Attachment_23_-_Section_09_97_13.16_Interior_Coating_of_Welded_Steel_Water_Tanks.pdf

FA4419-14-R-0102

Attachment 23

SECTION 09 97 13.16

INTERIOR COATING OF WELDED STEEL WATER TANKS

PART 1 GENERAL

1.1 REFERENCES

1.2 DEFINITIONS

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Contract Errors, Omissions, and Other Discrepancies

1.4.2 Corrective Action (CA)

1.4.2.1 Corrective Action Procedures

1.4.2.2 Implement Corrective Action

1.4.3 Coating Work Plan

1.4.4 Design Data

1.4.4.1 Environmental Control System

1.4.5 Test Reports

1.4.5.1 Metallic Abrasive Qualification Test Reports

1.4.5.2 Recycled Metallic Abrasive Field Test Reports (Daily and Weekly)

1.4.6 Qualifications

1.4.6.1 Qualifications of Certified Industrial Hygienist (CIH)

1.4.6.2 Qualifications of Certified Protective Coatings Specialist (PCS)

1.4.6.3 Qualifications of Coating Inspection Company

1.4.6.4 Qualifications of QC Specialist Coating Inspector

1.4.6.5 Qualifications Of Individuals Performing Abrasive Blasting

1.4.6.6 Qualifications of Testing Laboratory for Coatings

1.4.6.7 Qualifications of Testing Laboratory for Abrasive

1.4.6.8 Qualifications of Coating Contractors

1.4.6.9 Roof Joint Sealant Materials

1.4.6.10 Roof Joint Sealant Compatibility

1.4.6.11 Epoxy Coating Materials

1.4.6.12 Non-metallic Abrasive

1.4.6.13 Metallic Abrasive

1.4.7 Protective Coating Specialist (PCS)

1.4.8 Pre-Application Meeting

1.5 PRODUCT DATA

1.5.1 Roof Joint Sealant Instructions

1.5.2 Coating System Instructions

1.6 DELIVERY AND STORAGE

1.7 COATING HAZARDS

1.8 WORK SEQUENCE

1.9 JOB SITE REFERENCES

PART 2 PRODUCTS

2.1 ROOF JOINT SEALANT

2.2 COATING SYSTEM

2.2.1 NSF Certified Polyamide Epoxy Coating System

2.2.2 MIL-DTL-24441 Epoxy System for Potable Water Tanks

2.2.2.1 Epoxy Primer Coat

2.2.2.2 Epoxy Intermediate Coat

2.2.2.3 Epoxy Topcoat

2.2.3 MIL-DTL-24441 Epoxy System for Non-potable Water Tanks

2.2.3.1 Epoxy Primer Coat

2.2.3.2 Epoxy Intermediate Coat

2.2.3.3 Epoxy Topcoat

2.3 COATING SAMPLE COLLECTION AND SHIPPING KIT

2.4 ABRASIVE SAMPLE COLLECTION AND SHIPPING KIT

2.5 TEST KITS

2.5.1 Test Kit for Measuring Chloride, Sulfate and Nitrate Ions on Steel and

Coated Surfaces

2.5.2 Test Kit for Identifying Amine Blush on Epoxy Surfaces

2.6 ABRASIVE

2.6.1 Non-metallic Abrasive

2.6.2 Metallic Abrasive

2.6.2.1 New and Remanufactured Steel Grit

2.6.2.2 Recycled Steel Grit

PART 3 EXECUTION

3.1 REMOVAL OF COATINGS CONTAINING HAZARDOUS MATERIALS

3.2 COATING AND ABRASIVE SAMPLE COLLECTION AND TESTING

3.2.1 Coating Sample Collection

3.2.2 Abrasive Sample Collection

3.2.3 Coating Sample Test Reports

3.2.4 Abrasive Sample Test Reports

3.3 SLUDGE REMOVAL AND TANK CLEANING

3.4 LIGHTING

3.5 ENVIRONMENTAL CONDITIONS

3.5.1 Control System Requirements

3.5.2 Automated Monitoring Requirements

3.5.3 Humidity Control for Surface Preparation and Primer Application

3.5.4 Humidity Control for Application of Intermediate and Topcoats and Initial

Curing

3.6 EQUIPMENT USED IN TANK

3.7 SURFACES TO BE COATED

3.8 SURFACE PREPARATION

3.8.1 Abrasive Blasting Equipment

3.8.2 Operational Evaluation of Abrasive

3.8.3 Surface Standard

3.8.4 Pre-Preparation Testing for Surface Contamination

3.8.4.1 Pre-Preparation Testing for Oil and Grease Contamination

3.8.4.2 Pre-Preparation Testing for Soluble Salts Contamination

3.8.5 Abrasive Blasting

3.8.6 Disposal of Used Abrasive

3.8.7 Pre-Application Testing For Surface Contamination

3.8.7.1 Pre-Application Testing for Oil and Grease Contamination

3.8.7.2 Pre-Application Testing for Soluble Salts Contamination

3.8.7.3 Pre-Application Testing for Surface Cleanliness

3.9 MIXING AND APPLICATION OF SEALANT AND COATING SYSTEM

3.9.1 Preparation of Sealant and Coating Materials for Application

3.9.1.1 Mixing

3.9.1.2 Pot Life

3.9.1.3 Application Conditions and Recoat Windows

3.9.2 Amine Blush Testing of Epoxy Coat Prior to Overcoating

3.9.3 Application of Coating System and Roof Joint Sealant

3.9.3.1 Application of Roof Joint Sealant

3.9.3.2 Application of Stripe Coat

3.9.3.3 Application of Primer

3.9.3.4 Application of Intermediate Coat

3.9.3.5 Application of Topcoat

3.9.4 Holiday Testing

3.9.5 Procedure for Holiday and Spot Repairs of Newly Applied Coating

3.9.6 Tank Occupancy After Coating Application

