MOC-631-2D_Coating_Systems_for_Steel_Surfaces.pdf

MOC-631-2D

AUGUST 2002

SUPERSEDING

AMC-631-2C

AUGUST 1995

NATIONAL OCEANIC AND ATMOSPHERIC ADMINISTRATION (NOAA)

MARINE OPERATION CENTER, ATLANTIC

STANDARD SPECIFICATION MOC-631-2D

COATING SYSTEMS FOR STEEL SURFACES

1. SCOPE. This specification contains the general requirements for surface preparation and application of the coating systems most frequently used on the steel surfaces of NOAA steel ships and boats.

2. REFERENCES.

(a) SSPC: The Society for Protective Coatings Paint Application Specification No. 1 (SSPC-PA 1), “Shop, Field, and Maintenance Painting” (April 1, 2000)

(b) SSPC: The Society for Protective Coatings Paint Application Standard No. 2 (SSPC-PA 2), “Measurement of Dry Coating Thickness with Magnetic Gages” (June 1, 1996)

(c) SSPC: The Society for Protective Coatings Joint Surface Preparation Standard SSPC-SP 10/NACE No. 2, “Near-White Blast Cleaning” (September 1, 2000)

(d) SSPC: The Society for Protective Coatings Surface Joint Surface Preparation Standard SSPC-SP 12/NACE No. 5, “Surface Preparation and Cleaning of Steel and Other Hard Materials by High- and Ultrahigh-Pressure Water Jetting Prior to Recoating” (1995)

(e) SSPC: The Society for Protective Coatings Surface Preparation Specification No. 3 (SSPC-SP 3), “Power Tool Cleaning” (November 1, 1982 Editorial Changes September 1, 2000)

(f) SSPC: The Society for Protective Coatings Surface Preparation Specification No. 1 (SSPC-SP 1), “Solvent Cleaning” (November 1, 1982 Editorial Changes September 1, 2000)

(g) SSPC: The Society for Protective Coatings Surface Preparation Specification No. 11 (SSPC-SP 11), “Power Tool Cleaning to Bare Metal” (November 1, 1987 Editorial Changes September 1, 2000)

(h) SSPC: The Society for Protective Coatings Joint Surface Preparation Standard SSPC-SP 7/NACE No. 4, “Brush-Off Blast Cleaning” (September 1, 2000)

3. REQUIREMENTS.

3.1 General Requirements.

3.1.1 All paint application shall applied in compliance with

reference (a) as reinforced and supplemented by this specification.

3.1.2 Comply with the manufacturers' printed recommendations

and instructions for all aspects of handling, mixing, and application of the paint materials.

3.1.3 All paint shall be delivered to the jobsite in

original, unopened containers with labels intact. All containers shall remain unopened until required for use. Each container of paint shall be clearly marked or labeled to show paint identification, date of manufacture, batch number, analysis of contents, identification of all toxic substances, and special instructions.

3.1.4 Paint shall be used before its shelf life has expired.

If a paint has no stated shelf life or is more than one year old, the manufacturer must certify in writing that the paint is suitable for use.

3.1.5 All coating thicknesses are stated in dry film

thickness (DFT). All dry film thickness determinations shall be performed in accordance with reference (b).

3.1.6 Coatings shall be applied only when the following

conditions are maintained:

a. Apply paint only to dry surfaces and when there is no chance of precipitation until after the paint has cured. The steel surface temperature shall be at least five degrees Fahrenheit above the dew point. The dew point can be presumed to be satisfactory if a thin, clearly defined film of water applied to the cleaned surface with a damp cloth evaporates within 15 minutes. Otherwise, the dew point shall be measured prior to painting by taking the dry-bulb temperature of the surface and the wet-bulb temperature at the jobsite.

b. The air temperature and surface temperature must both be a minimum of 45 degrees Fahrenheit at all times, unless a lower temperature is specifically authorized by the paint manufacturer's printed instructions.

c. Painting is permitted only when the humidity is less than 95 percent.

d. When paint must be applied in damp or cold weather, the steel must be painted under cover and the surrounding air and the steel heated to establish the required conditions. The steel shall remain under cover or be protected until dry or until weather conditions permit its exposure.

