6. SECTION 09.97.13 GALVANIZING-jdg.pdf

USIBWC Amistad Reservoir and Dam Turbine Pit Pipeline and Supports Corrosion Mitigation

Val Verde County, Texas

July 2020 USIBWC Solicitation

Galvanizing 09.97.13-Page 1

SECTION 09.97.13

GALVANIZING

PART 1 - GENERAL

1.1 SECTION INCLUDES

Part 1 - General

1.1 Section Includes

1.2 Related Requirements

1.3 Reference Standards

1.4 Submittals

1.5 Measurement and Payment

1.6 General

Part 2 - Products

2.1 Materials

2.2 Zinc-Based Solders

2.3 Sprayed Zinc (Metallizing)

2.4 Zinc-Rich Paints

Part 3 - Execution

3.1 General

3.2 Galvanizing Weldments

3.3 Workmanship

3.4 Repairs

--End of Section--

1.2 RELATED REQUIREMENTS

(Not Used).

1.3 REFERENCE STANDARDS

A. American Association of State Highway and Transportation Officials (AASHTO)

1. AASHTO M180-12-UL Standard Specification for Corrugated Sheet Steel Beams for

Highway Guardrail

B. ASTM International (ASTM)

1. ASTM A123-15 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on

Iron and Steel Products

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May 26, 2017 USIBWC Solicitation IBM15D0002

2. ASTM A153-16 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

3. ASTM A653-15e1 Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galva-annealed) by the Hot-Dip Process

4. ASTM A780-09(2015) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

5. ASTM A924-14e1 Standard Specification for General Requirements for Steel Sheet, Metallic Coated by the Hot-Dip Process

6. ASTM B633-15 Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel

7. ASTM B695-04(2009) Standard Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel

1.4 SUBMITTALS

A. Submittals shall be transmitted by the Contractor in accordance with the requirements of

Section 01.33.00. The Contractor Quality Control (CQC) System Manager shall be responsible for certifying that all submittals are in compliance with the Contract requirements.

B. Required submittals in this Section include:

1. Shop Drawings The Contractor shall submit shop drawings prior to fabrication for compliance confirmation. Drawings shall include catalog cuts, templates, fabrication and assembly details and type, grade and class of materials as appropriate.

2. Record Shop Drawings During construction, the Contractor shall keep detailed records of any changes made to the metal placed. If any changes were made to fabricated items, resubmit a corrected shop drawing showing the actual fabrication.

3. Mill Certificates Provide mill certificates of all sizes and grades of metal that will be used on this project. Also provide County of Origin certificates for the steel used.

4. Prior to using any galvanizing materials, the Contractor shall submit to the COR all required product information.

a. Materials to be used.

b. Manufacturer product data.

c. Manufacturer recommendations for proper use of the product.

d. Certification of the products to ensure it meets or exceeds the Section requirements.

Val Verde County, Texas

July 2020 USIBWC Solicitation

09.97.13-Page 3

1.5 MEASUREMENT AND PAYMENT

The work performed by the Contractor under this Section shall not be paid for directly, but shall be included in the various Bid Items under this Contract.

1.6 GENERAL

A. In general, the Contractor shall galvanize on metal items of new pipe supports and other metal items as noted.

B. Items specified to be galvanized, when practicable and not indicated otherwise, shall be hot-dip galvanized after fabrication.

C. Galvanizing shall be in accordance with ASTM A123, ASTM A153, ASTM A653, or

ASTM A924, as applicable.

D. A manufacturer's certification for the galvanizing compound shall be certified for compliance with above requirements.

PART 2 - PRODUCTS

2.1 MATERIALS

A. The Contractor shall provide galvanized metal items that meet the standards in Table 3.

Table 3 - Galvanizing Standards Item Standard Fabricated items, rolled, pressed or forged steel shapes, plates, pipes, tubular items and bars ASTM A123

Assembled steel products ASTM A123

Steel or iron castings ASTM A153, Class A Bolts, nuts, screws, washers and other miscellaneous hardware

ASTM A153, Class C or D or ASTM B695, Class 50

Miscellaneous fasteners ASTM B633, Class Fe/Zn 8

Rail elements for metal beam guard fence or bridge railing AASHTO M180

Permanent supporting angles and incidental items ASTM A653, Coating Designation G165

B. Zinc coatings shall be applied in a manner and of a thickness and quality conforming to ASTM A123. Weight of coatings shall be as designated in Table 1 of the ASTM Section for class and thickness of material to be coated, but in no case shall it be less than 1.25

oz. per square foot.

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Galvanizing 09.97.13-Page 4

C. In all cases where zinc coatings are destroyed by cutting, welding or other causes, the affected areas shall be re-galvanized by the following methods:

1. Areas requiring repair larger than one (1) square inch shall be re-galvanized with a suitable low-melting zinc base alloy similar to the recommendations of the American Hot-Dip Galvanizers Association to the thickness and quality specified for the original zinc coating.

2. Smaller areas shall be re-galvanized by a repair compound conforming to ASTM A780.

2.2 ZINC-BASED SOLDERS

A. Zinc based solders shall meet one (1) of the following:

1. Zinc-tin-lead alloys with liquidus temperatures in the range of four hundred forty-six degrees Fahrenheit (446°F) to five hundred degrees Fahrenheit (500°F).