3.9.7 Extended Cure of Coating System Prior to Immersion Service

3.10 PROJECT IDENTIFICATION

3.11 FIELD QUALITY CONTROL

3.11.1 Coating Inspector

3.11.2 Field Inspection

3.11.2.1 Inspection Requirements

3.11.2.2 Inspection Report Forms

3.11.2.3 Daily Inspection Reports

3.11.2.4 Inspection Logbook

3.11.3 Inspection Equipment

3.11.3.1 Black Light

3.12 FINAL CLEANUP

-- End of Section Table of Contents --

SECTION 09 97 13.16

INTERIOR COATING OF WELDED STEEL WATER TANKS

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 D3276 (2007) Painting Inspectors (Metal Substrates)

ASTM D3925 (2002; R 2010) Sampling Liquid Paints and Related Pigmented

Coatings

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

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 9001 (2008; Corr 1 2009) Quality Management Systems- Requirements

NACE INTERNATIONAL (NACE)

NACE SP0188 (1999; R 2006) Discontinuity (Holiday) Testing of New Protective

Coatings on Conductive Substrates

NSF INTERNATIONAL (NSF)

NSF/ANSI 61 (2012; Errata 1013; Addenda 2013) Drinking Water System Components -

Health Effects

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC 7/NACE No.4 (2007; E 2004) Brush-Off Blast Cleaning

SSPC AB 2 (1996; E 2004) Cleanliness of Recycled Ferrous Metallic Abrasive

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

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

Projects

SSPC PA 1 (2000; E 2004) Shop, Field, and Maintenance Painting of Steel

SSPC PA 2 (2012) Measurement of Dry Coating Thickness With

Magnetic Gages

SSPC QP 1 (1998; E 2004) Standard Procedure for Evaluating Painting

Contractors (Field Application to Complex

Industrial Structures)

SSPC QP 5 (1999; E 2004) Standard Procedure for Evaluating the

Qualifications of Coating and Lining Inspection

Companies

SSPC QS 1 (2004) Standard Procedure for Evaluating a Contractor's

Advanced Quality Management System

SSPC SP 1 (1982; E 2004) Solvent Cleaning

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

SSPC SP COM (2004) Surface Preparation Commentary for Steel and

Concrete Substrates

SSPC VIS 1 (2002; E 2004) Guide and Reference Photographs for Steel

Surfaces Prepared By Dry Abrasive Blast Cleaning

U.S. DEPARTMENT OF DEFENSE (DOD)

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

Cleaning

MIL-DTL-24441 (2009; Rev D) Paint, Epoxy-Polyamide, General

Specification for

MIL-DTL-24441/20 (2009; Rev B) Paint, Epoxy-Polyamide, Green Primer, Formula 150, Type III

MIL-DTL-24441/22 (2009; Rev B) Paint, Epoxy-Polyamide, White Formula

152, Type III

MIL-DTL-24441/29 (2009; Rev B) Paint, Epoxy-Polyamide, Green Primer, Formula 150, Type IV

MIL-DTL-24441/31 (2009; Rev B) Paint, Epoxy-Polyamide, White, Formula

152, Type IV

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FED-STD-595 (Rev C; Notice 1) Colors Used in Government Procurement

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910-SUBPART Z Toxic and Hazardous Substances

29 CFR 1910.1000 Air Contaminants

29 CFR 1910.134 Respiratory Protection

29 CFR 1926.59 Hazard Communication

1.2 DEFINITIONS

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

a. CEILING - interior tank surfaces that extend from the horizontal plane at the designated maximum water line upward, including the upper portion of the tank shell

(walls), columns, structural steel, the underside of the roof plates and other steel components in this area.

b. BOWL - interior tank surfaces that extend from the horizontal plane at the designated maximum water line downward, including the tank walls, columns, piping, pipe supports, bottom plates, and other stee components in this area.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a

"G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] The following shall be submitted in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:

SD-05, Design Data

Environmental Control System

SD-06 Test Reports

Metallic Abrasive Qualification Test Reports

Coating Sample Test Reports

Abrasive Sample Test Reports

Inspection Report Forms

Daily Inspection Reports

Recycled Metallic Abrasive Field Test Reports (Daily and Weekly)

SD-07 Certificates

Contract Errors, Omissions, and Other Discrepancies

Corrective Action Procedures

Coating Work Plan

Qualifications of Certified Industrial Hygienist (CIH)

