COSME_AERATOR_SPEC.docx

Expected Date of Service:.

Summary

The City of St Petersburg Water Department is seeking an experienced coatings contractor to apply a new epoxy coating on various structures, including aerators, catwalks, railings, and more, ensuring compliance with all regulatory standards. The contractor will meet on-site with the owner's representative to review specifications, take measurements and submit a detailed production schedule with their bid. The contractor is responsible for surface and site preparation and coating under the guidance of an owner-provided Paint Representative, following specified methods and environmental regulations. They must also manage the safe storage and disposal of materials, adhering to detailed technical specifications and environmental protection measures throughout the project.

Timeline

Solicitation Published:

Site Visit:

Question Deadline:

Submittal Due Date:

Project Specifications

For the purpose of this specification, the term “Contractor” will always refer to the primary contractor bidding on this project. The term “Owner” will always refer to City of St Petersburg Contractor to provide the total number of days required to complete the planned scope of work in the bid response sheet

All fees incurred as a result of obtaining certification, including associated inspection fees and expenses from Regulatory inspectors, shall be paid by the Owner. Unless otherwise specified by these Specifications, all rules and regulations outlined by the Regulatory bodies noted in section 1.02 must be complied with by the Contractor during the project.

The Owner needs to install a new epoxy coating on 2 Aerators, catwalks, railings, pillars, light poles, piping, stairs, ladders and catwalk water troughs. The contractor shall have an opportunity to meet on site with the owner’s representative to take measurements and ask questions. Particular emphasis shall be placed on these specifications, safety, weather conditions, surface preparation, material application, and inspection.

The Contractor shall submit a production-level schedule using Microsoft Project or equal as part of their bid response. This schedule should include the itemized duration for all planned work identified in this Specification. A completed schedule should clearly identify the critical path, the overall duration, and any significant relationships between tasks. Contractor’s bid may be considered incomplete if a production schedule is not provided with the proposal.

This section of the Specification outlines the work that is required to be accomplished by the Contractor to renew the coating system. The areas to be cleaned, prepped, and coated may also include, but are not limited to, 2 Aerators, catwalks, railings, pillars, light poles, piping, stairs, ladders and catwalk water troughs. These areas shall be included in the bid response with the applicable paint group as described in the work items below. The Contractor shall provide equipment, tools, personnel and materials to accomplish the scope of work outlined in this Specification.

The Contractor shall work under the guidance of an Owner-furnished Paint Representative while accomplishing cleaning, surface preparation, and painting.

When grit blasting anywhere on the vessel, the grit shall be un-used garnet or mineral slag, and be free from iron chloride salts. The minimum pressure for grit blasting shall be no less than 109 psi, and the distance from the surface being treated shall be no more than two (2) feet at an angle of approximately 20 degrees from normal to the surface. The blasting air shall be free of oil and water. After abrasive blasting, areas of bare steel shall be cleaned of dust and blasting debris before commencement of paint application. Any surface prepared to SSPC-SP 6 (SA 2) shall be free from soluble salt contaminants. Alternatively, the use of ultrahigh-pressure water blasting is acceptable provided the paint manufacturer’s specifications are adhered to. Tables 150.2 and 150.3 shown below provide the definitions for common surface preparation and surface cleanliness standards.

General cleaning standard as referenced in the specifications is intended to mean the removal of all debris, soot, grease and surface contaminants to ensure the applications of coatings are successful.

The Contractor shall make arrangements for the purchase and safe storage of coating materials, and will be responsible for (the cost) and safe disposal of all empty paint containers, waste and debris in accordance with all applicable Federal, State and local regulations. In order to monitor the paint consumption during the repair period, empty paint cans shall be stored in a suitable location at the facility. No empty paint cans shall be removed from the work area without approval from the Owner’s Representative.

All paints shall be high shear, mechanically stirred without the introduction of air and applied using the airless spray method. The spray equipment pressure, nozzles, and fan angles shall be in accordance with the paint manufacturer’s recommendations. Thinning of paints shall only be done if approved by Paint Representative and as specified in the Product Data Sheets for that specific product.

At all times during the paint application, the temperature of the substrates shall be 5 degrees F above the dew point of the ambient air, and the relative humidity less than RH 85%. The air temperatures and RH shall be measured a minimum of four times daily during paint application. Coatings shall never be applied to surfaces where condensation is present.

