12.e. Revised Section 099713.27.pdf

SECTION 09 97 13.27 – HIGH PERFORMANCE COATING FOR STEEL

STRUCTURES 02/21, CHG 1: 08/22

PART 1 - GENERAL

Work under this specification section covers field coating to the existing bulkhead and steel piles, above Mean Lower Low Water (MLLW) elevation, as indicated on the drawings.

1.0 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.

A. ASTM International (ASTM)

1. ASTM D3276; (2015; E 2016) Standard Guide for Painting Inspectors (Metal

Substrates)

2. ASTM D4417; (2021) Standard Test Methods for Field Measurement of Surface

Profile of Blast Cleaned Steel

3. 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

B. Society For Protective Coatings (SSPC)

1. SSPC AB 1; (2015; E 2017) Mineral and Slag Abrasives

2. SSPC AB 3; (2023; R 2023) Ferrous Metallic Abrasive

3. SSPC Guide 6; (2021) Guide for Containing Surface Preparation Debris

Generated During Paint Removal Operations

4. SSPC PA 1; (2016) Shop, Field, and Maintenance Coating of Metals

5. SSPC PA 2; (2015; E 2018) Procedure for Determining Conformance to Dry

Coating Thickness Requirements

6. SSPC Guide 15; (2020) Field Methods for Retrieval and Analysis of Soluble Salts on Steel and other Nonporous Substrates

7. SSPC QP 1; (2019) Standard Procedure for Evaluating the Qualifications of

Industrial/Marine Painting Contractors (Field Application to Complex Industrial Steel Structures and Other Metal Components)

8. SSPC QP 5; (2022) Standard Procedure for Evaluating the Qualifications of Coating and Lining Inspection Companies

9. SSPC QS 1; (2015) Standard Procedure for Evaluating a Contractor's Advanced Quality Management System

10. SSPC SP 1; (2015) Solvent Cleaning

11. SSPC SP 6/NACE No. 3; (2007) Commercial Blast Cleaning

C. U.S. National Archives and Records Administration (NARA)

1. 29 CFR 1910.134; Respiratory Protection

2. 29 CFR 1910.1000; Air Contaminants

3. 29 CFR 1926.59; Hazard Communication

1.1 DEFINITIONS

Definitions are provided throughout this Section, generally in the paragraph where used, and denoted by capital letters.

1.2 SUBMITTALS

Government approval is required for all submittals. Submit the following in accordance with Section 01 00 00 GENERAL REQUIREMENTS:

A. Preconstruction Submittals

1. Quality Control Plan

2. Inspection Plan

B. Product Data

1. Blast Material

2. Moisture Tolerant Epoxy coating system

C. Design Data

1. Containment System

D. Test Reports

1. Inspection Report

E. Certificates

1. Corrective Action Procedures

2. Coating Work Plan

3. Qualifications of Individuals Performing Abrasive Blasting

4. Qualifications of Coating Inspector

5. Qualifications of Coating Contractors

6. Coating Materials

7. Coating System Component Compatibility

F. Manufacturer's Instructions

1. Coating System Instructions

G. Closeout Submittals

1. Disposal of Used Abrasive

1.3 QUALITY ASSURANCE

A. Quality Control Plan: Manufacturer's certifications must be submitted with test results for proposed materials. Certificates must certify compliance with the appropriate specification referenced herein. Do not place materials without prior approval from the

COR.

1. Corrective Action Procedures: The Quality Control Plan must also include corrective action procedures. These procedures must be developed to determine the root cause of each non-compliance, develop a plan to eliminate the root cause so that the non-compliance does not recur, and follow up to ensure that the root cause was eliminated. Develop Corrective Action Request (CAR) forms for initiating corrective action, and for tracking and documenting each step.

2. Implementing Corrective Actions: Action must be taken to identify and eliminate the root cause of each non-compliance so as to prevent recurrence. These procedures must apply to non-compliance in the work, and to non-compliance in the QC System. Corrective actions must be appropriate to the effects of the noncompliance encountered. Each CAR must be serialized, tracked in a Log to completion and accepted by the COR, and retained in project records. The Corrective Action Log, showing status of each CAR, must be submitted to the COR monthly. A CAR may be initiated by either the Contractor or the COR. The COR must approve each CAR at the root cause identification stage, the plan for elimination stage, and the close out stage after verification that the root cause has been eliminated.