Qualifications Of Individuals Performing Abrasive Blasting

Qualifications of Certified Protective Coatings Specialist (PCS)

Qualifications of Coating Inspection Company

Qualifications of QC Specialist Coating Inspector

Qualifications of Testing Laboratory for Coatings

Qualifications of Testing Laboratory for Abrasive

Qualifications of Coating Contractors

Roof Joint Sealant Materials

Roof Joint Sealant Compatibility

Epoxy Coating Materials

Non-metallic Abrasive

Metallic Abrasive

SD-08 Manufacturer's Instructions

Roof Joint Sealant Instructions

Coating System Instructions

SD-11 Closeout Submittals

Disposal of Used Abrasive[; G][; G, [_____]]

Inspection Logbook[; G][; G, [_____]]

1.4 QUALITY ASSURANCE

1.4.1 Contract Errors, Omissions, and Other Discrepancies

Submit all errors, omissions, and other discrepancies in contract documents the

Contracting Officer within 30 days of contract award for all work covered in this Section, other than the work that will not be uncovered until a later date. All such discrepancies shall be addressed and resolved, and the Coating Work Plan modified, prior to beginning the Initial and Follow-Up phases of work. Discrepancies that become apparent only after work is uncovered shall be identified at the earliest discoverable time and submitted for resolution. Schedule time (Float) should be built into the project schedule at those points where old work is to be uncovered or where access is not available during the first 30 days after award, to allow for resolution of contract discrepancies.

1.4.2 Corrective Action (CA)

CA shall be included in the Quality Control Plan.

1.4.2.1 Corrective Action Procedures

Develop procedures for determining the root cause of each non-compliance, developing a plan to eliminate the root cause so that the non-compliance does not recur, and following up to ensure that the root cause was eliminated. Develop

Corrective Action Request (CAR) forms for initiating CA, and for tracking and documenting each step.

1.4.2.2 Implement Corrective Action

The Contractor shall take action to identify and eliminate the root cause of each non-compliance so as to prevent recurrence. These procedures shall apply to non-compliance in the work, and to non-compliance in the QC System. Corrective actions shall be appropriate to the effects of the non-compliance encountered.

Each CAR shall be serialized, tracked in a Log to completion and acceptance by the Contracting Officer, and retained in project records. The Corrective Action

Log, showing status of each CAR, shall be submitted to the Contracting Officer monthly. A CAR may be initiated by either the Contractor or the Contracting

Officer. The Contracting Officer 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.

1.4.3 Coating Work Plan

This work plan shall be considered as part of the Quality Control Plan. 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. 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. 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 non-compliant work, and demobilization. Coordinate work processes with health and safety plans and confined space entry 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. Provide procedures for determining the existing surface profile under paint, and procedures for ensuring that the profile is not increased beyond the maximum profile specified herein. Provide procedures for correcting non-compliant 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 correct coating thickness non-compliance, any other areas of repair or rework that might be adversely affected by delays in preparing and approving new procedures. 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.

1.4.4 Design Data

1.4.4.1 Environmental Control System

Submit design details of the proposed environmental control system to include ventilation, humidity control, and temperature regulation. Provide calculations for humidity control during separate surface preparation and coating application procedures, ventilation requirements during coating application, and maximum allowable coating application rates to coincide with ventilation. Include basis of design data on local conditions. Provide equipment layout sketches and procedures showing function of each piece of equipment and fail-safe measures.

A Certified Industrial Hygienist shall approve calculations, work procedures and personal protective equipment.

1.4.5 Test Reports

1.4.5.1 Metallic Abrasive Qualification Test Reports

Submit results for abrasive as required in paragraph 4 REQUIREMENTS of

SSPC AB 3. Submit test results from independent laboratory of representative samples of each abrasive to be used on the jobsite. Samples must have been tested within the last three years. Note that this testing is for the purpose of prequalifying the abrasive.

1.4.5.2 Recycled Metallic Abrasive Field Test Reports (Daily and Weekly)

Submit test results from independent laboratory of daily and weekly Quality

Control testing required by SSPC AB 2, as modified in paragraph ABRASIVE.

1.4.6 Qualifications

1.4.6.1 Qualifications of Certified Industrial Hygienist (CIH)

Submit name, address, telephone number, FAX number, and e-mail address of the independent third party CIH. Submit documentation that hygienist is certified by the American Board of Industrial Hygiene in comprehensive practice, including certification number and date of certification/recertification. Provide evidence of experience with hazards involved in industrial coating application work.

1.4.6.2 Qualifications of Certified Protective Coatings Specialist (PCS) independent third party PCS. Submit documentation that specialist is certified by

SSPC: The Society for Protective Coatings (SSPC) as a PCS, including certification number and date of certification/recertification. If the PCS is employed by the same coating inspection company to which the coating inspector is employed, this does not violate the independent third-party requirements. The PCS shall remain certified during the entire project, and the

Contracting Officer shall be notified of any change in certification status within

10 days of the change. The PCS shall not be the designated coating inspector.