The wet film thickness (WFT) and dry film thickness (DFT) specified shall be adhered to and checked periodically in the presence of the Paint Manufacturer’s representative. Special attention shall be given to prevent sags, drips, runs, etc. during the coating application. Contractor shall also adhere to the Paint Manufacturer’s recommended cure time between coats whenever multiple coats of paint are being applied. Where necessary, remove all weld splatter, and smooth weld seams and sharp edges prior to applying paint. All edges where the base coating has been removed shall be feathered smooth.

Environmental Protection Contractor is responsible for ensuring that all local, State, and Federal environmental regulations are complied with during surface preparation and coating on the vessel. All tarping, containment, or other means of environmental protection shall be provided by the Contractor and installed prior to the commencement of work. Environmental protections that are installed by the Contractor must be removed before the end of the service period. All costs pertaining to environmental protection shall be included in the Contractor’s bid response under the individual item in which the costs will be incurred.

General Specification for Coating Applications:

Table 3.02-T provides the Coating Manufacturer’s recommended product list for this vessel. Alternative manufacturers may be used so long as the coating material meets the standards listed in section 1.02. Table 3.02-T specifies the products to be applied on each surface of the vessel, and the recommended thickness for each coat. This table should be used as a reference for all surface areas listed in this Specification.

1.00 GENERAL

1.01 Scope

A. This specification covers the work necessary to furnish and install a protective coating system on concrete aerators and misc metal substrates, as shown on the drawings and as specified herein. Work includes, but is not limited to, the following.

1. Surface preparation of all concrete and steel substrates to be coated under this specification.

1.02 Referenced Specifications Codes and Standards

A. Without limiting the generality of other requirements of these specifications, all work hereunder shall conform to the applicable requirements of the referenced portions of the following documents, to the extent that the requirements therein are not in conflict with the provisions of this Section. All references and standards listed shall be the latest revisions. Joint and individual documents are referenced.

1. SSPC – The Society for Protective Coatings 40 24th Street, 6th Floor Pittsburgh, PA 15222-4643

(412) 281-2331

2. NACE – National Association of Corrosion Engineers P.O. Box 218340 Houston, TX 77218-8340

(281) 492-0535

3. ICRI – International Concrete Repair Institute 1323 Shepard Dr., Suite D Sterling, VA 20164-4428

(703) 450-0116

4. ASTM – American Society for Testing and Materials 100 Barr Harbor Drive West Conshohocken, PA 19428-2959

(610) 832-9585

5. NSF – National Sanitation Foundation 789 N. Dixboro Road Ann Arbor, MI 48105

(734) 769-8010

a. NSF/ANSI/CAN 61: Drinking Water System Components

1.03 Submittals

A. Submit product data for each component specified including data substantiating that the proposed materials comply with specified requirements and recommendations by the manufacturer covering all materials.

1.04 Quality Assurance

A. The manufacturer of the specified products shall provide technical support during the bidding process as well as on-site technical support in addition to the owner’s inspectors and representatives.

B. Primers and undercoat materials produced by the same manufacturer, or recommended by manufacturer, for each type of Special Coating / Lining specified to ensure compatibility, and proper chemical and mechanical bond.

C. Contractor Qualifications: All bidding contractors must have a minimum of 3 large scale coating projects that they must submit the details of including, project description, project total value, project timeframe including dates and customer contact information for reference.

D. Equipment Requirements:

1. Acceptable airless pump sprayer and spray gun: 68:1 or greater capable of producing 6500-7000 PSI. ½” ID hose (25”), and Gun with a 21-31 spray tip.

2. Ultra High Pressure Washer with a minimum of 10,000 psi.

F. Pre-Installation Conference

1. The contractor shall have an opportunity to meet on site with the owner’s representative to take measurements and ask questions. Particular emphasis shall be placed on these specifications, safety, weather conditions, surface preparation, material application, and inspection.

2. The contractor shall submit to the owner’s representative any revisions or changes agreed upon, reasons thereof, and parties agreeing or disagreeing with them.

E. Substrate Conditions: Do not proceed with work until substrate preparation and tolerances have been approved by the owner’s representative, concrete tank lining system manufacturer’s representative, the approved installation sub-contractor, and the contractor.

1.05 Delivery, Storage, and Handling

A. Deliver products to the job site in manufacturer’s original, unopened containers bearing manufacturer’s name and label and the following information

B. Store materials in sealed original manufacturer’s containers. Store materials in a protected area out of direct sunlight. Keep containers clean and undamaged. Adhere to manufacturer’s published storage temperature and shelf life recommendations. Protect all materials from freezing.

