Attachment_5_-_Technical_Paint_Spec.pdf

INTERIOR AND EXTERIOR COATING OF STEEL STRUCTURES

PART 1 GENERAL

1.1 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.

ASTM INTERNATIONAL (ASTM)

ASTM D4285 (1983; R 2012) Indicating Oil or Water in Compressed Air

ASTM D7127 (2013) Measurement of Surface Roughness of Abrasive Blast Cleaned Metal Surfaces using a Portable Stylus Instrument

American Water Works Association (AWWA) Specifications: AWWA D102, "Coating Steel Water-Storage Tanks.”

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC AB 3 (2003; E 2004) Ferrous Metallic Abrasive

SSPC Guide 12 (1998; E 2004) Guide for Illumination of Industrial Painting Projects

SSPC Guide 6 (2015) Guide for Containing Surface Preparation Debris Generated During Paint Removal Operations

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

SSPC-SP 6/NACE No. 3 (200X) Commercial Blast Cleaning

SSPC SP 10/NACE No. 2 (2007) Near-White Blast Cleaning

FS TT-S-00230C - Sealing Compound: Elastomeric Type, Single Component

MIL-A-22262 (1993; Rev B; Am 2 1996) Abrasive Blasting Media Ship Hull Blast Cleaning

29 CFR 1910.1000 Air Contaminants

29 CFR 1910.134 Respiratory Protection

1.2 DEFINITIONS

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

1.3 SUBMITTALS

Submit the following information as required:

SD-06 Manufacture Data

Joint Sealant Submit manufacturer's printed instructions including detailed application procedures, minimum and maximum application temperatures, and curing procedures. Include manufacture’s printed materials safety data sheets (MSDS) for materials to be used at the job site.

Coatings

1. Submit manufacturer's literature describing products to be provided, giving manufacturer's name, product name, and product line number for each material.

2. Submit manufacturer's printed instructions including detailed mixing and application procedures, minimum and maximum application temperatures, and curing procedures.

Include manufacture’s printed materials safety data sheets (MSDS) for materials to be used at the job site. Also provide manufacturer’s published data concerning transportation, storage, and pot life.

3. Submit color charts showing manufacturer’s full range of standard colors.

Abrasive

Submit manufacturer's literature describing products to be provided, giving manufacturer's name, product name, and product line number for each material.

SD-07 Certificates

Coating Work Plan

1.4 DELIVERY AND STORAGE

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

Deliver to the job site in the original sealed containers with manufacturer's name, product name, type of product, manufacturer's specifications or catalog number, Federal specifications number, instructions for reducing where applicable, label analysis and be available and convenient for inspection.

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 Contracting Officer (CO).

Products may not be extended longer than allowed in the product specification.

1.5 COATING HAZARDS

Ensure that employees are trained in all aspects of the safety plan. 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. The Certified Industrial Hygienist (CIH) shall be consulted and approve work procedures and personal protective equipment.

PART 2 PRODUCTS

2.1 JOINT SEALANT

FS TT-S-00230C, Type II, Class B

2.2 COATING SYSTEMS:

Coating materials shall be products of a single manufacturer. The paint products specified shall be manufactured by Tnemec Company, Inc. of Kansas City, Missouri or approved equal products of other manufacturers. Approval to use other than Tnemec shall be approved by Contracting Officer (CO). In all cases, the coating system shall be from a single manufacturer.

2.2.1 COATING SYSTEM INTERIOR: AWWA D102 Paint System: ICS-5

System Type: Zinc-Rich Urethane/Epoxy/Epoxy

2.2.1.1 PRIME COAT:

Immediately after blasting and before any rusting occurs (within 12 hours maximum), apply one coat of Tnemec Series 91-H2O Hydro-Zinc to all bare steel surfaces. This coating shall be applied at a dry film thickness of 2.5 - 3.5 mils.

2.2.1.2 STRIPE COAT:

After the primer has cured in accordance with the manufacturer's recommendations, apply one stripe coat, by brush only, of Tnemec Series N140-39BL Delft Blue Pota-Pox Plus to all weld seams, edges of unseal welded roof plates, angles, and sharp edges.