3.1.7 Each coat of paint shall be in a proper state of cure

or dryness before the application of the succeeding coat. Paint shall be considered dry for recoating when an additional coat can be applied without the development of any detrimental film irregularities, such as lifting, wrinkling, or loss of adhesion of the undercoat. The time interval between coating applications shall be in compliance with the manufacturer's printed instructions.

3.1.8 All paint materials shall be furnished by the

Contractor and shall be applied using spray equipment, unless otherwise specified. When applying touch-up coatings to small areas disturbed by other work, brushes and rollers may be used.

3.1.9 Comply with and enforce all safety and environmental

protection regulations relative to removal, disposal, mixing, and application of paints and other materials.

3.1.10 Mask, tape, cover, and otherwise protect all equipment, machinery, cables, piping, insulation, glass, furnishings, and other government materials from damage, overspray and contamination. Remove and reinstall parts and loose gear as necessary to avoid damage.

3.1.11 Plug, wrap, blank, cover, or mask all openings as

needed to prevent entry of blast materials into the ship or boat and to confine blast materials inside the compartment being sandblasted. Install industrial foam filter materials on the intake and exhaust of ventilation systems which will be in use.

Renew filter materials when air flow becomes restricted.

3.1.12 When surface preparation and coating of a compartment

or surface is specified, included shall be all plating, frames, longitudinals, beams, stiffeners, brackets, baffles, and other structural steel members. Steel ladders in tanks, voids, and cofferdams are also to be included.

3.1.13 Surface preparation and paint application of shell

plating and frames below the Load Waterline shall be accomplished only while the ship is in drydock, unless otherwise and specifically authorized.

3.1.14 Where colors are not specified in this specification, the color for coatings shall be as specified in other procurement documents or specifications. Where colors are not specified elsewhere, the colors shall be selected by the COTR or other NOAA representative responsible for acceptance of the work.

3.2 Surface Preparation.

3.2.1 Unless otherwise specified, all steel surfaces shall be prepared by sandblasting to a "near white" surface in accordance with reference (c). or prepared by "ultrahigh-pressure water jetting” to a visual surface preparation condition of WJ-2 in accordance with reference (d).

3.2.2 When other procurement documents or specifications

require "power tool clean" surface preparation, the therein specified steel surfaces shall be prepared in accordance with reference (e).

3.2.3 When other procurement documents or specifications

require "solvent clean" surface preparation, the therein specified steel surfaces shall be prepared in accordance with reference (f).

3.2.4 When other procurement documents or specifications

require "power tool clean to bare metal" surface preparation, the therein specified steel surfaces shall be prepared in accordance with reference (g).

3.2.5 When other procurement documents or specifications

require “brush-off blast cleaning” surface preparation, the therein specified steel surfaces shall be prepared in accordance with reference (h).

3.2.6 The surfaces to be painted shall have the specified

surface preparation at the time of application of the paint. If the surface is degraded or contaminated subsequent to surface preparation and prior to painting, the surface shall be restored before paint application.

3.2.7 In order to prevent degradation or contamination of the prepared surfaces, the first coat of paint shall be applied as soon as possible after the surfaces have been prepared. The first coat shall always be applied the same day as surface preparation is completed. Succeeding coats shall be applied before contamination of the under surface occurs.

3.2.5 After surface preparation, surfaces shall be brushed

with clean brushes, blown off with compressed air, or cleaned by vacuum to remove all traces of blast products and dust.

3.2.6 Whenever sandblasting or spray painting is specified

for surface preparation of exterior steel surfaces at a Government facility, or when applicable regulations and laws prohibit release of blast materials and paint into the atmosphere, the surfaces shall be enclosed in a cover adequate to contain the blast materials and paint.

3.2.7 Cleaning and painting shall be so scheduled that

detrimental amounts of dust or other contaminants do not fall on wet, newly-painted surfaces.

3.3 Coating Systems. Following acceptance of the surface

preparation by the COTR, apply the coating system specified in the procurement document or detail specification and defined below. It is understood that newer coating systems have been and are being developed that may supercede the defined coating systems. The contractor may recommend application of these newer coating systems through the use of a Condition Report which is subject to acceptance by the COTR.

3.3.1 System STL-1:

a. Apply one coat, 3.0 to 4.0 mils DFT, of self-curing inorganic zinc silicate, using one of the products listed in Appendix A.

b. Allow the coating to dry for 24 hours and rinse with fresh water to remove the white crystallized drying salts.

