OEM_Maintenance_Owners_Manual_Oct_2019.pdf

Inspection and Maintenance Manual

Nellis AFB, Nevada Air Combat Command

Department of the Air Force

FA4861-17-P-C175

F15 Shade Structures Row 13

And Maintenance Pad Hanger #190

5 Bay Aircraft Shade Structures

Designed, Built and Installed

By

PVB Fabrications, Inc.

2311 North 14th Avenue

Tucson, AZ 85705 Phone 520-623-3529

Pvbfabs.com

December 9, 2018 By

PVB Fabrications Inc.

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Table of Contents

Table of Contents

INTRODUCTION

REPLACEMENT PARTS & SERVICE

INSPECTION GRID NUMBERING

DEFINITIONS

INSPECTION AND MANTAINCE SCHEDUAL

INSPECTION PLANNING

SCHEDULING YOUR INSPECTION

INSPECTION PERSONNEL REQUIREMENTS

INSPECTION AND MAINTENANCE TOOLS AND EQUIPMENT

SAFETY PRECAUTIONS

STRUCTURE GROUNDING INSPECTION

BELOW GRADE INSPECTION

INSPECTION RESISTANCE TESTING

ABOVE GRADE INSPECTION

CONCRETE AND GROUT INSPECTIONS

CONCRETE INSPECTION

ANCHOR BOLT AREA

AREAS WITHOUT ANCHOR BOLTS

GROUT INSPECTION

INSPECTION FOR CHANGES IN ISOLATION FOOTINGS

BOLTS INSPECTION

INSPECTION

TIGHTENING METHODS

TORQUEING BOLTS

TORQUE TABLES

SELF DRILLING FASTENERS

STRUCTURAL FRAME INSPECTION

ROOF INSPECTION

ROOF PANEL INSPECTION

WALL PANEL INSPECTION

STRUCTURE VALLEY RAIN GUTTER INSPECTION

INSPECTION AND MAINTENANCE EXAMPLE FORMS

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SHADE STRUCTURE MAINTENANCE

GENERAL

RUST

PAINT SCRATCHES

SURFACE PREPARATION STANDARDS

PANEL SURFACE CLEANING

REMOVING RUST FROM GALVANIZED STEEL AND FASTENERS

GENERAL GALVANIZE REPAIR

SHADE STRUCTURE ROOF AND WALL MAINTENANCE PANEL

Roof and Wall Panel Repairs

DISCLAIMER

Question? Concerns? Problems? Please call PVB Fabrications Inc. at 520-623-3529 for help with information needed.

WARNING

NEVER WELD, CUT OR MODIFY SHADE STRUCTURE COMPONENTS WITHOUT FIRST CONSULTING

PVB FABRICATIONS INC.

NEVER REMOVE MORE THAN ONE BOLT AT A TIME WHEN REPLACING FASTENERS

REFERENCE AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC) MANUAL OF STEEL

CONSTRUCTION, SPECIFICATIONS AND CODES, SPECIFICATION FOR STRUCTURAL JOINTS USING ASTM

A325 OR A409 BOLTS FOR PROPER PROCEDURES TO FOLLOW WHEN USING ANY TORQUE

TIGHTENING METHOD

ONLY QUALIFIED PERSONNEL FAMILIAR WITH STRUCTURE INSPECTION AND MAINTENANCE

PRACTICES SHOULD BE TASKED TO PERFORM WORK BECAUSE OF THE NECESSITY OF PROPERLY

INTERPRETING THESE PROCEDURES

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INTRODUCTION

PVB Fabrications Inc. would like to take this opportunity to again thank you for your recent acquisition of a PVB Aircraft Shade Structure. PVB Fabrications Inc. is a high-quality designer, manufacturer and installer of Aircraft Shade Structures. Your structure has been designed and manufactured to the highest quality standards. Your structure will require inspection and maintenance, as outlined in this document. By performing regular structure inspections and maintenance, you will keep your structure in its best possible condition for years. Timely scheduled inspections to spot and identify problems as they occur is the best preventative maintenance. This will help to optimize the service life of the structure, keep the structure functional and safe to protect your aircraft, equipment, and your personnel. This manual is for the inspection and maintenance of key PRIMARY items or areas on Aircraft Shade Structures. This manual is not intended to be or take place of an inspection test program. It only lists items that need to be inspected and the guide lines on how to do so. Other areas can be added to fit the needs of the structure’s owner.

The inspection part of this manual is intended to be a working document to be applied to each Aircraft Shade Structure. You may wish to have one manual for each structure, or you may wish to combine checklists for all structures into a single manual.

Because this manual is a living document, a guideline of areas and items that will need to be done along a timeline of inspections, maintenance and repairs, it can be changed to suit your needs, if these changes are approved by the owner’s Structural Engineer. You might find items that do not pertain to your specific situation and/or needs. Some inapplicable items over time may be seen as redundant and can be reviewed and approved to be omitted to save inspection time, as long as this is done by the owner’s Structural Engineer.

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REPLACEMENT PARTS & SERVICE

Replacement parts & service can be obtained through PVB Fabrications Inc. When calling PVB Fabrications Inc., have all the information that is on the shade structure name plate along with a picture of the name plate and the part needed or a description of the service needed. This will help us identify and locate your specific building and aid us in supplying replacement parts.

INSPECTION GRID NUMBERING

Your Aircraft Shade Structure is set up with grid marks and numbers to match the design and construction drawings. When inspecting and maintaining the structure, it is highly recommended the same system be used on inspection reports and maintenance logs. Use grid letters for column lines and grid numbers for rows to define the location of items on the structure reports.