B. Inspection Plan: Submit an Inspection Plan prior to the start of coating. The inspection plan must include inspection points, inspection report form, inspection procedures, inspection equipment, standards and procedures for calibration of equipment, and data requirements. At a minimum, inspections must be recorded after surface preparation, after each coat, after curing, and after testing. Coating must be 100 percent visually inspected.

1. Inspection Report: Inspections must include surface profile measurements, chloride measurements, holiday testing and thickness measurements. Submit an Inspection Report following each inspection. At a minimum, include the following information in the Inspection Report.

a. Environmental Conditions

b. Inspector

c. Date of Inspection

d. Materials

e. Areas Worked

f. Equipment

g. Data Collected

h. Nonconformances

C. Coating Work Plan

1. This work plan must be considered as part of the Quality Control Plan.

2. Provide procedures for reviewing contract documents immediately after award to identify errors, omissions, and discrepancies so that any such issues can be resolved prior to project planning and development of detailed procedures.

3. Provide procedures for verification of key processes during Initial Phase to ensure that contract requirements can be met. Key processes shall include surface preparation, coating application and curing, inspection, and documentation, and any other process that might adversely impact orderly progression of work.

4. Provide procedures for all phases of coating operations, including planned work, rework, repair, inspection, and documentation. Address mobilization and setup, surface preparation, coating application, coating initial cure, tracking and correction of noncompliant work, and demobilization. Coordinate work processes with health and safety plans. For each process, provide procedures that include appropriate work instructions, material and equipment requirements, personnel qualifications, controls, and process verification procedures. Provide procedures for inspecting work to verify and document compliance with contract requirements, including inspection forms and checklists, and acceptance and rejection criteria.

5. Provide procedures for determining the existing surface profile under paint, and procedures for ensuring that the profile is not increased beyond the maximum profile as specified by the coating system manufacturer.

6. Provide procedures for correcting noncompliant work. Detailed procedures are required in advance to avoid delays in meeting overcoat windows as well as to avoid delays in production. Provide procedures for repairing defects in the coating film, such as runs, drips, sags, holidays, overspray, as well as how to handle correct coating thickness noncompliance, any other areas of repair or rework that might be adversely affected by delays in preparing and approving new procedures.

7. If a procedure is based on a proposed or approved request for deviation, the deviation shall be referenced. Changes to procedures shall be noted by submittal number and date approved, clearly delineating old requirements and new requirements, so that the records provide a continuous log of requirements and procedures.

D. Design Data

1. Containment System: Submit complete design drawings and calculations for the scaffolding and containment system, including an analysis of the loads which will be added to the structure by the containment system and waste materials. A registered engineer shall approve calculations and scaffold system design.

E. Qualifications

1. Qualifications of Coating Inspector: Submit documentation that each coating inspector is employed, and qualified to SSPC QP 5, Level III, and ASTM D3276 by the selected coating inspection company. Each inspector shall remain employed by the coating inspection company while performing any coating inspection functions.

2. Qualifications of Individuals Performing Abrasive Blasting: Submit name of each person that will be performing abrasive blasting. Submit documentation that each blaster is qualified by SSPC to the SSPC C7 Abrasive Blaster Certification

Program. Each blaster must remain qualified during the entire period of abrasive blasting, and the COR must be notified of any change in qualification status.

3. Qualifications of Coating Contractors: All Contractors and Subcontractors that perform surface preparation or coating application shall be certified to SSPC QP 1 and SSPC QS 1 for field application, prior to contract award, and shall remain certified while accomplishing any surface preparation or coating application. The painting Contractors and painting Subcontractors must remain so certified for the duration of the project. If a certification expires, the firm will not be allowed to perform any work until the certification is reissued. Requests for extension of time for any delay to the completion of the project due to an inactive certification will not be considered and liquidated damages will apply. Notify the COR of any change in Contractor certification status. Submit qualifications of key personnel for coating operations. Key personnel include, but are not limited to, those who perform the following duties; surface preparation, coating application, quality control, and inspection.