3.3.2 System STL-2:

a. Coat one: Apply 3.0 to 4.0 mils DFT, self-curing inorganic zinc silicate, using one of the products listed in Appendix A. Allow the coat to dry for 24 hours and rinse with fresh water to remove the white crystallized drying salts.

b. Coat two: Apply a mist tie coat, 0.5 to 1.0 mils DFT, polyamide-epoxy primer, MIL-P-24441, formula 150 (green).

c. Coat three: While the previous mist tie coat is still tacky, apply 3.0 to 4.0 mils DFT, of polyamide-epoxy, MIL- P-24441, formula 150 (green).

d. Coat four: While the previous coat is still tacky, apply 2.0 to 3.0 mils DFT, of 30-percent modified silicone alkyd high gloss marine paint, using one of the products listed in Appendix B.

e. Coat five: Apply 2.0 to 3.0 mils DFT of 30-percent modified silicone alkyd high gloss marine paint same as previous coat.

3.3.3 System STL-3:

a. Coat one: Apply 2.0 to 4.0 mils DFT, polyamide-epoxy, MIL-P-24441, formula 150 (green).

b. Coat two: Apply 2.0 to 4.0 mils DFT, polyamide-epoxy, MIL-P-24441, formula 152 (white).

c. Coat three: Apply 2.0 to 4.0 mils DFT polyamide-epoxy, MIL-P-24441, formula 156 (red).

d. The thickness of the total 3-coat system shall not be less than 8 mils DFT nor more than 12 mils DFT.

e. When applying this system to the entire interior of tanks, voids, or bilges, apply an additional hand brush (stripe) coat after coat one and after coat two to weld seams, cutouts, corners, and butts. Each hand coat shall be unthinned and shall be a different color than the coat being covered, but may be the same color as the coat to follow.

3.3.4 System STL-4:

a. Coat one: Apply 2.0 to 4.0 mils DFT, polyamide-epoxy, MIL-P-24441, formula 150 (green).

b. Coat two: Apply 2.0 to 4.0 mils DFT, polyamide-epoxy, MIL-P-24441, formula 156 (red).

c. Coat three: Apply 2.0 to 4.0 mils DFT, polyamide-epoxy, MIL-P-24441, formula 152 (white).

c. The thickness of the total 3-coat system shall not be less than 8 mils DFT nor more than 12 mils DFT.

e. When using this coating system in potable water tanks, comply with the following requirements:

1. The total maximum DFT specified above shall not be exceeded except in isolated areas adjacent to shapes, frames, and stiffeners. In no case shall the maximum be exceeded by more than two mils DFT. The isolated areas shall not exceed two percent of the total area.

2. Insure that no formula substitutions are made.

3. The drying time between coats shall be a minimum of 48 hours at a minimum temperature of 70 degrees Fahrenheit. Provide heated air if necessary to maintain the temperature. Provide sufficient ventilation during the drying time for continuous flow of air through the tanks with at least one complete air change every four hours.

4. A minimum of seven calendar days curing time is required after application of the last coat before filling tanks with water. Complete application of the last coat at least seven days prior to the end of the contract performance period.

5. When applying this system to the entire interior of tanks, apply an additional hand brush (stripe) coat after coat one and after coat two to weld seams, cutouts, corners, and butts. Each hand coat shall be unthinned and shall be a different color than the coat being covered, but may be the same color as the coat to follow.

3.3.5 System STL-5:

a. Coat one: Apply 2.0 to 4.0 mils DFT, polyamide-epoxy, MIL-P-24441, formula 150 (green).

b. Coat two: Apply 2.0 to 4.0 mils DFT, polyamide-epoxy, MIL-P-24441, formula 151 (haze grey).

c. Coat three: Apply 2.0 to 4.0 mils DFT polyamide-epoxy, MIL-P-24441, formula 156 (red).

d. Coat four: Apply 2.0 to 4.0 mils DFT polyamide-epoxy, MIL-P-24441, formula 152 (white).

e. The thickness of the total 4-coat system shall not be less than 10 mils DFT nor more than 16 mils DFT.

f. When applying this system to the entire interior of tanks, apply an additional hand brush (stripe) coat after coat one and after coat two to weld seams, cutouts, corners, and butts. Each hand coat shall be unthinned and shall be a different color than the coat being covered, but may be the same color as the coat to follow.