2.00 PRODUCTS

2.01 Acceptable Manufacturers and Materials

A. The Lining System shall consist of one or more systems for concrete repair and corrosion protection. Products are specified as a standard of quality and are manufactured by The Sherwin-Williams Company.

1. Concrete repair– Bugholes, Honeycomb, Tie-rod holes and other imperfections that affect the coatings performance shall be filled back to the original plane of the concrete using Sherwin-Williams AW Cook Thin Patch Mortar or A.W Cook Cemtec MSM Microsilica Mortar. Thickness shall be sufficient to fill voids and restore the surface to required surface plane. The selection of cementitious or epoxy mortar shall be at the discretion of the contractor to meet the desired requirements of workability and cure time. Follow the manufacturers recommended installation practices provided on the materials technical data sheets(TDS).

2. Concrete Crack and Joint Details – Exposed cracks, construction joints, contraction joints, and isolation joints shall be prepared and detailed in accordance with the attached detail drawings. Should any conditions or joint design be discovered that is not detailed in the attached drawings, the contractor shall notify the owner and consult with the material manufacturer for recommendations.

3. Pit Filler for Metal Surfaces – Fill all pits 1/8” or greater using one of the following epoxy based pit fillers - Sherwin-Williams – FT910 Epoxy Patching Compound

4. Miscellaneous Metals Lining System: All interior concrete tank exposed metal surfaces shall receive application of one of the Specified lining system after proper surface preparation has been completed.

5. Concrete Primer (Optional): After Surface Preparation is complete apply one of the following concrete surface primer-Macropoxy 5000 400-500 sf per gallon. Maximum Recoat 7 days.

6. Steel Primer (Optional Hold Primer)- Corothane 1k Zinc Primer at 2-4 mils DFT. Maximum Recoat of 12 months

2.02 Performance Criteria

A. The lining system shall be resistant to the chemical concentrations, temperatures, and duration of exposure, as submitted by the owner or authorized owners’ representative.

3.00 EXECUTION

3.01 Surface Preparation

A. Concrete

1. Prior to any other surface preparation or placement of repair materials or linings all surfaces shall be cleaned as per SSPC- HPWC (High Pressure Water Cleaning with pressures of a minimum of 10,000 psi.

2. The NACE/SSPC Joint Surface Preparation Standards for concrete surface preparation are incorporated in and made part of this specification. All references to NACE No. 6/SSPC-SP 13, Class: W-WJ designate the definitions and other requirements in these documents. The International Concrete Repair Institute (ICRI) Technical Guideline No. 03732, Guide to Surface Preparation of Concrete to Receive Sealers, Coatings and Polymer Overlays shall be used to visually evaluate the concrete surface profile. Refer to Sherwin-Williams Guideline Instructions for Surface Preparation of Concrete.

3. Following surface preparation, concrete surfaces shall be tested for moisture vapor emissions in accordance with ASTM D4263, Standard Method for Indicating Moisture in Concrete by Plastic Sheet Method. Report results to owner’s representative and Sherwin-Williams’ Industrial & Marine Representative.

4. Inspect concrete surface for soundness, flatness, levelness and overall condition. Report any discrepancies to the owner’s representative.

5. Create a minimum surface profile for the system specified in accordance with the methods described in ICRI No. 03732 to achieve profile numbers CSP-3 to CSP-5 for standard mortar repair materials and epoxy lining.

6. Concrete Surface Repair and resurfacing: Bug holes, honeycombs and voids and spalled areas requiring full resurfacing

a. Provide a clean surface saturated dry (SSD) concrete surface with no free standing or moving water for the application of all repair mortars, with a minimum surface profile as defined above.

b. For full resurfacing or spot repairs in the tank shall be treated as follows; Bugholes, honeycombs and voids less than 1/2” deep shall be repaired using AW Cook Thin Patch Mortar. This product may be feather edged back to original plane.

c. Spalled concrete areas with exposed aggregate shall be resurfaced back to original plane using A.W Cook Cemtec MSM Microsilica Mortar repair mortars hand trowelled or spray applied by mortar pump and back trowelled to a thickness up to 4” thick in successive applications. All areas where the full resurfacing butts up to an area that does not require full resurfacing a ¼” x ¼” termination key shall be cut into the concrete and chiseled back as per the concrete termination detail drawing.

d. All mortar repairs shall be finished with a masonry brush to provide a brushed/broomed finish to promote adhesion of the lining system.

8. All substrates are to be blown down with clean, dry air to remove spent abrasive, dust and other foreign material that might interfere with the adhesion of the primer and lining.

