKHEAD REFURBISHEMENT

The Contractor service requirements are summarized into performance objectives that relate directly to mission essential items. The performance threshold briefly describes the minimum acceptable levels of service required for each requirement. These thresholds are critical to mission success.

Performance Objective Standard AQL Surveillance Method

Bulkhead Transportation (Sections 3.0, 7.0)

Bulkhead was transferred for rehabilitation and returned within the target date.

100% 100% Inspection

Inspection Reporting (Section 4.2)

Submitted inspection report for each bulkhead must be submitted within 5 business days of inspection to the Contracting Officer.

100% 100% Inspection

Coating Inspection Reporting (Section 4.6)

The Contractor’s inspector shall inspect, and document all work phases and operations.

Submit inspection reports as outlined.

100% 100% Inspection

SECTION 09 97 02.00 28

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM D153 (1984; R 2014) Specific Gravity of Pigments

ASTM D281 (2012; R 2016) Standard Test Method for

Oil Absorption of Pigments by Spatula

Rub-Out

ASTM D520 (2025) Standard Specification for Zinc

Dust Pigment

ASTM D561 (1982; R 2014) Carbon Black Pigment for

Paint

ASTM D740 (2011) Methyl Ethyl Ketone

ASTM D841 (2019) Standard Specification for

Nitration Grade Toluene

ASTM D1045 (2019) Standard Test Methods for Sampling and Testing Plasticizers Used in Plastics

ASTM D1152 (2006; R 2012) Methanol (Methyl Alcohol)

ASTM D1153 (2012) Methyl Isobutyl Ketone

ASTM D1200 (2010; R 2014) Viscosity by Ford Viscosity

Cup

ASTM D1210 (2005; R 2014) Fineness of Dispersion of

Pigment-Vehicle Systems by Hegman-Type Gage

ASTM D2917 (2007; R 2013) Methyl Isoamyl Ketone

ASTM D3465 (2014) Standard Test Method for Purity of

Monmeric Plasticizers by Gas Chromatography

ASTM D3721 (2005; R 2011) Synthetic Red Iron Oxide

Pigment

ASTM D4228 (2005; R 2017) Standard Practice for

Qualification of Coating Applicators for

Application of Coatings to Steel Surfaces

ASTM D4417 (2021) Standard Test Methods for Field

Measurement of Surface Profile of Blast

Cleaned Steel

ASTM D7091 (2021) Standard Practice for

Nondestructive Measurement of Dry Film

Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nondestructive Coatings Applied to

Non-Ferrous Metals

ASTM E1347 (2006; R 2020) Standard Test Method for

Color and Color Difference Measurement by

Tristimulus (Filter) Colorimetry

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC PA 2 (2015; E 2018) Procedure for Determining

Conformance to Dry Coating Thickness

Requirements

SSPC Paint 40 (2019) Zinc-Rich Moisture-Cure

Polyurethane Primer, Performance-Based

SSPC QP 3 (2010) Standard Procedure for Evaluating

Qualifications of Shop Painting Applicators

SSPC SP 1 (2015) Solvent Cleaning

SSPC SP 5/NACE No. 1 (2007) White Metal Blast Cleaning

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AMS-STD-595A (2017) Colors used in Government

Procurement

1.2 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government.

SD-01 Preconstruction Submittals

Qualified Shop Painting Contractor; G, ST

SD-03 Product Data

Manufacturer's Safety Data Sheet; G, ST

SD-04 Samples

Product Samples; G, CERL

Special Paint Formulas; G, ST

Solvent and Thinners; G, CERL

SD-06 Test Reports

Inspection Report PH-DT-4A-T; G, ST

Inspection Report PH-DT-4A-B; G, ST

Inspection Report PH-DT-4B-T; G, ST

Inspection Report PH-DT-4B-B; G, ST

Inspection Report PH-DT-5A-T; G, ST

Inspection Report PH-DT-5A-B; G, ST

Inspection Report PH-DT-5B-T; G, ST

Inspection Report PH-DT-5B-B; G, ST

Inspection Report PH-DT-6A-T; G, ST

Inspection Report PH-DT-6A-B; G, ST

Inspection Report PH-DT-6B-T; G, ST

Inspection Report PH-DT-6B-B; G, ST

SD-07 Certificates

Coating Thickness Gage Qualification; G, ST

Qualified Coating Applicator; G, ST

Certified Coating Inspector; I, ST

1.3 QUALIFICATIONS

Qualifications and experience must comply with the following.