1.4.6.3 Qualifications of Coating Inspection Company

Submit documentation that the coating inspection company that will be performing all coating inspection functions is certified by SSPC to the requirements of SSPC QP 5 prior to contract award, and shall remain certified while accomplishing any coating inspection functions. The coating inspection company must remain so certified for the duration of the project. If a coating inspection company's certification expires, the firm will not be allowed to perform any inspection functions, and all surface preparation and coating application work must stop, 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 Contracting Officer of any change in coating inspection company certification status.

1.4.6.4 Qualifications of QC Specialist Coating Inspector

Submit documentation that each coating inspector is employed, and qualified to

SSPC QP 5, Level III, by the selected coating inspection company. Each inspector shall remain employed by the coating inspection company while performing any coating inspection functions.

1.4.6.5 Qualifications Of Individuals Performing Abrasive Blasting

Submit name, address, and telephone number of each person that will be performing abrasive blasting. Submit documentation that each blaster is qualified by SSPC to the SSPC C-7 Dry Abrasive Blaster Qualification Program. Each blaster shall remain qualified during the entire period of abrasive blasting, and the

Contracting Officer shall be notified of any change in qualification status.

1.4.6.6 Qualifications of Testing Laboratory for Coatings

independent third party laboratory selected to perform testing of coating samples for compliance with specification requirements. Submit documentation that laboratory is regularly engaged in testing of paint samples for conformance with specifications, and that employees performing testing are qualified.

1.4.6.7 Qualifications of Testing Laboratory for Abrasive

independent third party laboratory selected to perform testing of abrasive for compliance with specification requirements. Submit documentation that laboratory has experience in testing samples of abrasive for conformance with specifications, and that employees performing testing are qualified.

1.4.6.8 Qualifications of Coating Contractors

All Contractors and Subcontractors that perform surface preparation or coating application shall be certified to either ISO 9001 or SSPC QP 1 and SSPC QS 1 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

Contractor's or Subcontractor's 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 Contracting

Officer of any change in Contractor certification status.

1.4.6.9 Roof Joint Sealant Materials

Provide manufacturer's certification of conformance to contract requirements, and is certified in accordance with NSF/ANSI 61.

1.4.6.10 Roof Joint Sealant Compatibility

Provide manufacturer's certification that the selected joint sealant is compatible with the epoxy primer and is suitable for application directly to prepared steel surfaces.

1.4.6.11 Epoxy Coating Materials

Provide manufacturer's certification that the epoxy lining materials are certified in accordance with NSF/ANSI 61 for tanks of the size being coated.

1.4.6.12 Non-metallic Abrasive

Provide manufacturer's certification that the materials are currently approved by the Naval Sea Systems Command and listed on the Qualified Products Lists

(QPL) for the specified materials.

1.4.6.13 Metallic Abrasive

Provide manufacturer's certification of conformance to contract requirements and provide copies of test results.

1.4.7 Protective Coating Specialist (PCS)

The PCS shall be considered a QC Specialist and shall report to the QC Manager, as specified in Section 01 45 00.00 40 QUALITY CONTROL. The PCS shall approve all submittals prior to submission to the QC Manager for approval or submission to the government for approval.

1.4.8 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, paint foreman, coating inspector, and PCS shall have a pre-application coating preparatory meeting. This meeting shall be in addition to the pre-construction conference. Specific items addressed shall include: corrective action requirements and procedures, coating work plan, safety plan, coordination with other Sections, inspection standards, inspection requirements and tools, test procedures, environmental control system, safety plan, and test logs. Notify Contracting Officer at least ten days prior to meeting.

1.5 PRODUCT DATA

1.5.1 Roof Joint Sealant Instructions

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

Include Materials Safety Data Sheets (MSDS) for materials to be used at the job site in accordance with 29 CFR 1926.59.

1.5.2 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 Materials

Safety Data Sheets (MSDS) for materials to be used at the job site in accordance with 29

CFR 1926.59.

1.6 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 75 degrees F, and air temperature more than 5 degrees F above the dew-point at all times. Inspect materials for damage and return non-compliant materials to manufacturer. Remove materials with expired shelf life from government property immediately and notify the

Contracting Officer. Expired materials may be returned to manufacturer, tested, and if compliant, issued a shelf life extension. If materials are approaching shelf life expiration and an extension is desired, samples may be sent to the manufacturer, along with complete records of storage conditions, with a request for shelf life extension. If the manufacturer finds the samples and storage data suitable for shelf life extension, the manufacturer may issue an extension, referencing the product evaluation and the review of storage records. Products may not be extended longer than allowed in the product specification.

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 tank 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 CIH shall approve work procedures and personal protective equipment.

1.8 WORK SEQUENCE

Coat tank interior following leak testing.

1.9 JOB SITE REFERENCES

Make available to the Contracting Officer at least one copy each of ASTM D3276, ASTM

D3925, ASTM D4285, ASTM D7127, NACE SP0188, SSPC SP COM, SSPC SP 1, SSPC

7/NACE No.4, SSPC SP 10/NACE No. 2, SSPC PA 1, SSPC PA 2, SSPC Guide 12, SSPC VIS

1, , SSPC QP 1, SSPC QS 1, and an SSPC Certified Contractor Evaluation Form at the job site.