2.2.1.3 INTERMEDIATE COAT:

Apply one complete coat of Tnemec Series N140-1255 Chicago Beige Pota-Pox Plus to all surfaces. This coating shall be applied at a dry film thickness of 4.0 - 6.0 mils.

2.2.1.4 FINISH COAT:

Apply one complete coat of Tnemec Series N140-15BL Tank White Pota-Pox Plus at a dry film thickness of 4.0 - 6.0 mils.

Total DFT: 12 – 15 mils

2.2.2 COATING SYSTEM EXTERIOR: AWWA D102 Paint System: OCS-6

System Type: Zinc-Rich Urethane/Epoxy/Polyurethane (color for each coat to be selected by Project Engineer – vary at least 2 shades for each coat)

2.2.2.1 PRIME COAT:

Immediately after blasting and before any rusting occurs (within 12 hours maximum), apply one coat of Tnemec Series 91- H2O Hydro-Zinc to all bare steel surfaces. This coating shall be applied at a dry film thickness of 2.5 - 3.5 mils.

2.2.2.2 INTERMEDIATE COAT:

Apply one complete coat of Tnemec Series N69 Hi-Build Epoxoline II at a dry film thickness of 2.0 - 3.0 mils.

2.2.2.3 FIRST FINISH COAT:

Apply one complete coat of Tnemec Series 1074 Endura-Shield II at a dry film thickness of 2.0 - 3.0 mils

2.2.2.4 SECOND FINISH COAT:

Apply one complete coat of Tnemec Series 1074 Endura-Shield II at a dry film thickness of 2.0 – 3.0 mils.

Total DFT = 10 – 12 mils

2.3 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.

2.3.1 Non-metallic Abrasive

Conform to MIL-A-22262, Type I. Use abrasive that is specifically selected and graded to provide a sharp, angular profile to the specified depth. Do not use ungraded abrasive.

Make adjustments to processes or abrasive gradation to achieve specified surface profile.

Recycled non-metallic abrasive shall meet all requirements of the specification each time that it is placed in the blast pot.

2.3.2 Metallic Abrasive

2.3.2.1 New and Remanufactured Steel Grit

Conform to the chemical and physical properties of SSPC AB 3 Class 1 Steel only. Class 2 Iron abrasive shall not be used. To develop a suitable work mix from new steel abrasive, a minimum of 200 - 400 recycles is required, therefore, it is advantageous for a Contractor to use remanufactured steel grit or grit reclaimed from a previous project.

Such grit shall be considered to conform if it can be traced to new grit conforming to SSPC AB 3 Class 1 and it meets all cleanliness requirements.

PART 3 EXECUTION

3.0 GENERAL

Perform all work, rework, and repair in accordance with approved procedures in the Coating Work Plan. Prepare and coat interior and exterior surfaces of tanks including steel roof, shell, stair, railing, pipe, covers and other exterior appurtenances. Again, all coatings must be supplied by one manufacturer. Manufacturers’ recommended curing times and recoat windows between each coat must be strictly adhered too. Each surface coat of paint shall also be of a different color or shade to easily distinguish between coats. The Contractor shall be responsible for any damage caused by his operations to vehicles, persons, or adjoining property, and shall provide at his expense protective means to guard against such damage.

Protect elements surrounding work from damage or disfiguration. Provide drop cloths, shields, and other protective equipment. These tanks are also protected by a fully functioning cathodic protection system. The contractor must take all necessary measures to protect the existing cathodic protection system from damage and return it to its fully functioning state at the completion of the coating process.

Removing the water and cleaning the sludge from the tanks prior to the start of the surface preparation process will be the responsibility of the contractor.

Employ only application equipment that is clean, properly adjusted, and in good working order, and of type recommended by coating manufacturer. All other equipment, (compressor, sand pots and etc.) shall be in good operating condition and of sufficient capacity to provide satisfactory results for cleaning and painting preparation.