1.3.1 Qualified Shop Painting Contractor

The Painting Contractor must be a certified SSPC QP 3 Painting Contractor or hold an AISC Complex Coatings (CC-1, CC-2, CC-3) Endorsement for all off-site surface preparation or coating application. Submit a copy of the applicable SSPC Certificates. The contractor must have been certified prior to award of this contract and must remain certified for the duration of this contract. Submit all renewals if they occur during the contract performance period. Renewals must be achieved prior expirations occurring.

1.3.2 Qualified Coating Applicator

Submit records of qualification tests for each Qualified Coating Applicator.

Prior to the initiation of any work all coating applicators must be tested and certified as meeting the requirements of ASTM D4228. Testing must be observed by an authorized government representative. Applicators failing the certification procedure will not be permitted to apply any paint on the project. Certification of coating applicators from previous projects will be accepted if documentation shows that the certification test met the requirements of this contract, including witnessing by a government representative, and if the test took place within 12 months prior to award of this contract.

1.3.2.1 Test Plate

The test plate shall consist of a 1.8 by 1.8 m 6 by 6 feet steel plate with a 10 mm 3/8 inch minimum thickness. The test plate shall have at least six bolts, three with bolt heads exposed and three with threads exposed, a 300 mm 12-inch wide flange and a 150 mm 6-inch diameter pipe each 450 mm 18 inches long welded perpendicular to the test panel and a 150 mm 6-inch deep

T-beam with sealed ends welded horizontal across the test panel one foot up from the bottom all within the area to be painted on one side. Bolts shall be 25 mm 1 inch minimum diameter. As an alternative, a test plate configuration, as described in ASTM D4228, may be used.

1.3.2.2 Certification Test Procedure

Conduct certification testing of coating applicators at the Contractor's painting facility. Supply the fabricated test plates to be used for the tests and provide crane service, rigging, and any other work necessary to provide accessibility for the certification testing and inspection. The test plate must be painted in a near vertical position. In preparation, clean and prepare the test plate in accordance with the requirements of the contracted work. Perform abrasive blasting with the blast media to be used in the contract. The paints to be applied are Contractor supplied materials and are those previously tested and approved for use on the contract. Paints must be applied as specified in this contract. The painter being tested must mix and thin the paints to be used in the test and set up and adjust the application equipment for use. Each painter must apply each of the types of paint comprising the specified system. The contractor's QC inspector must be present during the procedure to monitor the actions of the painter being tested. Each qualifying painter must paint an entire test plate.

1.3.2.3 Certification Criteria

Evaluate the paint applicator based on the conformance of the applied paint system to the requirements of this specification. Deficiencies in the coatings, improper mixing or improper application methods are basis for failure. The authorized Government Representative is the sole judge as to the acceptability of each coating applicator's performance. Certification test results shall clearly indicate results for each paint applicator.

1.3.3 Coating Thickness Gage Qualification

Submit Coating Thickness Gage Qualification documentation of manufacturer's certification for all coating thickness gages. Use magnetic flux thickness gages as described in ASTM D7091 to make all coating thickness measurements on ferrous metal substrates. Gages to be used on the job must have an accuracy of 3 percent or better and be certified by the manufacturer as meeting this requirement.

1.3.4 Certified Coating Inspector

Provide a certified coating inspector who is listed as an AMPP CIP Level 2, SSPC-PCI Level 2, or NACE CIP Level 2 for all surface preparation and painting activities. Submit a copy of the applicable AMPP, SSPC, or NACE

Certificates. Submit all renewals if they occur during the contract performance period. Renewals must be achieved prior expirations occurring.

1.4 DELIVERY, STORAGE, AND HANDLING

Process and package paints to ensure that within a period of one year from date of manufacture, they will not gel, liver, or thicken deleteriously, or form gas in the closed container. Paints, unless otherwise specified or permitted, must be packaged in standard containers not larger than 20 L 5 gal, with removable friction or lug-type covers. Containers for vinyl-type paints must be lined with a coating resistant to solvents in the formulations and capable of effectively isolating the paint from contact with the metal container. Each container of paint or separately packaged component thereof must be labeled to indicate the purchaser's order number, date of manufacture, manufacturer's batch number, quantity, color, component identification and designated name, and formula or specification number of the paint together with special labeling instructions, when specified. Paint must be delivered to the job in unbroken containers.

Paints that can be harmed by exposure to cold weather must be stored in ventilated, heated shelters. All paints must be stored under cover from the elements and in locations free from sparks and flames.