PART 2 PRODUCTS

2.1 ROOF JOINT SEALANT

Material shall be Industrial grade, two component, minimum 95 percent solids by volume, polysulfide type caulking material that has a minimum history of 10 years acceptable service in water tanks. Sealant shall be compatible with the epoxy primer and suitable for direct application to prepared steel surfaces. Sealant shall contain no more than 0.06 percent by dry weight Lead, no more than 0.06 percent by dry weight Cadmium, and no more than 0.00 percent by dry weight

Chromium.[ Sealant shall be certified in accordance with NSF/ANSI 61.]

2.2 COATING SYSTEM

Alternate systems or products will not be considered. All primer, intermediate, and topcoat materials shall be manufactured by one manufacturer. [The entire coating system is intended to be applied in the field. Alternatively, surface preparation may be accomplished in the shop, following all temperature, humidity, and testing requirements listed herein, followed by an application of a hold-primer. Upon completion of field fabrication, all shop-applied coatings shall be removed, surfaces prepared to SSPC SP 10/NACE No. 2, and the specified coating system applied. Adjust all shop preparation to avoid conflicts with final surface preparation requirements.]

2.2.1 NSF Certified Polyamide Epoxy Coating System

Select a commercially available, three coat polyamide epoxy coating system that is certified in accordance with NSF/ANSI 61 for contact with potable water in water storage tanks of the size being coated. The coating system shall be suitable for application in three even coats of 3-5 mils dry film thickness (DFT), for a total minimum of 9 milsDFT.

2.2.2 MIL-DTL-24441 Epoxy System for Potable Water Tanks

The epoxy coating materials shall be approved by the Naval Sea Systems Command and listed on their current Qualified Products List (QPL) for the specified materials.

2.2.2.1 Epoxy Primer Coat

Epoxy polyamide, MIL-DTL-24441/20 (Formula 150, Type III, Green).

2.2.2.2 Epoxy Intermediate Coat

Epoxy polyamide, MIL-DTL-24441/22 (Formula 152, Type III, White (Tinted)). Tint to approximately FED-STD-595 color number 27778 parchment using pigment dispersions prepared for epoxy paint tinting. Manufacturer shall tint material and appropriately label. All other requirements of this Military Specification apply.

2.2.2.3 Epoxy Topcoat

Epoxy polyamide, MIL-DTL-24441/22 (Formula 152, Type III, White).

2.2.3 MIL-DTL-24441 Epoxy System for Non-potable Water Tanks

The epoxy coating materials shall be approved by the Naval Sea Systems Command and listed on their current Qualified Products List (QPL) for the specified materials.

2.2.3.1 Epoxy Primer Coat

Epoxy polyamide, MIL-DTL-24441/29 (Formula 150, Type IV, Green).

2.2.3.2 Epoxy Intermediate Coat

Epoxy polyamide, MIL-DTL-24441/31 (Formula 152, Type IV, White (Tinted)). Tint to approximately FED-STD-595 color number 27778 parchment using pigment dispersions prepared for epoxy paint tinting. Manufacturer shall tint material and appropriately label. All other requirements of this Military Specification apply.

2.2.3.3 Epoxy Topcoat

Epoxy polyamide, MIL-DTL-24441/31 (Formula 152, Type IV, White). All other requirements of this Military Specification apply.

2.3 COATING SAMPLE COLLECTION AND SHIPPING KIT

Provide a kit that contains quart can for the base of each coating material, an appropriately sized can for each activator, dipping cups for each component to be sampled, a shipping box sized for the samples to to be shipped, and packing material. Mark cans for the appropriate component.

Provide shipping documents, including either pre-paid shipping or a shipper number that can be used by the QC Manager to arrange pickup, addressed to the approved coating testing laboratory.

2.4 ABRASIVE SAMPLE COLLECTION AND SHIPPING KIT

Provide a kit that contains one suitable plastic bag or container for each sample to be collected.

Mark containers for the appropriate component. Provide shipping documents, including either pre-paid shipping or a shipper number that can be used by the QC Manager to arrange pickup, addressed to the approved coating testing laboratory.

2.5 TEST KITS

2.5.1 Test Kit for Measuring Chloride, Sulfate and Nitrate Ions on Steel and Coated

Surfaces

Provide test kits called CHLOR*TEST CSN Salts, as manufactured by CHLOR*RID

International Inc. of Chandler, Arizona (www.chlor-rid.com) or equal. An "equal" test kit shall meet the following requirements:

a. Kit contains all materials,supplies, tools and instructions for field testing and on-site quantitative evaluation of chloride, sulfate and nitrate ions;

b. Kit extract solution is acidic, factory pre-measured, pre-packaged, and of uniform concentration;

c. Kit components and solutions are mercury free and environmentally friendly;

d. Kit contains new materials and solutions for each test extraction;

e. Extraction test container (vessel, sleeve, cell. etc.) creates a sealed, encapsulated environment during salt ion extraction;

f. Test extract container is suitable for testing the following steel surfaces: horizontal (up/down configuration), vertical, flat, curved, smooth, pitted, and rough;

g. All salt ion concentrations are directly measured in micrograms per square centimeter.