3.3.6 System STL-6:

a. Coat one: Apply 2.0 to 4.0 mils DFT polyamide-epoxy, MIL-P-24441, formula 150 (green).

b. Coat two: Apply 2.0 to 3.0 mils DFT latex fire-retardant paint, DOD-C-24596, Type I.

c. Coat three: Same as coat two.

3.3.7 System STL-7:

a. Coat one: Apply 2.0 to 4.0 mils DFT heat resistant aluminum paint, DOD-P-24555.

b. Coat two: Same as coat one.

3.3.8 System STL-8:

a. Coat one: Apply 3.0 to 4.0 mils DFT, self-curing inorganic zinc silicate, using one of the products listed in Appendix A. Allow the coat to dry for 24 hours and rinse with fresh water to remove the white crystallized drying salts.

b. Coat two: Apply a mist tie coat, 0.5 to 1.0 mils DFT, polyamide-epoxy primer, MIL-P-24441, formula 150 (green).

c. Coat three: While the previous mist tie coat is still tacky, apply 3.0 to 4.0 mils DFT, of polyamide-epoxy, MIL- P-24441, formula 150 (green).

d. Coat four: While the previous coat is still tacky, apply 5.0 mils minimum DFT, anti-sweat binder, DOD-P-15144, formula 34.

e. Coat five: While the binder is still tacky, blow a heavy coat of expanded vermiculite, ASTM C-516 onto the surfaces using compressed air.

f. Coat six: Apply 2.0 to 3.0 mils DFT of latex fire-retardant paint, DOD-C-24596, Type I.

3.3.9 System STL-9:

a. Coat one: Apply 2.0 to 4.0 mils DFT, polyamide-epoxy, MIL-P-24441, formula 150 (green).

b. Coat two: Apply 30.0 to 40.0 mils DFT, non-skid coating, DOD-C-24667, Type I, Composition G, Grade A, Class 2.

In the event this coating cannot be obtained, non-skid coating, MIL-D-24883, Type I may be substituted.

c. Coat one shall be allowed to cure a minimum of 24 hours, but not more than 48 hours, before application of coat two.

3.3.10 System STL-10:

a. Coat one: Apply 3.0 to 4.0 mils DFT, self-curing inorganic zinc silicate, using one of the products listed in Appendix A. Allow the coat to dry for 24 hours and rinse with fresh water to remove the white crystallized drying salts.

b. Coat two: Apply a mist tie coat, 0.5 to 1.0 mils DFT, polyamide-epoxy primer, MIL-P-24441, formula 150 (green).

c. Coat three: While the previous mist tie coat is still tacky, apply 2.0 to 4.0 mils DFT of polyamide-epoxy, MIL-P- 24441, formula 150 (green).

d. Coat four: While the previous coat is still tacky, apply 2.0 to 3.0 mils DFT of 30-percent modified silicone alkyd high gloss marine paint, using one of the products listed in Appendix B.

e. Coat five: Immediately after applying coat four, spread a coat of #40-mesh garnet over the coating while it is still wet. Completely cover the coating and allow the coating to dry for eight hours. Then, sweep off and vacuum up the excess garnet.

f. Coat six: Same as coat four.

3.3.11 System STL-11:

a. Coat one: Apply 4.0 to 8.0 mils DFT of Devoe Bar- Rust 235.

b. Coat two: Same as coat one. Total thickness of the two coats shall not be less than 12.0 mils DFT.

4. QUALITY ASSURANCE.

4.1 Certification and Records.

4.1.1 Whenever the surfaces to be prepared and coated

exceeds a total surface area of 10 square-feet, comply with the following prior to commencing the surface preparation:

a. Prepare and submit to the COTR a detail "Paint Plan" which clearly outlines the complete painting timetable and procedures, including methods for conducting and documenting inspections. Also to be included shall be copies of all applicable manufacturers' printed recommendations, instructions and product data sheets.

b. The Contractor's paint foreman shall meet with the COTR to discuss and review the "Paint Plan".

4.1.2 Provide to the COTR the following information:

a. Number of gallons of each type paint used.

b. Certification by the Contractor's paint foreman that the conditions specified in 3.1.5 were maintained during application and curing of the paint. If measured, wet-bulb temperature at the jobsite and dry-bulb temperature of the surface immediately before applying each coat of paint.

c. Date and time of starting and completing each coat of paint.

d. Complete set of all DFT measurements taken.