AIRCRAFT SHADE STRUCTURE - GRID DETAIL

FULL VIEW OF AIRCRAFT SHADE STRUCTURE

WITH COLUMN LETTERS AND ROW NUMBERS

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DEFINITIONS

Part glossary and terms:

Column: Nominally vertical structural member that has the primary function of resisting axial compressive force.

Horizontal Bracing: Horizontal member or system that provides stiffness and strength to limit the out-of-plane movement of another member at a brace point.

Diagonal Knee Brace: Angle brace running from column to girders.

Girder: A built up horizontal structural member that has the primary function of resisting bending moments, also referred to as a beam. They are mounted on top of columns and supports purlins.

Fly Brace: Angle brace running from bottom of a girder to a zee purlin (This only occurs at rows 1, 2, 3, & 4).

X Rod Bracing: Round rod that forms an X pattern inside the girder (at rows 2&3).

Purlins: Roof framing members that span parallel to the building eave and support the roof decking or sheeting. Purlins are most commonly used in Metal Building Systems, where Z-shapes are utilized in a manner that allows flexural continuity between spans

End Wall Cee Purlin: Connect end wall sag rods and vertical sag rods attached to roof.

Sag Rods: Sag rods run from purlin to purlin to keep zee purlins perpendicular to girder and prevents them from sagging.

Roof Panels: Standing seam roof panels cover the shade structure and are attach to purlins below them.

Wall Zee Girts: End wall horizontal zee shaped members that the wall panels are attached to.

Vertical Sag Rod: Support tie rods, holds wall girders level.

Wall Panels: Multi- ribbed wall panels are attached to wall girders to form end wall.

Roof Ridge: The highest point on a roof, represented by a horizontal line where two roof areas intersect or converge, running the length of the area.

Roof Valley: The lowest point of roof where two roofs intersect or converge.

Valley Gutter: Is in the roof valley to allow water runoff from inside the roof areas.

White Rust: Is a white, chalky substance that can form on the surface of zinc materials, like galvanized steel. White rust can form when zinc is exposed to hydrogen and oxygen. This combination creates a zinc hydroxide, as opposed to the iron oxide which is common form of rust. While it can form on any zinc material or zinc-coated material, white rust is a frequent problem for galvanized steel.

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Isolation footing: Also known as Pad or Spread footings are commonly used for shallow foundations in order to carry and spread concentrated loads. Isolated footings can consist either of reinforced or non-reinforced material.

Snug-tightened: A condition of tightness that is attained with a few impacts of an impact wrench or the full effort of an ironworker using an ordinary spud wrench to bring the plies into firm contact.

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INSPECTION AND MANTAINCE SCHEDUAL

The following items need to be inspected at the noted intervals at a minimum. Consult with engineering to determine if additional item need to be added to this list.

Weekly

Above Grade Grounding Connection (see pg. 12)

Quarterly

Below grade resistance test (see pg. 12)

Visual inspection (see pg. 9)

Bolted connection inspection (see pg. 15 thru 17)

Crack inspection (see pg. 13)

Grout inspection (see pg. 14)

Structural Frame inspection (see pg. 18)

Roof Panel inspection (see pg. 20)

Wall Panel inspection (see pg. 22)

Structure Valley Rain Gutter Inspection (see pg. 23)

INSPECTION PLANNING

Walking plan

Walk the shade structure to define the inspection in order to minimize time and personnel. Plan the path you will walk and note the parts and members to be reviewed as you review your inspection plan. List the items you can look at from the ground to eye level.

Driving Lift Platform plan

Drive a lift platform around the structure to define the way you would like the inspection to run to minimize time. Plan the path you will drive and the parts and members to be reviewed in the driving inspection as you review your inspection plan.

SAFETY RECOMMENDATION

FOR THE DRIVING INSPECTION YOU WILL NEED TO CLEAR THE INSPECTION AREA OF GROUND

PERSONNEL AND OTHER ITEMS THAT COULD BE DAMAGED BY FALLING ITEMS

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Visual Inspection Plan/List

When performing visual inspection these are some of the things that need to be considered or looked for during that inspection.

• Are there any cracked welds or any cracks in concrete?

• Are there missing or loose hardware?

• Are there any signs of rust, white rust, mildew or oxidation on the parts?

• Are there dents, scratches or damage to any framing members?

• Are there dents, scratches or damage to roof or wall panel?

• Are columns plumb, is the horizontal bracing level?

• Are there any areas where paint is peeling off parts?

SCHEDULING YOUR INSPECTION

Timely quarterly scheduled inspections to spot and identify problems as they occur is the best preventative maintenance. This will optimize the service life of your shade structures.

It is recommended that if there is a major event, like a severe wind storms, severe rain storms and major earthquakes, that you plan an early inspection. These unforeseen events can generate severe damage that will need to be addressed to maintain your Aircraft Shade Structure in a safe condition.

INSPECTION PERSONNEL REQUIREMENTS

For your quarterly inspections pick your inspection team from only qualified personnel familiar with structural steel inspection and maintenance practices.

In-between quarterly inspections use the personnel that work in the area to spot problems that may need earlier inspections and/or maintenance performed.