2.5.2 Test Kit for Identifying Amine Blush on Epoxy Surfaces

After coating and/or primer has hardened and prior to applying the next coat, test for unreacted amines using the AMINE BLUSH CHECK, manufactured by Elcometer, Rochester Hills, Michigan, or equal. To be considered for approval as an "equal" test kit it shall meet the following requirements:

a. Be a completely self-contained field test kit with all materials, supplies, tools and instructions to perform tests and indicate the presence of unreacted amines;

b. Use an identifiable, consistent, uniform, pre-packaged, factory pre-measured indicating solution;

c. Kit contains no mercury or lead and is environmentally friendly;

d. Kit contains a solution of an unreacted amine for the purpose of "self-checking" the indicator solution;

2.6 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.

2.6.1 Non-metallic Abrasive

Conform to MIL-A-22262, Type I (Inorganic materials)[ except that the gross gamma radioactivity shall not exceed 5 picocuries per gram]. Abrasive shall be approved by the Naval

Sea Systems Command and listed on the appropriate Qualified Products List (QPL) for the specified materials. Use sampling procedures and testing frequencies as prescribed in MIL-A-

22262. 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.

2.6.2 Metallic Abrasive

2.6.2.1 New and Remanufactured Steel Grit

Conform to the chemical and physical properties of SSPC AB 3 Class 1 (Steel) only[, except that the gross gamma radioactivity shall not exceed 5 picocuries per gram]. 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 of SSPC AB 3 Class 1 when brought to the current jobsite. Submit one representative sample of this work mix to the laboratory for testing, along with samples of new material. Acceptance and use of this work mix shall not be used to justify any deviation from surface preparation requirements.

2.6.2.2 Recycled Steel Grit

Conform to the chemical and physical properties of SSPC AB 2

PART 3 EXECUTION

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

Work Plan.

3.1 REMOVAL OF COATINGS CONTAINING HAZARDOUS MATERIALS

Coatings containing hazardous materials and identified for disturbance during surface preparation, including removal, shall be handled in accordance with Section 02 82 33.13 20

REMOVAL/CONTROL AND DISPOSAL OF PAINT WITH LEAD. Coordinate surface preparation requirements from Section 02 82 33.13 20 REMOVAL/CONTROL AND

DISPOSAL OF PAINT WITH LEAD with this Section.

3.2 COATING AND ABRASIVE SAMPLE COLLECTION AND TESTING

Sample and test materials delivered to the jobsite. Notify Contracting Officer three days in advance of sampling. The QC Manager, and either the PCS or coating inspector, shall witness all sampling.

3.2.1 Coating Sample Collection

Provide a sample collection kit as required in paragraph COATING SAMPLE

COLLECTION AND SHIPPING KIT. From each lot, obtain a one quart sample of each batch of each base material, and proportional samples of each activator based on mix ratio, by random selection from sealed containers in accordance with ASTM D3925.

Prior to sampling, mix contents of each sealed container to ensure uniformity. As an alternative to collecting small samples from kits, entire kits may be randomly selected and shipped to laboratory, observing all requirements for witnessing an traceability. For purposes of quality conformance inspection, a lot is defined as that quantity of materials from a single, uniform batch produced and offered for delivery at one time. A batch is defined as that quantity of material processed by the manufacturer at one time and identified by number on the label. Identify samples by designated name, specification number, batch number, project contract number, sample date, intended use, and quantity involved. The QC Manager will take possession of the packaged samples, contact the shipping company to arrange for pickup, and relinquish the samples only to the shipping representative for shipment to the approved laboratory for testing as required by the paragraph entitled "Coating Sample Test Reports."

3.2.2 Abrasive Sample Collection

Provide suitably sized containers for each sample to be taken. Provide a sample collection kit as required in paragraph ABRASIVE SAMPLE COLLECTION AND SHIPPING

KIT. For purposes of quality conformance inspection, a lot shall consist of all abrasive materials of the same type from a single, uniform batch produced and offered for delivery at one time. Obtain samples of each abrasive lot using the sampling techniques and schedule of MIL-A-22262. The addition of any substance to a batch shall constitute a new lot. Identify samples by designated name, specification number, lot number, project contract number, sample date, intended use, and quantity involved. The QC Manager will take possession of the packaged samples, contact the shipping company to arrange for pickup, and relinquish the samples only to the shipping representative for shipment to the approved laboratory for testing as required by the paragraph ABRASIVE SAMPLE

TEST REPORTS.

3.2.3 Coating Sample Test Reports

Submit test results for each lot of coating material delivered to the jobsite. Test samples of primer, intermediate, and topcoat materials for compliance with requirements of Table

I. Reject entire lot represented by samples that fail one or more tests, select new lots, and test samples.

3.2.4 Abrasive Sample Test Reports

Submit test results for each lot of abrasive delivered to the jobsite. Test samples of metallic abrasive to the requirements of paragraph REQUIREMENTS of SSPC AB 3, except paragraph 4.1.5 DURABILITY. Test samples of non-metallic abrasive as required in paragraph QUALITY CONFORMANCE INSPECTION of MIL-A-22262. Reject entire lot represented by samples that fail one or more tests, select new lots, and test samples.

3.3 SLUDGE REMOVAL AND TANK CLEANING

Remove sludge and clean storage tanks in accordance with [_____].