1.5 AMBIENT CONDITIONS

Paint must be applied in accordance with the manufacturers written instructions or to the special requirements contained herein. Surfaces that are less than 2.8 degrees C 5 degrees F above the dew point temperature must be monitored closely to assure that are completely free of moisture as determined by sight and touch. Paint must not be applied to surfaces upon which there is detectable frost or ice. Except as otherwise specified, paint must not be applied if the temperature of the surfaces to be painted and of air in contact therewith is less than 9 degrees C 45 degrees F during paint application nor if the surfaces can be expected to drop to 0 degrees C 32 degrees F or lower before the film has dried to a reasonably firm condition. During periods of inclement weather, painting may be continued by enclosing the surfaces and utilizing climate control equipment

(e.g. dehumidification, heaters, etc.), provided the minimum temperatures and surface dryness requirements prescribed previously are maintained.

Paint must not be applied to surfaces heated by direct sunlight or other sources to temperatures that will cause detrimental blistering, pinholing, or porosity of the film.

PART 2 PRODUCTS

2.1 PRODUCT SAMPLES

The Contractor shall have all paint materials certified by the CERL Lab. If the paint materials are not currently certified by the CERL Lab, submit product samples of each batch of thinner, solvent, and paint to the

Government for testing. Submit manufacturer's Safety Data Sheet (SDS) for each type of paint used; for products that are specified to be applied in accordance with the manufacturer's recommendations, submit the paint manufacturer's product data sheet (PDS) or other written instructions for those products. Allow at least 30 days from time of delivery to the contracting officer for testing of samples of paints and thinners.

Sampling may be at the jobsite or source of supply. Coordinate sampling and submission of all samples of paint and thinner with the Contracting

Officer. Standard sample size for liquid paints and thinners is 1 L 1-quart

; powders and other additives for multi component paints may be of appropriately smaller size. The sample must be labeled to indicate formula or specification number and nomenclature, batch number, batch quantity, color, date made, and applicable project contract number. Testing will be performed by the Government. Costs for retesting rejected material will be deducted from payments to the Contractor at the rate of 2200 dollars for each paint sample retested and 450 dollars for each thinner retested. Send samples and direct questions to the CERL Lab to the following address:

US Army CERL

ATTN: Paint Laboratory

2902 Newmark Drive

Champaign, IL 61822 paint@usace.army.mil

2.2 SPECIAL PAINT FORMULAS

Special paints must have the composition as indicated in the formulas listed herein. Where so specified, package paint formulation components in separate containers for mixing on the job. If not specified or otherwise prescribed, the color must be that naturally obtained from the required pigmentation.

2.3 PAINT FORMULATIONS

Special paint formulas must comply with the following:

2.3.1 Formula VZ-108D

This formula is for Vinyl-Type Zinc-Rich Impacted Immersion Coating, the ingredients are shown below.

INGREDIENTS PERCENT BY WEIGHT KILOGRAMSPOUNDS LITERSGALLONS

COMPONENT A

Vinyl Resin, Type

16.6 49.5109.2 36.539.65

Methyl Isobutyl

Ketone

80.6 239.9528.9 300.1879.30

Suspending Agent E 0.7 2.14.6 1.060.28

Suspending Agent F 0.4 1.22.7 0.720.19

Methanol 0.5 1.53.3 1.890.50

Synthetic Iron

Oxide (Red)

1.2 3.67.9 0.720.19

Total 100.0 297.8656.6 341.1090.11

COMPONENT B

Silane B 100.0 1.84.1 1.780.47

INGREDIENTS PERCENT BY WEIGHT KILOGRAMSPOUNDS LITERSGALLONS

COMPONENT C

Zinc Dust 100.0 249.5550.0 35.669.42

Total Volume 378.54100.00

(mixed paint)

a. Disperse the iron oxide and suspending agents into the vehicle

(Component A) to a fineness of grind of not less than 4 on the Hegman scale (ASTM D1210). Grinding in steel-lined containers or using steel-grinding media will not be permitted. The paint must show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods. The sole purpose of the iron oxide pigment is to produce a contrasting color. A red iron oxide-type 3 vinyl resin vehicle paste may be used in place of dry iron oxide provided compensating adjustments are made in the additions of

Type 3 resin and methyl isobutyl ketone. The finished product with zinc dust added must produce a paint which has a red tone upon drying and a reflectance of not more than 16 (ASTM E1347).