TRAIN ON SITE PERSONNEL

TRAIN ON SITE PERSONNEL TO “SAY SOMETHING IF THEY SEE SOMETHING” FOR INSPECTION

SUPPORT

INSPECTION AND MAINTENANCE TOOLS AND EQUIPMENT

Recommended tools:

• 25’ Tape measure, 100’ tape measure

• 4’ spirit level and electronic level with digital inclinometer

• 3/8” and ½” sockets, ratchet wrenches and break-over bar

• Combination wrench set for socket backup

• 3/8” and ½” calibrated torque wrenches

• Hand tools - screwdriver and picketing tools

• Hand scrapers Power tools:

• Flashlight or power flood lights

• Power cords

• Generator if power not available

• Cordless power tools - drill and drives Power lift platform:

• 2-3 person powered drivable lift platform 35’to 45’ lift height Special tools:

• Ohm meter or Multi-meter

• Concrete crack-width comparator

• Inspection report printed out or on a computer / laptop

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SAFETY RECOMMENDATION

DO NOT USE EXTENSION LADDERS ON YOUR SHADE STRUCTURE. THEY WILL DAMAGE THE SIDE OF

STRUCTURES GUTTER AND FLASHING. EXTENSION LADDERS ARE DANGEROUS AT THE REQUIRED

ELEVATIONS OF AN AIRCRAFT SHADE STRUCTURE

SAFETY PRECAUTIONS

As safety practices differ within organizations, it is best to incorporate your own procedures and precautions into your shade structure inspection and maintenance in addition to the ones noted below.

General safety rules that are required for you to follow in addition to the safety rules and recommendation are listed throughout this document.

• Never remove more than one bolt from shade structure frame assemblies at a time.

• Never cut on any member or modify structural frame members.

• Never add additional loads to structure without an Engineering review and approval.

• Never walk on, sit on, hang from or climb on structure members.

• Never hang wind breaks or wind sails from structural frame.

• Never tie off equipment or use structure as an anchorage to hold items down.

• Never take shelter, nor come in contact with any metal on the shade structure in a lightning storm.

• Never operate machinery that you have not been trained to use.

• Always keep area clean. Good housekeeping is an aid to safety.

• Always put all tools/or equipment back in their proper place after use.

SAFETY RULES

SAFETY RULES MUST BE FOLLOWED TO KEEP STRUCTURE AND PERSONNEL SAFE

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STRUCTURE GROUNDING INSPECTION

COLUMN FRAME GROUNDING DETAIL - (12 EACH PER STRUCTURE)

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BELOW GRADE INSPECTION

Properly installed bonded grounding connections are important in the protection of the structure and personnel. For your first performed quarterly scheduled inspection, a resistance test needs to be performed and recorded to confirm the electrical continuity to ground. An inspection test program is needed to ensure the continued adequacy of grounding connections by comparing the recorded data.

The flexible leads used for grounding conductors are subject to mechanical damage, wear, corrosion, and general deterioration. For this reason, they should be inspected quarterly or when condition warrant an early inspection. The in-ground well that houses the grounding rod and conductor and the Ultra-weld bond connection, are very critical to the inspection (see figure on page 11).

The well is open to soil so the ground rod and its bond can become submerged underwater increasing the risk of corrosion. The inspection of the underground connection should determine the cleanliness of the connection. It is recommended that the connection be treated with an electrical grade corrosion resistant oxide coating to extend the life of this connection as needed. The type of coating should be determined by client engineering department.

INSPECTION RESISTANCE TESTING

Attach one lead of the ohm-meter to a clean spot on the structural frame and the other lead to the grounding rod.

1) The measured resistance should read from 1 to 25 ohms. Record the reading and monitor the increase over time as the grounding rod oxidizes and corrodes. If the resistance reading is in excess of 25 ohms an engineer needs to be notified.

2) Repeat 1 and 2 for each ground connection. Your Shade structure has 12 ground connections wells and it is recommended that you label the wells with column letters and row numbers to keep track of test recording data. See pages 5 of this manuals for grid marking information.

ABOVE GRADE INSPECTION

The above ground flexible leads used for grounding conductors are subject to mechanical damage, wear, including corrosion, and general deterioration. For this reason, they should be inspected quarterly or when condition warrant an early inspection. The cables are clamped in place to hold them in a defined location. This prevents cables from becoming crimped, crushed, cut, run over, or otherwise damaged.

The bond between ground cable to column can also be damaged, knocked off column, or become corroded. Personnel working under or around the shade structure must visually check the above grade grounding connection weekly, to assure its connection to the structure.

LOSS OF EARTH GROUNDING CONNECTIONS IS A HAZARD TO STRUCTURE AND PERSONNEL

Photo references of copper wire corrosion damage

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CONCRETE AND GROUT INSPECTIONS

CONCRETE INSPECTION

ANCHOR BOLT AREA

Any crack that forms at the anchor bolt or within 10’ the anchors bolts in the foundation needs to be checked and monitored. Cracks in this area are to be checked to define their condition and to determine if they are expanding. These checks and any monitoring need to be done under the direction and supervision of the client’s structural engineer. A Concrete crack-width comparator (see below image) may be used to size the crack and keep a record of any movement. When continued movement is observed in the foundation’s column base anchor cracks, they should be evaluated for possible corrective action.

Concrete foundation with crack-width comparator

It is recommended that the crack not be sealed until the movement can be reviewed by an engineer and determined to be safe. If a crack has been sealed or filled in and you notice it has re-opened or grown larger (and it is not shrinkage of the filler product) then there is reason to suspect movement.

If movement is suspected, then the crack needs to be monitored again.