3.4 LIGHTING

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

3.5 ENVIRONMENTAL CONDITIONS

3.5.1 Control System Requirements

Provide and utilize dehumidification and ventilation equipment to control humidity, temperature, and vapor levels in tank from beginning of abrasive blasting through coating application and for four days after the last coating is applied. System shall maintain vapor concentrations at or below 10 percent of Lower Explosive Limit (LEL). System may incorporate any combination of solid desiccant and direct expansion refrigeration equipment. No liquid, granular, calcium chloride, or lithium chloride drying systems will be accepted. Use only electric, indirect fired combustion, indirect friction, or steam coil auxiliary heaters. System shall be compatible with removal of dust and solvent vapors, and shall have fail-safe measures to ensure reliability during operations.

3.5.2 Automated Monitoring Requirements

Provide continuous monitoring of DH equipment, and temperature, relative humidity, and dew point data at pertinent points on the structure, during surface preparation, coating application, and initial cure. Locate sensors to provide pertinent data for the surface preparation and coat application being performed. Make data available to the Contracting

Officer through Internet access. Provide monitoring equipment to perform as follows:

a. Data is collected in the field unit in one minute increments, and available for download (on-site) in a standard format. Contractor shall collect this data and make available to the Contracting Officer;

b. Monitoring equipment shall have backup power such that data collection and transmission to web server will be uninterrupted during the entire period of the dehumidification requirement;

c. Monitoring equipment shall have capability to measure surface temperatures at a minimum of four locations anywhere on a 150 foot diameter by 50 foot high tank;

d. Monitoring equipment shall have capability to measure interior and exterior dry bulb temperature (DB), relative humidity (RH), and dewpoint temperature (DP);

e. Data shall be available continuously through secure internet connection, using widely available web browsers;

f. Internet accessible data shall be collected and stored in maximum 15 minute increments, and lag time between data collection and online availability shall be no greater than 70 minutes;

g. Internet accessible data shall be available for viewing online in tabular format, and graphical format using selected data;

h. Internet accessible data shall be available for download in user-defined segments, or entire project to date, in a standard format usable by Microsoft Excel and other spreadsheet programs.

i. Internet-based controls shall provide alerts to pre-designated parties through email messaging;

j. Internet-based controls shall monitor data uploads from field unit and issue alert if data not initiated within 60 minutes of last upload;

k. Internet-based controls shall monitor operation of DH equipment and issues alert when power remains off for more than 15 seconds, or if pre-determined temperature, RH, or DP conditions are exceeded; The requirements listed here were developed around the Munters Exactaire Monitoring System, as this was the only monitoring system having Internet connectivity known to be commercially available. There is no requirement for connectivity of the monitoring system to control the DH equipment, therefore, any combination of equipment having the required functionality will be accepted.

3.5.3 Humidity Control for Surface Preparation and Primer Application Provide and utilize dehumidification equipment to maintain relative humidity at appropriate level to prevent prepared steel surfaces from corroding at all times during abrasive blasting through primer application. Failure of humidity control system, or failure to maintain proper conditions, during surface preparation stage may allow surface rusting, which will be rejected and require rework. All surfaces to be coated must meet all requirements at time of primer application. Failure of humidity control system during primer application stage will be cause for removal and replacement of all materials applied and cured while conditions were not as prescribed above.

3.5.4 Humidity Control for Application of Intermediate and Topcoats and Initial

Curing

Provide and utilize dehumidification equipment to maintain relative humidity at the coldest steel surface in tank below 55 percent at all times during coating application, and during the first four days of initial curing after application of topcoat. This measurement is not the same as measuring the relative humidity of ambient air in the tank, and will require either electronic equipment to monitor relative humidity at the steel surface, or complex calculations to convert relative humidity of air in tank to relative humidity at steel surface. An approved alternative method of monitoring dehumidification that requires less sophisticated equipment or calculations is to maintain a minimum dew point depression of 18 degrees F below coldest steel surface temperature. This is in lieu of specific relative humidity and dew point requirements in this Section. Failure to maintain specified humidity control during this phase will be cause for extension of humidity controlled cure time to ensure four consecutive days at specified relative humidity at steel surfaces. Formation of condensation in coating application stage prior to the indicated dry-hard time will be cause for removal and replacement of all materials contacted by condensation.

3.6 EQUIPMENT USED IN TANK

Equipment used in the tank after surface preparation begins shall not leave any oily residue from exhaust or other sources. Internal combustion driven equipment, other than that powered by natural or bottled gas, shall not be used.

3.7 SURFACES TO BE COATED

Prepare and coat interior tank surfaces, including[ CEILING][, BOWL][spot repair of [_____] spots of [_____] square meters square feet][_____].

3.8 SURFACE PREPARATION

3.8.1 Abrasive Blasting Equipment

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

Maintain a minimum pressure of 650 kPa 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.

3.8.2 Operational Evaluation of Abrasive

Test abrasive for salt contamination and oil contamination as required by the appropriate abrasive specification daily at startup and every five operating hours thereafter.

3.8.3 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 300 mm 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.