4.2 Inspections.

4.2.1 Prior to any sandblasting or painting, conduct an

inspection with the COTR of all protective coverings and masking to insure that the protection is adequate.

4.2.2 After completion of surface preparation, the COTR or

other person designated by the COTR shall inspect the surfaces before the first coat of paint is applied.

4.2.3 Prior to applying each coat of paint, verify to the

COTR or other person specified by the COTR that the conditions exist as prescribed in paragraph 3.1.5.

4.2.4 After each coat of paint is applied and prior to the

next coat, take DFT readings in accordance with reference 2.a.

The COTR or other person specified by the COTR shall be permitted to witness the measurements. Provide magnetic gages, calibrated immediately before taking the measurements in presence of the COTR or other person specified by the COTR.

4.2.5 In the event the COTR or other person specified by

the COTR is unable to witness the required inspections and measurements, the Contractor shall nonetheless conduct and document the inspections and measurements to verify compliance with the requirements of this specification.

5. NOTES.

5.1 The surfaces and extent of coating to be applied will be

specified in other procurement documents or specifications.

5.2 A paint system may be specified for use in any location or for any purpose. However, the systems are normally used in the following applications:

System Normal Use STL-1 Appearance is unimportant.

STL-2 Exterior freeboard and superstructure

STL-3 Bilges

STL-4 Chain lockers and tanks, including potable water tanks

STL-5 CHT/MSD tanks

STL-6 Interior bulkheads, overheads, insulation

STL-7 Hot surfaces exceeding 125 degrees Fahrenheit

STL-8 Surfaces subject to condensation

STL-9 Decks requiring non-skid

STL-10 Decks requiring non-skid

STL-11 Voids, bilges, and tanks (not approved for potable water tanks)

APPENDIX A

ACCEPTABLE INORGANIC ZINC SILICATES

Product Manufacturer

Carbozinc 11 HFP Carboline Company Galvosil 1570 Hemple's Marine Metalhide 100 Pittsburg Plate Glass Mobilzinc 7 Mobil Chemical Mobilzinc 13-F-12 Mobil Chemical Uni-Pac 13-C-10 Mobil Chemical Rust-Ban 191 Exxon Chemical Rust-Ban 188 Exxon Chemical Zinc-ite Plus-Chemical Interzinc HF-2410/2411 International Paint Interzinc 2410/2411 International Paint Quram 3365 WZ Philadelphia Quartz Zinc Prime 200 Grow Chemical BPS Vitazine 2946 Patterson Sargent Stancoat 711R Standard Paint & Varnish Farbozinc 76 Farboil Farbozinc 114 Farboil Durazinc 500 Southern Imperial Coatings Pro-zinc 202 Proline Paint Briner Five-65 Briner Paint Manufacturing Phyllyzinc 1 Philadelphia Resins SA-13446/SA-13447 Andrew Brown Rel-Zinc No. 63

(gray-green) Reliance Universal Zincguard No. 3 Sherwin-Williams/Seaguard Zincguard No. 6 Sherwin-Williams/Seaguard Zinc-Lock 351-NF and

Zinc-Lock 351-HF Porter Paint Ganicin 347-934:EID Dupont de Nemours Ganicin 347--947 Dupont de Nemours Napko 5-Z (high flash) Napko Ameron 2066 and

Dimetcote 9HF Ameron Mo-Zinc No. 4

(Gray 28-DH-51) Valspar Ind.

Mo-Zinc No. 5

(Green 28-DH-52) Valspar Ind.

ByCo Zinc-Gard 102-SP Bywater Coatings IC 531 Inorganic Zinc Inorganic Coatings Cathacoat 304 Devoe Marine Paint and

Coatings

APPENDIX B

30-PERCENT MODIFIED SILICONE ALKYD PAINTS

Product Manufacturer

Gloss Silicone Alkyd(series) Devoe Marine Coatings SA-22 Silicone Alkyd Porter Coatings CMB000 Silicone Alkyd International Paint Silalx 300 International Paint 21-W-9 Silicone Alkyd Valspar 434U-1000 Silicone Alkyd Hempel's Marine Paints Series 5539 Glidden Coatings and Resins 40-E Silicone Alkyd Farboil HM-70 Carboline MIL-E-24635 Sherwin-Williams/Seaguard

END OF SPECIFICATION