AREAS WITHOUT ANCHOR BOLTS

For concrete foundation and cement floors, hairline cracks and cracks less than 1/16” (1.5 mm) wide (the thickness of a penny), are fairly common and do not warrant corrective action or monitoring. Most of these small cracks are caused from normal settlement of the structure which usually occurs within the first few years after construction.

Cracks that are larger than 1/16” (1.5 mm) or less 3/16” should be sealed with cement paint, caulk, or mortar to prevent water from getting in. This action will help slow crack growth and aid in monitoring.

Be aware that flexible caulks should not be used to fill cracks that you wish to monitor. Flexible caulk stretches and will not show continued movement.

Large cracks, 3/16” (4.8 mm) and greater should be carefully monitored after sealing to ensure there is no continued movement. Report any cracks to Engineer or supervisor that are 3/32” (2.4 mm) or greater

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GROUT INSPECTION

Grout is a critical part of the transferring of column loads into the foundation. There are several causes for non-shrink grout to crack at a column base:

• Grout was insufficiently packed into the joint on installation.

• Grout was made with an excessive amount of water or polymer additive.

• Grout was installed in a partially cured state before installation.

• Grout cracking from foundation cracking as a continuation crack.

• Cracking from excessive deflection in the foundation or column.

Grout cracks and gaps must be inspected and monitored to see what caused them. If a gap appears between the column base plate and the grout that appears to be shrinking, the grout will need to be repaired.

COLUMN BASE PLATE SIDE AND TO VIEW

INSPECTION FOR CHANGES IN ISOLATION FOOTINGS

The isolation footing will need to be inspected for anchor bolt cracking the same as the non- isolated foundations. The isolation footings will need to be inspected for changes in level or elevation. Inspect the footing to see if it is level with the top of surrounding foundations. The change can be either up or down from the surrounding foundation surface. The movement needs to be monitored for safety as a tripping hazard. If the isolation footing shows signs of sinking below the sorrounding foundation, report the sinking to owner’s structural Engineer for review once they reach 1/2” (12.6 mm).

ISOLATION FOOTINGS

SAFETY HAZARD

SAFETY HAZARDS MUST BE FIXED OR REPAIRED TO KEEP STRUCTURE AND PERSONNEL SAFE

NOTICE

IF THERE IS MOVEMENT YOU WILL SEE CRACKS OR SEPARATION IN SEALANT MATERIAL AROUND THE

ISOLATION FOOTING

¾” Dia HILTI HIT-500-V3

+ Has B7, 9” Embed.

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BOLTS INSPECTION

The use of ASTM A325 fasteners throughout the structural frame is standard and marked on the head of bolts. Sag rods and vertical sag rods are made of 36ksi steel and are equivalent to ASTM A307 fasteners.

The Aircraft Shade Structures bolts will loosen over time; therefore, the structures connections will move. The first inspection will be your base line for the structure to log and maintain records of all bolts / fastener tightness.

INSPECTION

A primary inspection requirement is to check bolts for snug tightness in these key areas noted below.

Check fasteners for snug tightness in these key areas. If it determined that a bolt was not tightened to the correct torque value, the fastener should be backed off from one-half to one full turn and retightened to the correct torque value.

• Anchor bolts – see Hilti specification section 05 05 19 for post-installed concrete anchors

• Horizontal and diagonal bolt

• Girder bolt

• Fly bracing bolt

• Column u bolt

• Zee purlin bolt

• Zee tie rod nut

For reference, table 8.2 from the Research Council on Structural Connections (RCSC), 2014, appears above:

REFERENCE AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC) MANUAL OF STEEL

CONSTRUCTION, SPECIFICATIONS AND CODES, SPECIFICATION FOR STRUCTURAL JOINTS USING ASTM

A325 OR A409 BOLTS FOR PROPER PROCEDURES TO FOLLOW WHEN USING ANY TORQUE

TIGHTENING METHOD

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TIGHTENING METHODS

The method of tightening bolts that are found to be in a no snug-tight condition need to be tightened per your structural engineers’ recommendations. Below are some possible methods of tightening.

TORQUEING BOLTS

If you decide to use a torque wrench to Re-Torque or perform a Torque Check on bolted fasteners with a torque setting, the following will need to be considered.

In accordance with standard practices, checking fasteners accurately to determine if they have been tightened to the required fastener torque, is not possible. But if torqueing of the bolts is stipulated them the two methods noted below are guidelines, if approved by clients engineering.

NOTE

NOTE: DO NOT USE TORQUE WRENCH TO LOOSEN FASTENERS

RE-TORQUE

When a re-torque is specified in the applicable inspection publication or it is uncertain if a joint has been properly torqued, back off the fastener one or two turns, then tighten to the required torque as follows.

• Remove all torque from the fastener (loosening) until no preload is on the fastener.

• Torque the fastener to its designated torque value.

• If the fastener is one in a multi-fastener pattern requiring a torque sequence, then all the fasteners will require "re-torque."

TORQUE CHECK

When a Torque Check is needed in the inspection procedures, it should be accomplished by torqueing in the tightening direction. Do not loosen the fastener(s).

The value applied should be one of the following:

• If the fasteners torque is known from when the fastener was originally installed (i.e., torque table), then this is the torque value applied for Torque Check purposes.

• If the original fasteners torque was not recorded, then the fasteners torque for Torque

Check purposes would be the minimum Specified Torque or minimum Standard Torque, as applicable.

• If during the application of the fasteners torque as detailed above, no motion is detected between the fasteners, then the joint is considered acceptable.