3.1 REMOVAL OF COATINGS CONTAINING HAZARDOUS MATERIALS

The interior and exterior coatings for both tanks have been tested for lead content. The test results indicate the lead content of the coatings is below the threshold criteria of “greater than” 1.0 mg/cm sq. for lead-based paint.

3.2 LIGHTING

Provide lighting for all work areas as prescribed in SSPC Guide 12.

3.3 ENVIRONMENTAL CONDITIONS

3.3.1 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 2A. 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.

It is the Contractors responsibility to insure the feasibility and workability of the containment system. The Contractor shall perform his operations and work schedule in a manner as to prevent leakage of the containment system. The containment system shall be properly maintained. If the containment system fails to function satisfactorily, the Contractor shall suspend all operations, except those required to minimize adverse impact on the environment or government property. Operations shall not resume until modifications have been made to correct the cause of the failure.

3.3.2 Environmental Monitoring Requirements

Provide continuous monitoring of temperature, relative humidity, and dew point data to ensure conditions meet coating manufactures requirements.

3.4 SURFACE PREPARATION

3.4.1 Abrasive Blasting Equipment

Use abrasive blasting equipment of conventional air, force-feed, or pressure type.

Maintain a minimum pressure of 95 psig at nozzle. Confirm that air supply for abrasive blasting is free of oil and moisture when tested in accordance with ASTM D4285. Test air quality at each startup, but in no case less often than every five operating hours.

Abrasives used for blast cleaning shall be those mentioned in this specification under paragraph 2.3 ABRASIVE. Particular attention shall be given to the maximum particle size requirements. Abrasives must be selected to provide the recommended surface profile and degree of cleanliness required.

3.4.2 Surface Standard

Inspect surfaces to be coated and select plate with similar properties and surface characteristics for use as a surface standard. Blast clean one or more 1 foot square steel panels as specified in paragraph SURFACE PREPARATION. Record blast nozzle type and size, air pressure at nozzle and compressor, distance of nozzle from panel, and angle of blast to establish procedures for blast cleaning. Measure surface profile in accordance with ASTM D7127. When the surface standard complies with all specified requirements, seal with a clearcoat protectant. Use the surface standard for comparison to abrasive blasted surfaces throughout the course of work.

3.4.3 Abrasive Blasting

3.4.3.1 Tank Interior Blasting

Steel shall be thoroughly cleaned of rust, mill scale, dirt and all other foreign substances.

Abrasive blast steel surfaces to near-white metal in accordance with SSPC SP 10/NACE No. 2. Prepared surfaces shall match the prepared test-panels. If surfaces fail to meet requirements, discontinue abrasive blasting, and modify processes and materials to provide the specified profile. When surfaces are reblasted for any reason, retest profile as specified. Following abrasive blasting, remove dust and debris by vacuum cleaning. Do not attempt to wipe surface clean.

3.4.3.2 Tank Exterior Blasting

Steel shall be thoroughly cleaned of rust, mill scale, dirt and all other foreign substances.

Abrasive blast steel surfaces to "Commercial Blast Cleaning" accordance with SSPC SP6/NACE No. 3. Prepared surfaces shall match the prepared test-panels. If surfaces fail to meet requirements, discontinue abrasive blasting, and modify processes and materials to provide the specified profile. When surfaces are reblasted for any reason, retest profile as specified. Following abrasive blasting, remove dust and debris by vacuum cleaning.

Do not attempt to wipe surface clean.

3.4.4 Disposal of Used Abrasive

Dispose of used abrasive off Government property in accordance with Federal, State, and Local mandated regulations.

3.4.5 Pre-Application Testing For Surface Contamination/Cleanliness

Apply coatings to surfaces that are oil, grease, dust, and salt free. Test surfaces as necessary to ensure contamination free:

Oil and grease with mist water for beading Salt test surfaces for chloride contamination Dust apply strip of clear adhesive tape to surface

3.5 MIXING AND APPLICATION OF SEALANT AND COATING SYSTEM

3.5.1 Preparation of Coating Materials for Application

Each of the primer, intermediate, and topcoat materials is a two-component material supplied in separate containers.