3.8.4 Pre-Preparation Testing for Surface Contamination

Perform testing, abrasive blasting, and testing in the prescribed order.

3.8.4.1 Pre-Preparation Testing for Oil and Grease Contamination

Inspect all surfaces for oil and/or grease contamination using two or more of the following inspection techniques:

1) Visual inspection,

2) WATER BREAK TEST,

3) BLACK LIGHT TEST, and

4) CLOTH RUB TEST.

Reject oil and/or grease contaminated surfaces, clean [using a water based pH neutraldegreaser ]in accordance with SSPC SP 1, and recheck for contamination until surfaces are free of oil and grease.

WATER BREAK TEST - Spray atomized mist of distilled water onto surface, and observe for water beading. If water "wets" surface rather than beading up, surface can be considered free of oil or grease contamination. Beading of water

(water forms droplets) is evidence of oil or grease contamination.

BLACK LIGHT TEST - Inspect surfaces for oil and grease contamination using the light specified in the paragraph BLACK LIGHT. Use light no more than 15 inches from surface unless testing indicates that the specific oil or grease found in tank fluoresce at a greater distance. Use light in tank that is completely sealed from light infiltration, under a hood, or at night. Any fluorescing on steel surfaces is indication of petroleum oil/grease contamination. Use either WATER BREAK

TEST or CLOTH RUB TEST to confirm both contaminated and non-contaminated areas detected by BLACK LIGHT TEST. The BLACK LIGHT

TEST may not be used during inspection of prepared surfaces for oil and grease contamination unless proven to fluoresce the oil and/or grease found in the specific tank and documented during testing prior to abrasive blasting. Generally, only petroleum oil/grease will fluoresce, however, some may not fluoresce sufficiently to be recognized and other methods, such as the WATER BREAK

TEST or CLOTH RUB TEST, must be used to confirm findings of the BLACK

LIGHT TEST.

CLOTH RUB TEST - Rub a clean, white, lint free, cotton cloth onto surface and observe for discoloration. To confirm oil or grease contamination in lightly stained areas, a non-staining solvent may be used to aid in oil or grease extraction.

Any visible discoloration is evidence of oil or grease contamination.

3.8.4.2 Pre-Preparation Testing for Soluble Salts Contamination

Test surfaces for soluble salts, and wash as required, prior to abrasive blasting.

Soluble salt testing is also required in paragraph PRE-APPLICATION TESTING

FOR SOLUBLE SALTS CONTAMINATION as a final acceptance test of prepared surfaces after abrasive blasting, and successful completion of this phase does not negate that requirement. This phase is recommended since pre-preparation testing and washing are generally more advantageous than attempting to remove soluble salt contamination after abrasive blasting. Effective removal of soluble salts will require removal of any barrier to the steel surface, including rust. This procedure may necessitate combinations of wet abrasive blasting, high pressure water rinsing, and cleaning using a solution of water washing and soluble salts remover. The soluble salts remover shall be acidic, biodegradable, nontoxic, noncorrosive, and after application, will not interfere with primer adhesion.

Delays between testing and preparation, or testing and coating application, may allow for the formation of new contamination. Use potable water, or potable water modified with soluble salt remover, for all washing or wet abrasive blasting. Test methods and equipment used in this phase are selected at the Contractor's discretion.

3.8.5 Abrasive Blasting

Abrasive blast steel surfaces to near-white metal in accordance with SSPC SP 10/NACE

No. 2. Prepared surfaces shall conform to SSPC VIS 1 and shall match the prepared test-panels. Provide a 2 to 3 mil surface profile. Reject profile greater than 3 mils, discontinue abrasive blasting, and modify processes and materials to provide the specified profile.

Measure surface profile in accordance with ASTM D7127, using Rmax as the measure of profile height. Record all measurements required in this standard. Measure profile at rate of three tests for the first 1000 square feet plus one test for each additional 1000 square feet or part thereof. 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.

3.8.6 Disposal of Used Abrasive

Dispose of used abrasive off Government property in accordance with Federal, State and

Local mandated regulations.

3.8.7 Pre-Application Testing For Surface Contamination

3.8.7.1 Pre-Application Testing for Oil and Grease Contamination

Ensure tank surfaces are free of contamination as described in paragraph PRE-

PREPARATION TESTING FOR OIL AND GREASE CONTAMINATION.

3.8.7.2 Pre-Application Testing for Soluble Salts Contamination

Test surfaces for chloride contamination using the Test Kit described in paragraph

TEST KIT FOR MEASURING CHLORIDE, SULFATE AND NITRATE IONS

ON STEEL AND COATED SURFACES. Test all surfaces at rate of three tests for the first 1000 square feet plus one test for each additional 2000 square feet or part thereof. [Concentrate testing of bare steel at areas of coating failure to bare steel and areas of corrosion pitting. ][Perform 30 percent of tests on bare steel at welds, divided equally between horizontal and vertical welds. ]One or more readings greater than nondetectable for chlorides, sulfates, or nitrates is evidence of soluble salt contamination. Reject contaminated surfaces, wash as discussed in paragraph PRE-PREPARATION TESTING FOR SOLUBLE SALTS

CONTAMINATION, allow to dry, and re-test until all required tests show allowable results.