• If during this inspection loose bolts are found, they may only need to be tightened.

Looseness may occur until the component’s “seat” themselves and the fasteners simply only need to be tightened. This is not cause for disassembly; however, the fastener(s) will have to be Torque Checked again at the same scheduled interval set for the first Torque Check until the assembly is completely seated. If a specific torque sequence is to be followed, as initially torqued, then this same sequence should be followed during the Torque Check. Some fasteners in the sequence may accept additional torque while others may not; this is acceptable.

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• Joints that have not retained torque will require disassembly and inspection. If the fastener(s) move, the assembly shall be rechecked for damage, corrosion, improper assembly, etc.; if no problems are found, the fastener(s) may be re-torqued to the fastener torque value. In this case, the fastener(s) would have to be Torque Checked again at the same scheduled interval set for the first Torque Check.

TORQUE TABLES

Note: For small bolts and screws use the above ASTM A307 loads for these fasteners.

SELF DRILLING FASTENERS

Any fastener that was not seated properly will work itself out eventually. Replace any unseated, loose, or stripped fastener with the next larger size.

NOTE

NOTE: FOR SELF DRILLING STRIPPED FASTENERS USED THE CHART BELOW

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STRUCTURAL FRAME INSPECTION

FRAME MOVEMENT

As part of your primary inspection, you will need to form a baseline to define the plumb condition of columns, the levelness of horizontal bracing, and record the positions of the angles to track changes in the structure. These changes can be part of other conditions in a cause and effect relationship i.e.

cracks in foundation or grout failure to movement in frame columns and bracing. Train your inspection team to look for the effects of movement in other areas of the structure.

Movement in frames can come from the items listed below:

• Earthquakes

• Windstorms

• Rainstorms

• Impacts into frame by equipment, vehicles or aircraft.

CRACKS IN WELDED MEMBERS

As your inspection team is walking the structure, have them scan the welds and look for cracks that radiate thru welded areas. These may be found via missing or chipped paint, discolored areas in paint, rusted lines on surface of paint, and stretch lines or marks in paint finish. Cracks can also run along the sides of welded area as a toe crack or across the weld as a transverse crack. It is a primary inspection responsibility to report these cracks to the Structural Engineer for review and to define a repair.

Visual weld cracks (a) at weld ends (b) at joints to look for inspections

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FRAME DAMAGE TO STRUCTURE

Note and log any damage to frame structure or large dents in columns or bracing. These may need to be reviewed by Structural Engineer to define the significance and determine a repair or when a repair is needed.

RUST AND CORROSION INSPECTION

Inspect the structural frame members for rust and corrosion. There are many different types of corrosion, each of which can be classified by the cause of the metal's chemical deterioration. The list of corrosion types that is shown below will help you train your inspection team to understand corrosion and what to look for to report and log.

GENERAL ATTACH CORROSION

Also known as uniform attack corrosion, general attack corrosion is the most common type of corrosion and is caused by a chemical or electrochemical reaction that results in the deterioration of the entire exposed surface of a metal. Ultimately, the metal deteriorates to the point of failure.

General attack corrosion accounts for the greatest amount of metal destruction by corrosion but is considered as a safe form of corrosion, due to the fact that it is predictable, manageable and often preventable.

LOCALIZED CORROSION

Unlike general attack corrosion, localized corrosion specifically targets one area of the metal structure.

Localized corrosion is classified as one of three types:

• Pitting: Pitting results when a small hole, or cavity, forms in the metal, usually as a result of depassivation of a small area. This area becomes anodic, while part of the remaining metal becomes cathodic, producing a localized galvanic reaction. The deterioration of this small area penetrates the metal and can lead to failure. This form of corrosion is often difficult to detect due to the fact that it is usually relatively small and may be covered or hidden by corrosion-produced compounds.

• Crevice corrosion: Similar to pitting, crevice corrosion occurs at a specific location. This type of corrosion is often associated with a stagnant micro-environment, like those found under gaskets, washers and clamps. Acidic conditions or a depletion of oxygen in a crevice can lead to crevice corrosion.

• Filiform corrosion: Occurring under painted or plated surfaces when water breaches the coating, filiform corrosion begins at small defects in the coating and spreads to cause structural weakness.

GALVANIC CORROSION

Galvanic corrosion, or dissimilar metal corrosion, occurs when two different metals are located together in a corrosive electrolyte. A galvanic couple forms between the two metals, where one metal becomes the anode and the other the cathode. The anode, or sacrificial metal, corrodes and deteriorates faster than it would alone, while the cathode deteriorates more slowly than it would otherwise.

Three conditions must exist for galvanic corrosion to occur:

• Electrochemically dissimilar metals must be present

• The metals must be in electrical contact, and

• The metals must be exposed to an electrolyte

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Environmental Cracking

Environmental cracking is a corrosion process that can result from a combination of environmental conditions affecting the metal. Chemical, temperature and stress-related conditions can result in the following types of environmental corrosion:

• Stress Corrosion Cracking (SCC)

• Corrosion fatigue

• Hydrogen-induced cracking

• Liquid metal embrittlement

Flow-Assisted Corrosion (FAC) Flow-assisted corrosion, or flow-accelerated corrosion, results when a protective layer of oxide on a metal surface is dissolved or removed by wind or water, exposing the underlying metal to further corroding and deterioration.