3.5.1.1 Mixing Sealant, Primer and Intermediate Coat Materials

Mix in accordance with manufacturer's instructions, which may differ for each product.

Do not mix partial kits, or alter mix ratios. Mix materials in same temperature and humidity conditions specified in paragraph DELIVERY AND STORAGE. Allow mixed material to stand for the required induction time based on its temperature.

3.5.1.2 Mixing Topcoat Material

Do not mix partial kits, or alter mix ratios. Mix polyurethane coating materials in same temperature conditions specified in paragraph DELIVERY AND STORAGE. The polyurethane coating material is moisture sensitive and any introduction of moisture or water into the material during mixing or application will shorten usable pot life. Use a mixer that does not create a vortex. Do not add solvent without specific written recommendation from the manufacturer. No induction time is required, only thorough agitation of the mixed material.

3.5.1.3 Pot Life

As specified by manufacturer, but no more than:

Epoxy primer and intermediate materials 4 hours Polyurethane topcoat materials 2 hours.

3.5.1.4 Application Conditions and Recoat Windows

The application condition requirements for the coating system are very time and temperature sensitive, and are intended to avoid the delamination problems frequently found on industrial structures. Plan coating application to ensure that specified temperature, humidity, and condensation conditions are met. If conditions do not allow for orderly application of primer, stripe coat, intermediate coat and topcoat, application process must stop.

Air and steel surface temperature must be between 60 and 100 degrees F during application and the first four hours of cure for epoxy coats and the first eight hours of cure for polyurethane coats. Steel surface temperature must be more than 5 degrees F above the dew-point of the ambient air for the same period.

Use data specified by manufacture to determine appropriate recoat windows for each coat after the initial coat. Apply each coat during appropriate RECOAT WINDOW of preceding coat. If a RECOAT WINDOW is missed, the minimum and maximum primer and intermediate coat thickness may be adjusted to accommodate a FILL COAT, however, requirements for total epoxy coating thickness and total coating thickness will not be modified. Missing more than one RECOAT WINDOW may require complete removal of coating if maximum total coating thickness requirements cannot be achieved.

If coating is not applied during RECOAT WINDOW, gloss removal may be required as determined by COR. If next planned coat is topcoat, apply FILL COAT if required to fill sanding marks. Sanding marks from GLOSS REMOVAL of intermediate coat reflecting through topcoat will be considered as noncompliant.

FILL COAT - Where indicated, apply coat of intermediate coat epoxy, at 2 to 3 mils DFT, then apply next specified full coat within recoat window of FILL COAT. A FILL COAT may be used to adjust coating thickness to comply with requirements or to fill sanding marks in intermediate coat.

GLOSS REMOVAL - Where required, hand sand in a linear fashion to remove gloss using 120-200 grit wet/dry sandpaper, followed by solvent wiping with a clean rag soaked with denatured alcohol to remove all dust. GLOSS REMOVAL of primer coat is to scarify surface and shall consist of removal of approximately 1 mil of coating. If steel is exposed during GLOSS REMOVAL, repair in accordance with paragraph

PROCEDURE FOR HOLIDAY AND SPOT REPAIRS OF NEWLY APPLIED

COATING. GLOSS REMOVAL of intermediate coat may include removal of up to 3 mils of coating to avoid excess thickness, prior to application of FILL COAT.

3.5.2 Application of Coating System and Joint Sealant

Apply coatings in accordance with SSPC PA 1 and as specified herein. Apply coatings to surfaces that meet all stated surface preparation requirements.

3.5.2.1 Paint Application Methods

Paint may be applied by the following methods unless otherwise stated:

(1) Brushing

(2) Roller application

The method best suited for application depends on the type of paint, degree of complexity of the surface being painted, paint viscosity, and other considerations. The paint manufacturer and a professional painting contractor must use best application method to meet the intent of the specifications for the tanks being painted.

After application of primer coat and prior to application of each subsequent coat, perform testing prescribed in paragraph PRE-APPLICATION TESTING FOR SURFACE CONTAMINATION, as necessary, to ensure minimal inter-coat contamination.