2. Zinc-cadmium alloys with liquidus temperatures in the range of five hundred eighteen degrees Fahrenheit (518°F) to five hundred twenty-seven degrees Fahrenheit (527°F).

2.3 SPRAYED ZINC (METALLIZING)

Zinc coating applied by spraying with droplets of molten metal using wire, ribbon, or powder processes. Zinc used shall be ninety nine percent (99%) pure or greater.

2.4 ZINC-RICH PAINTS

Zinc-rich paints based on organic or inorganic binders that are premixed and formulated specifically for use on repair of galvanized steel surfaces and will provide a dried film containing a minimum of ninety two percent (92%) zinc dust, by weight (usually 65% to 69% by volume).

PART 3 - EXECUTION

3.1 GENERAL

A. If fabricated members or assemblies are required to be hot-dip galvanized, the Contractor shall provide for proper filling, venting and draining during cleaning and galvanizing.

The Contractor shall provide drain holes or slots as required, except where prohibited by the Contract Drawings.

B. If assembling tapered members using slip-joint splices, drain to the small end of the

Section. Ensure that cleaning and galvanizing do not produce hydrogen embrittlement.

C. Before galvanizing material one-quarter (¼) inch or greater in thickness remove all sharp burrs and chamfer to approximately 1/16 inch all edges exposed to electrical conductors or to human activity.

Val Verde County, Texas

July 2020 USIBWC Solicitation

09.97.13-Page 5

D. If painting is specified on galvanized materials, paint in accordance with requirements shown on the Contract Drawings. Do not water-quench or chromate-quench galvanized surfaces to be painted.

3.2 GALVANIZING WELDMENTS

If problems develop during galvanizing of welded material, the USIBWC may require a test of the compatibility of the combined galvanizing and welding procedures and may require modification of one or both of the galvanizing and welding procedures.

3.3 WORKMANSHIP

A. Coverage

Bare spots less than one (1) square inch in area may be repaired. Bare spots greater than one (1) square inch in area must be re-galvanized. Runs or drips of zinc coating are acceptable unless they interfere with the intended use of the product. Carefully hand-file excessive zinc accumulations.

B. Adhesion

To test coating adhesion, the Contractor shall tap the coated area with a small hammer.

The coating is acceptable if it is not brittle and does not scale or flake.

C. Appearance

1. White Rust A white powdery residue indicates moisture. The Contractor shall remove heavy layers of white rust that have caused the coating to pit. Light coatings may remain unless the USIBWC requires chemical removal. The Contractor shall remove white rust from articles that will be in direct contact with soil.

2. Red Rust Red rust on galvanized items indicates uncoated areas. See Paragraph 3.3Aherein for acceptance criteria.

3. Alligator Cracking or Spider Webbing The composition of the base metal may cause dark lines resembling alligator skin.

See Paragraph 3.3Bherein to determine whether the coating is acceptable.

4. Dull Gray Coating The composition of the base metal can cause a dull gray color. See Paragraph 3.3Bherein to determine whether the coating is acceptable.

D. Coating Thickness

The Contractor shall galvanize to the thickness specified.

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3.4 REPAIRS

A. The Contractor shall use zinc-based solders, sprayed zinc, or zinc-rich paints for repairs.

For items galvanized for this project, the zinc-rich paint used shall be selected by the galvanizer.

B. Contractor shall repair galvanizing in conformance with ASTM A780.

C. Zinc-Based Solders

1. The Contractor shall remove moisture, oil, grease, dirt, corrosion products and welding slag or flux from surfaces to be repaired

2. Clean surface to white metal by wire brushing, light grinding, or mild blasting extending into the surrounding undamaged galvanized coating.

3. Preheat cleaned areas to at least six hundred degrees Fahrenheit (600°F) but not more than seven hundred fifty degrees Fahrenheit (750°F).

4. Wire-brush while heating and evenly distribute a layer of zinc solder.

5. When repair is completed, flush the repaired area with water or wipe with a damp cloth to remove flux residue.

D. Sprayed Zinc (Metallizing)

1. The Contractor shall remove oil, grease, corrosion products and any welding slag or flux from surfaces to be repaired and ensure that the surfaces are dry.

2. Clean surface to white metal by wire brushing, light grinding, or mild blasting extending into the surrounding undamaged galvanized coating.

3. Apply coating by metal-spraying pistols fed with either zinc wire or zinc powder.

4. Provide a coating that is uniform and free of lumps, coarse areas, or loose particles.

E. Zinc-Rich Paints

1. Do not use paint to repair galvanizing damage caused by welding.

2. The Contractor shall remove oil, grease, corrosion products and welding slag or flux from surfaces to be repaired and ensure that the surfaces are clean and dry.

3. Clean surface to near-white metal by wire brushing, light grinding, or mild blasting extending into the surrounding undamaged coating to provide a smooth repair.

4. Spray or brush-apply the paint to the prepared area in accordance with the paint manufacturer’s instructions to attain the required dry-film thickness.

5. Provide multiple passes when using spray application.

F. Repair Coating Thickness

1. After completing repair and cooling or curing, measure thickness in the repaired area and report to the COR.

2. The minimum thickness required is the same as that required for the specified galvanizing.

3. However, if the repair uses zinc-rich paints, the minimum coating thickness is fifty percent (50%) higher than the specified galvanizing thickness, but not greater than four (4.0) mils.

--End of Section--

SECTION 09.97.13 GALVANIZING