• Erosion-assisted corrosion

• Impingement

• Cavitation

Intergranular corrosion Intergranular corrosion is a chemical or electrochemical attack on the grain boundaries of a metal. It often occurs due to impurities in the metal, which tend to be present in higher contents near grain boundaries. These boundaries can be more vulnerable to corrosion than the bulk of the metal.

Fretting corrosion Fretting corrosion occurs as a result of repeated wearing, weight and/or vibration on an uneven, rough surface. Corrosion, resulting in pits and grooves, occurs on the surface. Fretting corrosion is often found in rotation and impact machinery, bolted assemblies and bearings, as well as to surfaces exposed to vibration during transportation.

SAFETY RULES FIRST

ROOF INSPECTION

Walking on a metal roof is dangerous. Safety must always be the priority when walking on, inspecting, or performing maintenance on your structure’s roof system. Always use safety equipment such as fall protection as required by OSHA and other regulatory agencies. Failure to do so could result in serious injury and/or death. In addition, you may also be subject to citations for non-compliance. You should always use extreme caution when walking on metal roofs with steep slopes, near roof edges, or on roofs that are wet or covered with ice or snow. Insure that all personnel are trained in safety procedures and that all safety equipment is in proper working condition. When walking on a metal roof, inspecting, or performing roof maintenance, always take the following precautions:

• Use fall protection and other safety equipment as required.

• Do not walk on roof flashings such as gutter, rake, hip or ridge flash.

• Step only in the panel flat directly on or in close proximity to a supporting roof structural member.

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ROOF PANEL INSPECTION

Your structures roof system should be inspected quarterly, and whenever any of the following occur:

• After a fire, vandalism or any known damage to the roof or an adjacent roof area.

• After exposure to severe weather, including, but not limited to: high winds, hail, heavy rains, ice, snow, or other abnormal conditions

• Items to check after high winds include:

o Debris scattered on the roof o Loose flashing or other roof components o Punctures from falling or flying objects o Loose fasteners (Replace stripped-out fasteners by removing existing fastener; apply butyl sealant into hole; install an oversize, long-life fastener into hole) o Any other damage

• Items to check after a hail storm include:

o Punctures o Damaged trim o Loose fasteners (Replace stripped-out fasteners by removing existing fastener; apply butyl sealant into hole; install an oversize, long-life fastener into hole) o Any other damage

• Items to check after abnormally heavy rains include:

o Roof for ponding water o Gutters for ponding water o Roof curbs and penetrations and other special trim conditions to ensure water is not ponding upslope from these areas o Loose fasteners (Replace stripped-out fasteners by removing existing fastener; apply butyl sealant into hole; install an oversize, long-life fastener into hole) o Any other damage

• Items to check after ice or snow events include:

o Check trim and gutters for damage from sliding ice or snow o Roof for ponding water o Roof curbs and penetrations and other special trim conditions to ensure water is not ponding upslope from these areas o Damage to gutters from sliding ice or snow o Damage to snow retention devices o Loose fasteners (Replace stripped-out fasteners by removing existing fastener; apply butyl sealant into hole; install an oversize, long-life fastener into hole) o Any other damage

• After other trades have been on the roof for any reason;

o Inspect the roof for damage caused by workers, chemical or solvent spills, scratches in the paint or Galvalume coating, and excessive foot traffic and punctures.

o Make sure that any debris or scrap left behind by the workers is removed from the roof immediately.

o Avoid using cutoff saws and welding equipment over the roof. In cases where this is not possible, the roof must be adequately protected. A fire cloth is recommended.

o Items such as drill shavings, wire, metal scrap and other debris can corrode and damage the roof. Sharp pieces of metal, such as those left by a nibbler, can stick in a worker's shoes and scratch the paint as they walk on the roof.

o Mortar or concrete will etch the paint or Galvalume coating. Roof panels in areas where there is a possibility of any masonry product being spilled on them should be protected. In the event

P a g e | 22 that the panels do have a masonry product spilled on them, they should be cleaned and the panels rinsed.

o Should any solvent or chemical be spilled on the roof, clean up immediately and thoroughly rinse the affected area. Panels should be cleaned with mild detergent.

SAFETY RULES FIRST

Safety should always the priority when walking on, inspecting, or performing maintenance on your structures roof system. You should always use safety equipment such as fall protection as required by OSHA and other regulatory agencies. Failure to do so could result in minor or severe jury. In addition, you may also be subject to citations for non-compliance. Insure that all personnel are trained in safety procedures and that all safety equipment is in proper working condition. When performing inspects or maintenance on a metal wall, always use fall protection and other safety equipment as required.

WALL PANEL INSPECTION

Your structures wall system should be inspected quarterly and whenever any of the following occur:

• After a fire, vandalism or any known damage to the roof or an adjacent roof area.

• After exposure to severe weather, including, but not limited to, high winds, hail, heavy rains, ice, snow, or other abnormal conditions.