F. Coating Materials: Provide manufacturer's certification of conformance to contract requirements.

G. Coating System Component Compatibility: Provide certification from each manufacturer of components of the coating system that the supplied coating material is suitable for use in the specified coating system. Each manufacturer must identify the specific products, including manufacturer's name, which their product may be used with. The certification must provide the name of the manufacturer that will provide technical support for the entire system. When all coating materials are manufactured by one manufacturer, this certification is not required.

H. Pre-Application Meeting: After approval of submittals but prior to the initiation of coating work, Contractor representatives, including at a minimum, project superintendent and QC manager, coating foreman, and coating inspector must have a pre-application coating preparatory meeting. This meeting must be in addition to the pre-construction conference. Specific items addressed must include: corrective action requirements and procedures, coating work plan, safety plan, inspection standards, inspection requirements and tools, test procedures, environmental control system, safety plan, and test logs.

Notify COR at least ten days prior to meeting.

1.4 PRODUCT DATA

A. Coating System Instructions: Submit manufacturer's printed instructions including detailed mixing and application procedures, number and types of coats required, minimum and maximum application temperatures, and curing procedures. Include Safety Data Sheets (SDS) for materials to be used at the job site in accordance with 29 CFR 1926.59.

1.5 DELIVERY AND STORAGE

Ship, store, and handle materials in accordance with SSPC PA 1, and as modified in this Section.

Maintain temperature in storage spaces between 40 and 85 degrees F, and air temperature more than 5 degrees F above the dew-point at all times. Inspect materials for damage prior to use and return non-compliant materials to manufacturer. Remove materials with expired shelf life from government property immediately and notify the COR.

1.6 ENVIRONMENTAL CONDITIONS

Start work only when ambient and curing temperatures are within limits of coating manufacturer's written recommendations and at least 5 degrees F above dew point temperature.

For application over water, the coating must be applied at the start of ebb tide to ensure sufficient drying and curing time and continuing down the steel member as the tide falls.

1.7 COATING HAZARDS

Ensure that employees are trained in all aspects of the safety plan. Specified coatings may have potential health hazards if ingested or improperly handled. The coating manufacturer's written safety precautions shall be followed throughout mixing, application, and curing of the coatings.

During all cleaning, cleanup, surface preparation, and paint application phases, ensure that employees are protected from toxic and hazardous chemical agents which exceed concentrations in 29 CFR 1910.1000. Comply with respiratory protection requirements in 29 CFR 1910.134.

PART 2 - PRODUCTS

2.1 COATING SYSTEM

Alternate systems or products may be considered if they meet or exceed the requirements of the contract. All materials must be supplied by one supplier. The entire coating system is intended to be applied in the field for in-situ maintenance. Upon completion of installation in the field all damaged surfaces must be inspected and repaired. Remove all damaged surfaces by means of the specified surface preparation followed by re-application of the coating system . The final surface of any repairs must meet all requirements of the specifications and the manufacturer.

A. Coating: Moisture Tolerant Epoxy coating system. Finished coating color must be black.

The product must be an impermeable coating system specifically designed for use and submersion in the marine environment for corrosion protection of steel. The product must have excellent resistance to abrasion, chemical degradation, moisture and surface tolerant, and ultraviolet exposure. The product must be in accordance with the latest Federal and State environmental standards. At a minimum, the coating system must meet the following criteria:

1. 800 psi minimum adhesion to steel substrate

2. Suitable for damp application and be capable of immersion shortly after application (within one tidal cycle)

3. Below the state VOC limit

Submit coating system product data, certificates, manufacturer's data, material safety data sheets, catalog cuts, and other relevant descriptive data for approval. Submit manufacturer's written recommendations and literature for field repair procedures of specified coating.