B. Iron and steel

1. The NACE / SSPC Joint Surface Preparation Standards for abrasive blasting approved in October 1994 are incorporated in and made a part of this specification. All references to SSPC-SP7 / NACE No. 4 and SSPC-SP10 / NACE No. 2 designate the definitions and other requirements in these documents. SSPC VIS 1-89 Visual Standard for Abrasive Blast Cleaned steel shall be used to visually evaluate the blast cleanliness.

2. Remove all oil and grease form surface by solvent cleaning per SSPC-SP1. Minimum surface preparation is SSPC-SP10 / NACE No. 2 (or WJ-2), Near White Metal Blast Cleaning for all immersed substrates and SSPC-SP 7/NACE No. 4-2006 (or WJ-4), Brush-Off Blast Cleaning for all atmospheric substrates. Prime any bare steel the same day as it is cleaned and before flash rusting occurs. Refer to Sherwin-Williams Guidelines Procedures for Surface Preparation of Metals.

a. Inspect the surfaces to be lined. All holes in the steel surfaces or pits greater than 1/8 inch shall be repaired in accordance with the tank owner’s repair procedures.

b. Prepare all steel surfaces to NACE SP0178 “Surface Finishes Practices for Tanks and Vessels to be Lined for Immersion Service” standards.

c. Remove or grind down all sharp burrs, edges, and weld spatter from all steel that is to be coated. Corners and edges shall be chamfered 1/16” at a 45° angle minimum or rounded to a 1/16” radius (1/8” diameter) minimum. The anchor profile shall be restored by abrasive blasting prior to the application of lining materials.

d. All substrates are to be blown down with clean, dry air to remove spent abrasive, dust and other foreign material that might interfere with the adhesion of the primer and lining.

e. The maximum allowable residual salt contamination, as measured with a KTA Scat Kit or equivalent field test method, immediately prior to the application of the first coat is as follows:

· 5 micrograms per square centimeter (50mg/m2) most commodities up to 120oF

· 2 micrograms per square centimeter (20mg/m2) most commodities at 120oF and greater

· 2 micrograms per square centimeter (20mg/m2) for demineralized (deionized, distilled) water

f. Corrosion pits in the blasted steel shall be filled flush with the substrate with an approved epoxy patching and surfacing compound putty/patching and surfacing compound.

g. Projections and lap joints on welded plates and on riveted plates to be coated shall be filled with an approved epoxy patching and surfacing compound putty/patching and surfacing compound in order to smooth out the surface and provide for a smooth transition of the lining over the substrate.

3.02 Application

A. Comply with manufacturers written installation procedures and individual product data sheet application bulletins.

B. Apply materials in accordance with the following material coverage.

Concrete and Steel Lining System

Table 3.02-T

Concrete – Atmospheric Exposure

Crack Repair – Concrete & Masonry Patch Primer – Loxon Conditioner (Optional if Chalking) Intermediate – Loxon XP Topcoat – SuperPaint Exterior

As Needed 1 Coat @ 200-300 sqft per gal 1 Coat @ 90-110 sqft per gal 1 Coat @ 300-400 sqft per gal

Metal – Atmospheric Exposure

Primer – Macropoxy 646 Topcoat - Sherloxane 800

1 Coat @ 5.0-10.0 mils DFT 1 Coat @ 3.0-5.0 mils DFT

Concrete - Immersion

Cemtec Thin Patch Cemtec MSM

Primer – Sherplate 600 Intermediate – Sherplate 600 Topcoat – Sherplate 600

As Needed up to ½ inch As Needed ½ inch-2 inch

1 Coat @ 3.0-6.0 mils DFT 1 Coat @ 12.0-18.0 mils DFT 1 Coat @ 12.0-18.0 mils DFT

Metal - Immersion (AWWA D102 No. 6)

Primer - Corothane Galvapack 1k Zinc Topcoat – Sherplate 600

1 Coat @ 2.5 mils DFT 1 Coat @ 10.0-18.0 mils DFT

3.03 Inspection and Testing

A. The Contractor must follow the AMPP QP1 inspection guidelines during the surface preparation, application and final inspection of the installed system and report all inspection information to the Owner.

B. If test results indicate noncompliance with the specification, the following corrective action may be required of the contractor

C. Minimum requirements of the chemical resistant coating/lining system are that it be free of the following

3.04 Protection

A. The Lining System shall be protected from damage or detrimental elements during cure and until the time of final acceptance.

4.00 Warranty

A. Sherplate 600 shall be warrantied from the manufacturer for a period of 10 years.