b. Supply VZ-108D paint as a kit. Each kit must consist of 17 L 4.5 gal (

15 kg 33.1 pounds) of Component A in a 20 L 5-gallon lug closure type pail, 12 kg 27.5 pounds of zinc dust (Component C) packaged in a 4 L

1-gal plastic pail, and 89 mL 3 fluid ounces of silane (Component B) packaged in a glass bottle of suitable size having a polyethylene lined cap. Place the bottle of silane on the zinc dust in the 4 L 1-gal pail. In addition to standard labeling requirements, identify each container of each component as to component type. Each container label of Component A must carry the following: MIXING AND APPLICATION

INSTRUCTIONS: WARNING - THIS PAINT WILL NOT ADHERE TO STEEL SURFACES

UNLESS COMPONENT B IS ADDED. Remove the 89 mL 3 ounces of bottled

Component B (silane) from the Component C (zinc dust) container and add to the base paint Component A) with thorough stirring. Then sift the zinc dust into the base paint while it is being vigorously agitated with a power-driven stirrer and continue the stirring until the zinc dust has been dispersed. At some point strain the mixed paint through a

30-60 mesh screen to prevent zinc dust slugs from reaching the spray gun nozzle. Stir the paint continuously during application at a rate that will prevent settling. If spraying is interrupted for longer than

15 minutes, vigorously whip the entire length of the hose to redisperse the zinc. If the spraying is to be interrupted for more than 1 hour, empty the hose by blowing the paint back into the paint pot. Thinning will not normally be required when ambient temperatures are below about

26 degrees C 80 degrees F, but when the ambient and steel temperatures are higher, methyl isoamyl ketone (MIAK) or methyl isobutyl ketone

(MIBK) should be used. If paint is kept covered at all times, its pot life will be about 8 days.

2.3.2 Formula V-766E

This formula is for Vinyl-Type White (or Gray) Impacted Immersion Coating, the ingredients are shown below.

INGREDIENTS PERCENT BY MASS

Vinyl Resin, Type 3 5.6

Vinyl Resin, Type 4 11.6

Titanium Dioxide and (for Gray)

Carbon Black

13.0

Plasticizer 2.9

Methyl Isobutyl Ketone 32.0

Toluene 34.7

Ortho-Phosphoric Acid 0.2

Total 100.0

a. Disperse the pigment by means of pebble mills or other approved methods to produce a fineness of grind (ASTM D1210) of not less than 7 on the

Hegman scale. Grinding in steel-lined or steel-ball mills will not be permitted. No grinding aids, antisettling agents, or any other materials except those shown in the formula will be permitted. Measure the ortho-phosphoric acid accurately and dilute it with at least four parts of ketone to one part of acid. Add it slowly into the finished paint with constant and thorough agitation.

b. The finished paint must show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods, and have a viscosity between 60 and 90 seconds using ASTM D1200 and a No. 4 Ford cup.

c. Furnish the white and gray paints in the volume ratio designated by the purchaser. The gray paint must contain no pigments other than those specified. Include enough carbon black to produce a dry paint film having a reflectance of 20-24 (ASTM E1347). The resulting gray color must approximate color 26231 of SAE AMS-STD-595A.

2.4 INGREDIENTS FOR SPECIAL PAINT FORMULAS

The following ingredient materials and thinners apply only to those special paints whose formulas are shown above in detail.

2.4.1 Pigments and Suspending Agents

2.4.1.1 Carbon Black

Carbon black must conform to ASTM D561, Type I or II.

2.4.1.2 Zinc Dust

Zinc dust pigment must conform to ASTM D520, Type II.

2.4.1.3 Iron Oxide

Iron oxide, (Dry) synthetic (red), must conform to ASTM D3721. In addition, the pigment must have a maximum oil absorption of 24 and a specific gravity of 4.90 to 5.20 when tested in accordance with ASTM D281 and ASTM D153, Method A, respectively. When the pigment is dispersed into specified vinyl paint formulation, the paint must have color approximating

SAE AMS-STD-595A color 10076 (dark red paint), and show no evidence of incompatibility or reaction between pigment and other components after 6 months storage.

2.4.1.4 Titanium Dioxide

Titanium dioxide in vinyl paint Formula V-766E must be one of the following: Kronos 2160 or 2101, Kronos, Inc.; Ti-Pure R-960, E.I. Dupont

DeNemours and Co., Inc.