• Items to check after high winds include:

o Debris scattered on the wall panels.

o Loose flashing or other roof components o Punctures from falling or flying objects o Loose fasteners (Replace stripped-out fasteners by removing existing fastener; apply butyl sealant into hole; install an oversize, long-life fastener into hole) Any other damage

• Items to check after a hail storm include:

o Punctures o Damaged trim o Loose fasteners (Replace stripped-out fasteners by removing existing fastener; apply butyl sealant into hole; install an oversize, long-life fastener into hole) o Any other damage

• Items to check after abnormally heavy rains include:

o Loose fasteners (Replace stripped-out fasteners by removing existing fastener; apply butyl sealant into hole; install an oversize, long-life fastener into hole) o Any other damage

• After other trades have been working near the wall for any reason;

o Inspect the wall for damage caused by workers including chemical or solvent spills, scratches in the paint or Galvalume coating, excessive foot traffic and punctures.

o Make sure that any debris or scrap left behind by the workers is removed from the wall immediately.

o Avoid using cutoff saws and welding equipment over the wall. In cases where this is not possible, the wall must be adequately protected. A fire cloth is recommended.

o Items such as drill shavings, wire, metal scrap and other debris can corrode and damage the wall.

o Mortar or concrete will etch the paint or Galvalume coating. Wall panels in areas where there is a possibility of any masonry product being spilled on them should be protected. In the event that the panels do have a masonry product spilled on them, they should be cleaned and the panels rinsed.

o Should any solvent or chemical be spilled on the wall, clean up immediately and thoroughly rinse the affected area. Panels should be cleaned with mild detergent.

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STRUCTURE VALLEY RAIN GUTTER INSPECTION

The valley gutters are lined with 60 mil fiber reinforced EPDM rubber membrane bonded to the sheet metal gutters. Always clean gutters at the time of inspection to keep sand and dirt from building up in gutters. Check for cuts and gouges in the membrane. Your inspection will need to check the bond between rubber and sheet metal. The inspector checks this by looking for bubbles in the membrane or a membrane that has pulled loose from the sheet metal. Log and report any problems within the valley gutters.

FRONT VIEW OF VALLEY GUTTER AT THE CENTER OF COLUMN

SECTION VIEW OF VALLEY GUTTER AT THE CENTER OF COLUMN

VALLEY

GUTTE

R

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INSPECTION AND MAINTENANCE EXAMPLE FORMS.

Examples below are for reference and may contain more information then you need.

It is recommended that the client builds an excel file for reports and record keeping for the new Aircraft Shade Structure. This example will help you to fit your record keeping into your own systems and standards you use on a daily basis rather than forcing you to use a system you do not know or that will take an extended time to learn. It is recommend that you tie inspection to maintenance reporting in order to close out open items in your systems.

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Examples continued

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Examples continued

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SHADE STRUCTURE MAINTENANCE

Scheduled maintenance is required for long-term success in keeping roof and wall systems water-tight.

Proper maintenance is also required to preserve the integrity of the protective coating of the steel sheets. This required system maintenance is the responsibility of the building owner.

GENERAL

Roof and wall panels should not come in contact with graphite or lead markers. Roof and wall panels should not come in contact with copper, lead flashing, exposed iron or debris. The use of treated lumber in association with painted steel sheets are a known corrosive and will cause premature deterioration of the protective panel coating. Wall panels should be kept clear of dirt & soil.

RUST

Inspect the panels for rust. Should any rust or rust stains be found, determine the source, such as steel filings from drilling, sawing, grinding, etc. and remove them. The rust stain can generally be cleaned off with one of the following: soap and water, mineral spirits, or a mild automotive polishing compound. If you have any questions or concerns regarding rust on panel or trim surfaces, contact PVB Fabrications, Inc.

PAINT SCRATCHES

Scratches to the paint should be brush touched (artist brush) with touchup paint. If the scratched area has not rusted, the paint may be applied without surface preparation. If the area is rusted, remove the rust; prime the affected area and brush with color matched touchup paint.

Paint repair: All structural members and panels shall be painted with one primer coat of zinc chromate anti-corrosion paint (dry film thickness of 3-5 mils), followed by two coats of Frazee paint number 213 Travatan color for outdoor metal surfaces (dry film thickness of 6-10 mils).

Total mil finish 9-15 mils.

To touch-up scratches in paint (not to bare metal), clean area to be painted with mineral spirits SSPC-SP solvent. Rinse thoroughly and dry. Using a small artist's brush, lightly apply the absolute minimum amount of touch-up paint required to fill the scratch. If scratch is deeper or rust has started it must be cleaned to NACE standard SSPC-SP2 (hand tool clean) or SSP-SP3 (power tool clean) and then repaint area.

SURFACE PREPARATION STANDARDS

The basic standards for preparing metal substrates are a joint effort between the Society for Protective Coatings (SSPC) and the National Association of Corrosion Engineers International (NACE).

SSPC-SP1 Solvent Cleaning Remove all visible oil, grease, soil, drawing and cutting compounds, and other soluble contaminants from steel surfaces with solvent, vapor, cleaning compound, alkali, emulsifying agent, or steam.

SSPC-SP2 Hand Tool Cleaning Remove all loose mill scale, loose rust, loose paint, and other loose detrimental foreign matter by hand chipping, scraping, sanding, or wire brushing.

SSPC-SP3 Power Tool Cleaning Remove all loose mill scale, loose rust, loose paint, and other loose detrimental foreign matter by power wire brushing, power sanding, power grinding, power tool chipping, or power tool descaling.

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PANEL SURFACE CLEANING

Non-Water-Soluble Deposits on Zinc-Aluminum Finishes Use mineral spirits (with a Neutral PH) to remove non-water-soluble deposits (tar, grease, oil, paint, graffiti, etc.) from the panel surface. Do not use any other harsh caustics, acidic compounds, or cleaners that could potentially cause premature failure of the coating and otherwise create permanent damage to the protective panel finish.

Non-Water-Soluble Deposits on Silicon-Polyester & Kynar paint finishes Use a diluted mixture of the common household commercial cleanser such as “Tide” & Water to remove non-water-soluble deposits (tar, grease, oil, paint, graffiti, etc.) from the panel surface. Do not use any other harsh caustics, abrasives, acidic compounds, or cleaners that could potentially cause premature failure of the coating and/or otherwise create permanent damage to the protective panel finish.

