634-1B_DECK_COVERINGS.pdf

MOC-634-1B

MARCH 2005

SUPERSEDING

AMC-634-1A

SEPTEMBER 1991

NATIONAL OCEANIC AND ATMOSPHERIC ADMINISTRATION (NOAA)

ATLANTIC MARINE CENTER

STANDARD SPECIFICATION AMC-634-1B

DECK COVERINGS

1. SCOPE This specifications contains the general requirements for removal and installation of deck coverings on NOAA ships.

2. REFERENCES

None

3. REQUIREMENTS

3.1 General The following requirements apply to all deck covering removals and installations:

3.1.1 Comply with the manufacturer's printed recommendations

and instructions for all handling, mixing, and application of deck covering materials. In the event a conflict should occur between these specifications and the manufacturer's instructions and recommendations, the manufacturer's instructions and recommendations shall take precedence.

3.1.2 Installation of all underlayment and deck covering

materials shall be accomplished by workers regularly employed installing deck coverings and experienced with the specified deck covering. Deck covering installers shall have installed at least ten deck covering of the specified type during the preceding 12 months.

3.1.3 At least 3 working days before starting installation of deck covering materials, provide to the COTR a copy of the manufacturer's printed recommendations and instructions for handling, mixing and application of the applicable deck covering materials.

3.1.4 Completely remove and scrap all existing deck covering

materials, including underlayment and other fillers, on deck surfaces having new deck coverings installed. Power tool clean the deck surface (and vertical bounding surface if base covings are required) in accordance with Steel Structures Painting Council Surface Preparation Specification No. 3 (SSPC-SP 3-82), "Power Tool Cleaning".

3.1.5 Before any rusting occurs, apply one 2.0-4.0 dry mil thick coat of polyamide-epoxy primer, MIL-P-24441, formula 150 to all power tool cleaned surfaces. For PRC Proreco I covering systems, substitute PRC Primer #420 Marine for the polyamide-epoxy primer.

3.1.6 Apply underlayment to the entire deck surface to fill all low spots and to level the deck surface. Slope underlayment toward drains to provide adequate drainage. Minimum thickness of underlayment shall be inch for deck tile and electric sheet installations and ¼ inch for other deck coverings. Underlayment shall conform to MIL-D-3135, type II, class 2 for deck tile, quarry tile, and electric sheet deck coverings. Underlayment for monolithic deck coverings shall conform to MIL-D-3135, type I.

Underlayment for the Proreco I covering shall be as specified in section 3.6.

3.1.7 After the underlayment has properly cured, install the

specified top deck covering.

3.1.8 The color of the deck covering may be specified in Detail Specifications or other procurement document. If the color is not specified, provide to the COTR a minimum of 8 color samples of the applicable deck covering. The color samples shall be a variety of different light and dark colors. If the deck covering is provided in color combinations, a minimum of 8 color combinations samples shall be provided. The color, or color combinations shall be as specified by the COTR.

3.1.9 Unless otherwise specified, all flush scuttles and hatches in a specified space shall receive the same deck covering as the space.

3.2 Deck Tile

3.2.1 Deck tiles shall be inch thick and 12-inch square, and

shall conform to MIL-T-18830 or SS-T-312, type III.

3.2.2 Secure the deck tiles to the underlayment with epoxy

adhesive complying with MIL-A-24456.

3.2.3 New deck tiles shall be stored at a minimum of 70 degrees Fahrenheit for at least 24 hours immediately prior to installation.

3.2.4 Except as otherwise specified, deck tile installation

shall be from bulkhead to bulkhead. A beading sealer shall be used to waterproof all edges against bulkheads, stationary furniture, pipes, stanchions, and other deck fittings. The sealer color shall match the adjacent surfaces or deck tiles. Exposed edges of tiles not butting a bulkhead or fitting shall be protected by a 1 inch by

0.08 inch stainless steel strip secured to the deck.

3.2.5 Immediately after the tile has been installed, roll a

150-pound sectional roller over the tiles thoroughly in both directions to ensure proper adhesion to the underlayment.

3.3 Monolithic Deck Covering

3.3.1 The deck covering shall be an epoxy marble chip, 100-percent monolithic deck cover recommended by the manufacturer for installation in thickness of ¼ to ½ inch and which produces a smooth, decorative, terrazzo-like surface without grinding.

SELBALUX (manufactured by Selby Battership & Co.) and DEX-O-TEX "Decor Flor" (manufactured by Crossfield Products Corp.) meet these requirements.

3.3.2 The deck covering material shall be applied to a minimum thickness of ¼ inch and a maximum thickness of ½ inch.

3.3.3 Install a ½ inch thick 3 inch high base coving at all

vertical bounding surfaces.

3.3.4 Thoroughly seal the cured deck covering by applying the minimum number of sealer coats recommended by the deck covering manufacturer, plus two additional sealer coats.

3.4 Quarry Tile

3.4.1 Deck tiles shall be red quarry tile, 6 inch by 6 inch by ½ inch, 7 percent silicon carbide non-skid, standard vitrified backed and ground on all four edges after firing. Base tiles shall be 5 inch by 6 inch by ½ inch round-top cove base red quarry tile, 7 percent silicon carbide, standard vitrified backed.

3.4.2 Epoxy adhesive and grouting mortar shall be used and shall be resistant to urine, dilute acid and alkali, petroleum distillates, oil, solvents, and food waste, and shall meet the following physical requirements:

Compression strength...............3500 psi minimum Bond strength...................... 750 psi minimum Water absorption................... 4 percent maximum Smoke contribution factor Flame contribution factor

3.4.3 Materials shall be delivered to the job site in original containers with the manufacturer's identification on each package.