2.2 ABRASIVE

The referenced abrasive specifications have maximum limits for soluble salts contamination, however, this maximum level of contamination does not guarantee that contamination will not be transferred to the steel surface during abrasive blasting. Other factors such as on-site handling and recycling can allow contamination of abrasive. Contractors are cautioned to verify that the chosen abrasive, along with work and storage processes, allow the final surface cleanliness requirements to be achieved. Successful testing of chlorides in abrasive does not negate the final acceptance testing of steel surfaces.

A. Blast Material: The blast material must meet either of the following requirements. Silica sand, shot, or spherical shaped abrasives are not permitted.

1. SSPC AB 1. Type 1, natural mineral abrasive, grade to achieve required surface profile.

2. SSPC AB 3. Class 1, steel abrasive, grit size G25.

PART 3 – EXECUTION

Perform all work, rework, and repair in accordance with approved procedures in the Coating Work Plan.

3.1 SURFACES TO BE COATED

Coat surfaces as depicted on the Contract Drawings.

3.2 ENVIRONMENTAL CONDITIONS

A. Containment: Design and provide a containment system for the capture, containment, collection, storage and disposal of the waste materials generated by the work under this Section, to meet the requirements of SSPC Guide 6, Class 3. Vapor concentrations shall be kept at or below 10 percent of Lower Explosive Limit (LEL) at all times. Containment may be designed as fixed containment for complete structure or portable containment for sections of structure, however, containment shall remain in any one place from beginning of abrasive blasting through initial cure of coating. Waste materials covered by this paragraph shall not include any material or residue from removal of coatings containing lead, chromium, cadmium, PCB, or any other hazardous material.

Insure the feasibility and workability of the containment system. Perform operations and work schedule in a manner as to minimize leakage of the containment system. The containment system must be properly maintained and must not deviate from the approved drawings. If the containment system fails to function satisfactorily, suspend all operations, except those required to minimize adverse impact on the environment or government property. Operations must not resume until modifications have been made to correct the cause of the failure.

3.3 SURFACE PREPARATION

Clean and prepare the existing steel by completely removing the existing coating, rust, chlorides, etc., within the limits of work shown on the drawings and in accordance with the coating system’s manufacturer’s recommendations.

A. Solvent Cleaning: SSPC SP 1. Remove visible oil, grease, drawing, and cutting compounds by solvent cleaning.

B. Blast Cleaning: SSPC SP 6/NACE No. 3. After solvent cleaning, complete surface preparation by commercial blast cleaning. Remove residual dust from the blasted surface by blowing with dry, oil-free air, vacuuming, or sweeping. Areas where blast cleaning is to occur are to be fully contained so that the grit, coating, and corrosion does not fall into the water. A suitable blast cleaning collection system must be employed.

C. Water Cleaning: The surfaces to be coated must be washed with high-pressure, clean water and detergent, then thoroughly rinsed.

D. Surface Profile: Provide surface profile in accordance with manufacturer's written recommendations or at least 2 mil thickness. Brush blast off the existing surface to create a roughened surface. No material, including solids and liquids, must be permitted to fall into the water. Waste material must be captured by a suitable collection system. Waste materials must be transferred to the shore and disposed of properly. Prior to coating, in the presence of the COR, test 10 percent of each type of element cleaned to ensure the required surface profile has been achieved. Perform surface profile testing per accepted SSPC procedures and ASTM D4417.

E. Air Dry: Blow down the surfaces using clean oil-free compressed air and sweep with clean, natural bristle brushes.

F. Chloride Testing: SSPC Guide 15. Test surfaces for chloride contamination. If present, wash with a super surfactant and water, then dry with compressed air.

G. Disposal of Used Abrasive: Dispose of used abrasive off Government property in accordance with Federal, State, and Local mandated regulations.

H. Coating Application: The coating must be sprayed, brushed or roller applied in accordance with the manufacturer's directions. For applications over water, apply the approved coating system during the ebb tide and ensure that the surfaces remain free of wind blown contaminants.

3.4 MIXING AND APPLICATION OF COATING SYSTEM

A. Preparation of Sealant and Coating Materials for Application: Each of the coating materials are a two-component material supplied in separate containers.