Solvents that may also be used to remove these items from paint panel finishes include:

Alcohols - Not aesthetically detrimental when properly applied Denatured Alcohol (Ethanol) Isopropyl (Rubbing) Alcohol Methanol (Wood Alcohol)-Note: Methanol is toxic

Petroleum Solvents - Not aesthetically detrimental when properly applied VM & P Naphtha Mineral Spirits Turpentine (Wood or Gum Spirits)

Aromatic and Other - Use with caution:

Xylol (Xylene) Toluol (Toluene)

Limit contact time to under 5 minutes and test before using. Exposure that causes damage to the paint finish will void your finish warranty.

DO NOT use Acetone, paint remover, Lacquer thinners, Esters, Ketones, Methyl Ethyl Ketone (MEK), or Methyl Isobutyl Ketone on Kynar or Silicon-Polyester paint surfaces.

Contact and exposure with these products can result in blemishes detrimental to the aesthetics of your metal building and will void your warranty.

Most organic solvents are flammable and/or toxic and must be handled accordingly. Keep away from open flames, sparks and electric motors. Use adequate ventilation, protective clothing and goggles. A fresh water rinse should be used after application of alcohol, solvents, or aromatics to ensure that all residue is removed.

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REMOVING RUST FROM GALVANIZED STEEL AND FASTENERS

Over time the bolts / fasteners and galvanized members will rust. You can use a rust preventive to keep rust in check when performing your regular maintenance on the structure. Use cold galvanizing spray to restore the galvanization to the steel.

Rusted galvanized bolts

GENERAL GALVANIZE REPAIR

Galvanized steel is designed not to rust, so if you have a galvanized steel item that has rusted, it means that the galvanization has worn off completely in those areas. Galvanization involves zinc, which corrodes instead of the actual metal to prevent rust, when the zinc is all gone rust sets in. You can remove rust from galvanized steel, but you will need to repair the area that rusted to prevent the rust from returning when the metal is again exposed to moisture.

Step 1 Clean the galvanized steel. Wipe down small pieces of steel using cleaning rags with three drops of liquid detergent in order to remove dirt, dust, grime and sometimes large chunks of rust. Larger items can be pressure-washed or hosed down. The point is to remove grime so that you can target rusted areas more specifically.

Step 2 Scrape off large areas of rust with a wire brush, use firm pressure with a back-and-forth motion to remove rust from the metal. The wire brush may scratch the metal, but this is acceptable since you will have to paint and re-galvanize it anyway. Wear protective goggles from this point forward to keep rust particles from flying into your eyes.

Step 3 Sand off any remaining rust. Use firm pressure and rub the sandpaper back and forth just over the affected areas.

Step 4 Clean off the rust dust. Use the hand broom to dust off all the rust particles and to clear the area to be sure that there is no more rust. Wipe down the area with a damp cleaning rag and three drops of liquid detergent, then dry it completely to prevent the formation of flash rust in the exposed areas.

Step 5 Take preventative measures to inhibit further rust. Paint the item (or at least the sanded and scrubbed areas) with zinc-rich paint or cold galvanizing spray to restore the galvanization to the steel. Apply two to three coats of paint, but allow at least 90 minutes between coats to ensure that the area has dried completely.

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SHADE STRUCTURE ROOF AND WALL MAINTENANCE PANEL

Roof and Wall Panel Repairs

Never allow maintenance workers to "fix" leaks by applying caulk, elastomeric membranes, plastic roof cement, etc. to the roof surface. This is never a long-term solution for repairing a leak. Surface applied caulks and compounds will eventually lose their bond to the metal. This will allow water to become trapped between the repair material and the roof panel, which will cause severe corrosion.

Leaks at panel or trim joints, should be repaired by disassembling the metal joint and reinstalling the proper sealant between the metal layers. Leaks caused by roof punctures must be evaluated on an individual basis. In some cases, the affected roof panel may need to be replaced. Always consult PVB Fabrications Inc. before initiating repair work. PVB Fabrications Inc. can give you helpful information as to how to make the repair and repair work.

Keep roof foot traffic to a minimum. Heavy foot traffic can cause ponding on low pitched roofs.

Always walk in the flat of the panel near a supporting roof structural member. Do not walk on trim or in gutters. On painted roofs, excessive foot traffic may cause black burnish marks. Only authorized personnel are allowed onto the roof with booties worn over their shoes to keep wear to a minimum.

In addition, a log book should be kept of all visits to the roof and the reason for such visits.

Avoid stepping on the ridge caps.

Avoid stepping on lap joints in roof panels and flashings.

Avoid walking near roof curbs or other roof penetrations.

Avoid stepping on panel ribs between purlins.

DO NOT step in or on gutters or the gutter hanger system.

If regular foot traffic is planned for a roof, provisions should be made for a properly designed and installed roof walkway system. Contact PVB Fabrications Inc. for help with this.

DISCLAIMER

The information, material, and content in this document are intended for general information purposes only. Any use of content related to this material to any specific application, structure or condition should be based on independent evaluation, review, and verification of its unrestricted availability for such use, and determination of suitability for the application by professionally qualified personnel.

No license under any PVB Fabrications Inc. or other proprietary interest is implied by the publication of this information. Those making use of or relying upon the information enclosed assume all risks and liability arising from such use or reliance.

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