Materials shall be used as supplied from the manufacturer.

Modification by addition of cement, sand, water, or other materials will not be permitted.

3.4.4 Work shall not be performed when the temperature of the work area is less than 50 degrees Fahrenheit.

3.4.5 The compartment shall be closed to all traffic until the tile is set up, and all tile work shall be protected from damage which might be caused by the work of others.

3.4.6 Lay out the work prior to placing the setting bed by

centering in both directions and laying tiles from centerlines toward bulkheads. Prepare setting mortar using epoxy adhesive by combining one volume of part "A" resin with one volume of part "B" resin and stirring thoroughly. Add filler powder to bring the mortar to trowelable consistency. Apply mortar with the proper knotched trowel to give a uniform inch to 3/16 inch thick setting bed after the quarry tiles have been set and beaten in. Quarry tile, which have ribs or indentations on the back, shall have a skin coat of mortar applied to the back, just prior to placing in the freshly combed mortar on the deck/underlayment. Beat or tap the tiles with a rubber mallet or block after placing in the mortar to produce a level surface and to embed the tiles.

3.4.7 Joints between tiles shall be a uniform width of inch.

Excess mortar shall be wiped from the surface, using a wet cloth or sponge, while the mortar is fresh. Allow tiles to set firmly in the mortar before grouting.

3.4.8 Prepare epoxy grout using the epoxy adhesive by combining part "A" with part "B". Add filler powder to make a soft trowelable consistency. Pour the grout onto the deck covering, spread and compact into the joints using a hard rubber grouting float. Use firm pressure on the float to compact the mortar into the joints. Remove excess grout from the surface. After the grout mixture has been worked into the joints, a small quantity of dry filler powder may be dusted lightly over the entire surface and allowed to remain five to ten minutes until the joints stiffen. Rub the surface with a coarse cloth, burlap or with a power buffing machine using nylon scrubbing pads to remove the thin film of grout paste from the surface. Use a circular motion to rub the surface. Use minimum water for cleaning to eliminate pulling or shrinking of the joints.

After the rubbing operation, sweep up all dry materials. Dampen the deck covering with clean water and allow the joints to absorb the water. Allow to soak 15 to 30 minutes and use a power scrubbing machine with a coarse texture nylon pad to remove the grout film.

Use a cleaner recommended by the adhesive manufacturer to remove hardened grout film or haze.

3.4.9 Cover the deck covering with waterproof paper with all

joints lapped at least four inches and the laps tape-sealed or held down with planks or other weights. Allow deck covering to cure for at least 72 hours before foot traffic is permitted.

3.5 Electric Grade Sheet

3.5.1 Electric grade sheet shall be inch thick with smooth

marbleized surface and shall conform to MIL-M-15562, type I.

3.5.2 Secure the sheet material to underlayment using a latex adhesive complying with MIL-A-21016.

3.5.3 Unless otherwise specified, install the sheet material

from bulkhead to bulkhead. A beading sealer shall be used to waterproof all seams against bulkheads, stationary furniture, pipes and other deck fittings.

3.5.4 Install the sheet such that the number of seams are

minimized. Insofar as possible, no seams shall be located within three feet of an electrical hazard. Seal all seams between sheets with thermoplastic deck coverings, fused chemically or heat welded or fused with a special hot air gun.

3.5.5 Immediately after the sheet is installed, roll a 150-pound sectional roller over the deck thoroughly in both directions to ensure adhesion to the underlayment.

3.6 PRC Proreco I

3.6.1 The deck covering shall be a random-chip Proreco I interior decking system manufactured by Products Research & Chemical Corporation. All mixing and application of materials shall be accomplished by personnel specially-trained and certified in writing as an authorized system installer by the manufacturer. Copies of the written certification shall be provided to the COTR prior to beginning the work.

3.6.2 After allowing Primer #420 Marine to cure a minimum of 4 hours, but not more than 24 hours, apply PR-1537-L underlayment as required to fill low spots and level the deck and to insure that the final deck covering is smooth and level. Application of underlayment may not be necessary if the required leveling can be obtained during application of the basecoats.

3.6.3 Apply PR-1539-U basecoat to a minimum thickness of -inch.

Additional thickness is to be applied where needed to fill low spots and level the deck surface. PR-1539-U Camber Grade may be substituted for PR-1539-U where underlayment is not used, on decks that have a great degree of slope, and in those areas where fairing at doubler plates or similar irregularities is needed. Allow PR-1539-U to cure for 16-24 hours, but not more than 24 hours, prior to proceeding.

3.6.4 Apply two coats, 2.0-3.0 dry mils each of PR-1141 color coat specified by the COTR.

3.6.5 As soon as the last coat of PR-1141 reaches a tack-free condition, install PR-1155 decorative color chips and PR-1154-F sealer coats. The following requirements amplify the manufacturer's application instructions:

a. The COTR may select up to two chip colors to be combined.

Chips shall be provided and installed in amounts equal to 50 square feet per pound (provides approximately 15 percent deck coverage).

b. A total of six coats of PR-1154-F sealer shall be applied.

3.7 Carpet

3.7.1 All new carpeting shall have pile specifications for

“heavy traffic areas.”

3.7.2 All new carpeting shall qualify as a Coast Guard approve carpet style. In order to qualify as a Coast Guard approved carpet style, the product has to pass the Flooring Radiant Panel (ASTM E648) test with a rating of 0.80 kw/cm2 and have a smoke density (ASTM E662) of <450 in both the flaming and non-flaming mode. Provide certification of these test to the COTR upon request.

END OF SPECIFICATION