1. Mixing Materials: Mix in accordance with the manufacturer's instructions, which may differ for each product. Do not mix partial kits or alter mix ratios. Mix materials under the temperature conditions as specified by the manufacturer.

Allow mixed material to stand for the required induction time based on its temperature. Power stir components to a smooth, uniform consistency. Follow the coating manufacturer's requirements for induction time and pot life of mixed batches.

2. Proportioning of Coating System: The epoxy coating system consists of a two-component system that includes a base, Component A and a hardener, Component B. Mix both components in a ratio as specified by the manufacturer. Thinning of coating system is not permitted.

3. Pot Life: Apply mixed products within the stated pot life for each product. Stop applying when the material becomes difficult to apply in a smooth, uniform wet film. Usable pot life depends on the temperature of the material at the time of mixing and the sustained temperature at the time of application. Other factors such as the shape of the container and volume of mixed material, may also affect pot life.

4. Application Conditions and Recoat Windows: The application conditions requirements for the coating system are very time and temperature-sensitive. Plan coating application to ensure that specified temperature, humidity, and condensation conditions are met. If conditions do not allow for the orderly application of the coating system, use appropriate means of controlling air and surface temperatures, as required. Partial or total enclosures, insulation, heating or cooling, or other appropriate measures may be required to control conditions to allow for orderly application of all required coats. Maintain the air and steel surface temperatures as required by the coating manufacturer and determine the appropriate recoat windows based on the manufacturer’s guidance.

B. Application of Coating System: Apply coatings in accordance with SSPC PA 1, the manufacturer’s recommendations, and as specified herein. Apply coatings to surfaces that meet all stated surface preparation requirements.

1. General: Apply coating in accordance with the manufacturer’s recommendations and not more than 4 hours after blast cleaning. Apply coats of each system so that finished surfaces are free from runs, sags, brush marks, and variations in color.

2. Application of Coating Material: Apply all field applications of coating materials in accordance with manufacturer's printed instructions and literature. Field Applications should be applied in one continuous half lapped spray coat, overlapping 50 percent of the previous spray pass to the "Ideal DFT" mils thickness. Test in accordance with SSPC PA 2, Appendix 1 and 3 for conformance.

3. Dry Film Thickness: Provide total system minimum dry film thickness of 16 mils.

Measure using a magnetic gage.

4. Procedure for Holiday and Spot Repairs of Applied Coating: Repair coating film defects at the earliest practicable time, preferably before application of the succeeding coat. Observe all requirements for soluble salts contamination, cleanliness between coats, and application conditions. Prepare defective area in accordance with manufacturer’s recommendations. Protect adjacent areas from damage and overspray. Remove dust and solvent wipe the prepared area plus an additional 4 inches beyond the prepared area with clean denatured alcohol. Apply each coat within the manufacturer's specified recoat window of preceding coat.

3.5 FIELD TESTS

Conduct testing in presence of the COR. Advise the Contracting Officer five days prior to performing each field test.

A. Holiday Testing: Test for holidays in total coating system. Use a low-voltage holiday detector of less than 90 volts in accordance with manufacturer's instructions. After manufacturer's written recommendation, retest with a low-voltage holiday detector.

Submit test results in accordance with Paragraph entitled "Inspection Reports". Dry Film Thickness: After repair of holidays, measure dry film thickness using a magnetic dry film thickness gage in accordance with ASTM D7091 and SSPC PA 2. Re-measure after an additional coat is applied, and add it to meet minimum thickness requirements. Submit test results in accordance with Paragraph entitled "Inspection Reports".

3.6 FINAL INSPECTION

A final inspection of the coating work must be completed at the end of the project. The final inspection must ensure coating conforms to specifications and is free from defects.

3.7 FINAL CLEANUP

Following completion of the work, remove debris, equipment, and materials from the site.

Remove temporary connections to Government or Contractor furnished water and electrical services. Restore existing facilities in and around the work areas to their original condition.

END OF SECTION 09 97 13.27