Generally, oil and grease contamination and soluble salts contamination are not encountered if subsequent coats are applied within specified recoat windows and unusual atmospheric events do not occur.

Apply each coat in a consistent wet film, at 90 degrees to previous coat.

Ensure that primer and intermediate coat "cold joints" are no less than six inches from welds. Apply stripe coat by brush. Apply all other coats by roller application unless approved by COR. Use appropriate controls to prevent airborne coating fog from drifting beyond 15 feet from the structure perimeter. Cover or protect all surfaces that will not be coated. The cleanliness, temperature, recoat windows, and airborne paint containment requirements may necessitate the use of enclosures, portable shelters, or other appropriate controls.

3.5.2.2 Application of Primer

When applying primer coat, maintain constant agitation of paint to ensure that zinc does not settle in container.

3.5.2.3 Application of Stripe Coat

Apply a stripe coat of intermediate coat epoxy material within RECOAT WINDOW of primer, allowing sufficient dry time to allow application of intermediate coat within RECOAT WINDOW of primer. Apply by brush, working material into corners, crevices, angles, and welds, and onto outside corners and angles.

3.5.2.4 Application of Intermediate Coat

Apply intermediate coat within RECOAT WINDOW of primer coat.

3.5.2.5 Non-skid for Ladder and Top

Install non-skid adhesive to ladder and grit on top to manway opening. Where non-skid grit is required, apply a second intermediate coat, and immediately follow with application of non-skid grit, broadcast at the rate of 2 pounds per 100 square feet, and backroll. Apply topcoat as specified.

3.5.2.6 Application of Topcoat

Make all required repairs to primer and intermediate coats as specified in paragraph entitled "Procedure for Holiday and Spot Repairs of Newly Applied Coating" prior to applying topcoat. Apply topcoat within RECOAT WINDOW of intermediate coat. The polyurethane topcoat may require multiple passes to achieve desired aesthetics and required thickness. Consult manufacturer for thinning and application procedures for anticipated temperature, humidity, and wind conditions. Touch-up blemishes and defects within recoat window of polyurethane topcoat. Retain sample of polyurethane topcoat, from the same batch used to coat structure, to make touch-ups that might be required later.

3.5.2.7 Application of Joint Sealant

Apply joint sealant to back-to-back steel joints that are less than 3/8 inches wide and are not seal welded. Apply sealant to top and bottom, or each side, of narrow joints. Apply sealant within 48 hours of application of the topcoat, and touch-up with topcoat after appropriate cure of the sealant.

3.5.2.8 Procedure for Holiday and Spot Repairs of Newly 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 surface preparation requirements of this specification and feather coating as required to leave 4 inches of each succeeding coat feathered and abraded. 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 RECOAT WINDOW of preceding coat. Within four hours of preparation, apply zinc-rich primer to prepared steel and feather onto prepared primer.

Apply intermediate coat to primed area and feather to prepared intermediate area. Apply topcoat to intermediate coat and feather to prepared topcoat. Apply each repair coat to approximate thickness of surrounding coating system.

3.5.2.9 Structure Occupancy after Coating Application

Use clean canvas or other approved shoe covers when walking on coated surfaces, regardless of curing time allowed. For heavily trafficked areas, provide cushioned mats for additional protection.

3.6 PROJECT IDENTIFICATION

At the completion of the work, stencil the following information on the tank exterior adjacent to the main manway opening in 3/4 to one inch Helvetica style letters of contrasting color using acrylic stencil paint:

Date exterior coated:

Project Number:

Contractor:

Address:

Coating System Surface Prep: SSPC SP ____ Profile: ______ Primer: __________________ Thickness: ____ Intermediate: ____________ Thickness: ____ Topcoat: _________________ Thickness: ____

Total Thickness: _________

3.7 DISINFECTION OF THE WATER STORAGE TANK

The tank interior paint system shall be allowed to cure a minimum of seven (7) days or longer as recommended by the paint manufacturer according to surface temperature, before the cleaning and disinfection process is initiated. The contractor will be responsible for the disinfection of the water storage tank after the complete coating system has fully cured.

3.8 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