2.4.1.5 Suspending Agent E

Suspending Agent E must be a light cream colored finely divided powder having a specific gravity of 2 to 2.3. It must be an organic derivative of magnesium aluminum silicate mineral capable of minimizing the tendency of zinc dust to settle hard without increasing the viscosity of the paint appreciably. M-P-A-14, produced by Elementis Specialties, has these properties.

2.4.1.6 Suspending Agent F

Suspending Agent F must be a light cream colored finely divided powder having a specific gravity of approximately 1.8. It must be an organic derivative of a special montmorillonite (trialkylaryl ammonium hectorite).

Bentone 27, produced by Elementis Specialties, has these properties.

2.4.2 Resins, Plasticizer, and Catalyst

2.4.2.1 Plasticizer

The plasticizer must be either Di 2-propyl Heptyl Phthalate (DPHP) or

Diisodecyl Phthalate (DIDP). DPHP must have an ester content of not less than 99.5 percent (ASTM D3465), must contain not more than 0.1 percent water, and must have an acid number (ASTM D1045) of not more than 0.07.DIDP must have a purity of not less than 99.0 percent, must contain not more than 0.1 percent water, and must have an acid number (ASTM D1045) of not more than 0.10.

2.4.2.2 Vinyl Resin, Type 3

Vinyl resin, Type 3, must be a vinyl chloride-acetate copolymer of medium average molecular weight produced by a solution polymerization process and must contain (by weight) 85 +/- 1.0 percent vinyl chloride and 15 +/- 1.0 percent vinyl acetate by weight. The resin must have film-forming properties and must, in specified formulations, produce results equal to

Vinnol H 15/50, as manufactured by Wacker Chemie AG.

2.4.2.3 Vinyl Resin, Type 4

Vinyl resin, Type 4, must be a vinyl chloride-acetate type produced by a solution polymerization process, must contain 1 percent interpolymerized dicarbonic acid, 84 +/- 1.0 percent vinyl chloride, and 15 +/- 1.0 percent vinyl acetate. The resin must have film-forming properties and must, in the specified formulations, produce results equal to Vinnol H 15/45 M, as manufactured by Wacker Chemie AG.

2.4.2.4 Ortho-phosphoric Acid

Ortho-phosphoric acid must be a chemically pure 85-percent grade.

2.4.3 Solvent and Thinners

2.4.3.1 Methanol

Methanol (methyl alcohol) must conform to ASTM D1152.

2.4.3.2 Methyl Ethyl Ketone

Methyl ethyl ketone (MEK) must conform to ASTM D740.

2.4.3.3 Methyl Isobutyl Ketone

Methyl isobutyl ketone (MIBK) must conform to ASTM D1153.

2.4.3.4 Methyl Isoamyl Ketone

Methyl isoamyl ketone (MIAK) must conform to ASTM D2917.

2.4.3.5 Toluene

Toluene must conform to ASTM D841.

2.4.4 Silane B

Silane B for Formula VZ-108D must be N-beta-(aminoethyl)-gamma-aminopropyltrimethoxy silane. Silquest A-1120, produced by Momentive

Performance Materials Inc., and Silane Z-6020, produced by Dow Corning

Corporation, are products of this type.

2.5 TESTING

2.5.1 Chromatographic Analysis

Solvents in vinyl paints and thinners are subject to analysis by programmed temperature gas chromatographic methods and/or spectrophotometric methods, employing the same techniques that give reproducible results on prepared control samples known to meet the specifications. If the solvent being analyzed is of the type consisting primarily of a single chemical compound or a mixture or two or more such solvents, interpretation of the test results must take cognizance of the degree of purity of the individual solvents as commercially produced for the paint industry.

2.5.2 Vinyl Paints

Vinyl paints are subject to the following adhesion test. When V-766 or

V-106 formulations are tested, spray apply 125 to 175 microns 5 to 7 mils

(dry) to mild steel panels. The steel panels must be essentially free of oil or other contaminants that may interfere with coating adhesion and be dry blast cleaned to a White Metal grade in compliance with

SSPC SP 5/NACE No. 1. The surface must have an angular profile of 50 to 63 microns 2.0 to 2.5 mils as measured by ASTM D4417, Method C. When V-102 or

V-103 formulations are tested, spray apply the product over 38 to 63 microns

1.5 to 2.5 mils (dry) of V-766 or V-106 known to pass this test. When

VZ-108 is tested, the coating must be mixed in its proper proportions and then spray applied to a dry film thickness of 38 to 63 microns 1.5 to 2.5 mils above the blast profile. The VZ-108 must be top coated with a V-766 known to pass this test.