0903-RevB_A_UNDERWATER_HULL_PRESERVATION.doc

RAPPAHANNOCK

(T-AO 204 )

1.0

ABSTRACT

1.1 Perform a blast/ultra-high pressure water blast to the entire ship's underwater hull from the keel up to the 37'0" WL mark, including rudder, rudder posts, shaft hubs, stern frames and all sea chest strainer plates and vessel draft marks, and fully paint hull.

2.0

REFERENCE/ENCLOSURES

2.1

REFERENCES

2.1.1 MSC SWIRRR # 13, Issued 22 March 2010, “Underwater Hull Preservation”

2.2

ENCLOSURES

2.1.1 MSC SWIRRR # 13, Issued 22 March 2010, “Underwater Hull Preservation”

3.0

ITEM DESCRIPTION/LOCATION

3.1

LOCATION/QTY

3.1.1 Ship's bottom from keel to the 37 ft load line and boot topping

3.1.2 Approximately 91,000 square feet of surface area for paint system undercoat blast.

3.1.3 Approximately 91,000 square ft of surface area for two (2) full prime coats and two (2) full coats of AF.

3.1.4 Coating System (coating system shall be applied under the direction of the paint representative):

Anode Areas

Rudders, Seachest, Struts Shaft Tubes and Skeg

Boot Topping

4.0

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE

4.1 GOVERNMENT FURNISHED EQUIPMENT - None

4.2

GOVERNMENT FURNISHED MATERIAL

The following PPG Paint shall be provided:

150 Gal

110 Gal

12 Gal

* Solvents are for viscosity control only, not equipment clean up.

4.3

GOVERNMENT FURNISHED SERVICES

4.3.1 Manufacturer’s Paint Field Representative

5.0

NOTES

5.1 The Government shall furnish all paint, solvents, and the paint manufacturer’s technical representative.

5.2 Government furnished solvents are for viscosity control only, not for equipment clean up.

5.3 This item shall be worked in conjunction with all other drydock related work items of this specification package.

5.4 Square footages provided in para. 3.1 are estimates only. It is the responsibility of the contractor to verify the actual quantity of surface area to be dealt with during the Bidder’s Survey.

6.0

QUALITY ASSURANCE REQUIREMENTS

6.1 All work performed on this item shall be in strict compliance with reference 2.1.1.

6.2 All work performed on this item shall be under the direct supervision of the government furnished paint manufacturer’s technical representative.

6.3 All work performed shall be to the requirements of the Paint Manufacturer's Technical Representative.

7.0

STATEMENT OF WORK REQUIRED

7.1 All work conducted on this item will be under the direct supervision of a government furnished paint manufacturer's representative and shall be in strict compliance with Ref 2.1.1.

7.1.1 Immediately following the completion of high pressure fresh water washing of the underwater hull surfaces to the top of the boot top, conduct a hull coatings survey with following: MSCREP, Master, Chief Engineer, Chief Mate, contractor’s Paint Representative, the government provided Paint Representative and the ABS surveyor.

7.2 Preparation for Blasting and Sweep.

7.2.1 Perform all the requirements of Reference 2.1.1 and Enclosure 2.2.1 paragraph A in preparation for Blasting the underwater hull.

7.2.4 Prior to blasting, the deep and light load lines and other hull markings shall be marked.

7.2.4.1 Bead in, and outline all draft marks and other hull markings as required to restore worn or missing weld marks.

7.2.5 Remove all sea chest strainer plates. All surfaces of strainer plates shall be cleaned and coated as specified for the ship's underwater hull. Upon completion of hull coating, all strainer plates shall be reinstalled. All new Monel bolting and lock wire shall be used to secure strainer plates.

7.2.5.1 All sea suction lines and overboard discharge lines shall be plugged with wooden plugs and all interior surfaces of all sea chests shall be cleaned and coated as specified for the ship's underwater hull. Remove plugs upon completion of coating.

7.2.5.2 Before reinstallation of strainer plates, all sea chests and overboard discharges shall be inspected in presence of MSCREP for removal of plugs.

7.2.6 Grit and/or other abrasive used for blasting, shall be new, clean and shielded from rain and water by suitable means.

7.3 Surface Cleaning

7.3.1 Pneumatic descaling: Heavily scaled surfaces shall be descaled by pneumatic tools and/or hammers prior to abrasive blasting.

7.3.2 Remove and subsequently replace all scupper extensions with required securements. Provide and install rubber chutes and connect to all overboard discharges to keep water from the ship's side and bottom during all painting operations. Run all chutes lines to dry-dock floor.

7.3.3 Degrease the hull exterior with suitable solvents prior to blasting. Wash down and dispose of solvents used in accordance with all applicable Federal, State and Local anti-pollution/environmental protection statues and regulations.

7.4 Inspection

7.4.1 An inspection team shall be present throughout the entire period of preparing the surfaces prior to coating applications. The inspection team will inspect the quality of surface preparation achieved. The inspection team will be composed of the following members: MSCREP, the Paint Manufacturer's Field Service Engineer, and contractor's QA inspector. No paint shall be applied until surfaces have been approved by the Manufacturer’s Technical Paint Representative.

7.4.2 Provide articulated man lifts (cherry pickers) for use by inspection team when inspecting hull surface preparations and coatings.

7.5 Hull Blast

7.5.1 Blasting shall be performed in accordance with Reference 2.1.1 and Enclosure 2.2.1 paragraph B (1) or (2). Contractor shall utilize abrasive blast or ultra-high pressure water blast to the entire U/W hull to "near white metal" (SSPC-SP-10) or SSPC-SP12, WJ-2, SC2 condition, as agreed upon by the port engineer and the contractor.

7.6 Coating System

7.6.1 Upon completion of exterior surface preparation and approval by MSCREP, apply coating systems under the direct supervision of the paint manufacturer's representative and in accordance with Reference 2.1.1 and Enclosure 2.2.1 paragraph C. Government shall furnish all paint required. As indicated in paragraph 4.0, anti-corrosive coating shall be Amercoat 240 red/black and anti-fouling coating shall be ABC-4 black/red. All anti-fouling coats in the boot-top shall be black and top coat red below the light load line.

7.6.1.1 Paint in all hull markings as original. Boot-topping shall be black anti-fouling (A/F) and shall be straight and neatly cut in. Draft marks below load waterline shall be painted with Amercoat 5450 White A/F and draft marks above deep load waterline shall be Amercoat 5450 Black. Plimsoll marks shall be repainted as original.

7.6.1.2 The entire 91,000 sq ft of hull surface shall have two (2) full coats of primer and two (2) full coats of anti-fouling (AF).

7.6.2 Paint shall not be applied to hull surfaces when the humidity is above the recommend level as specified by paint manufacturer or the temperature is below 40 degrees Fahrenheit or as limited by the paint manufacturer's recommendations, unless prior permission is obtained from the MSCREP in writing.

7.6.2.1 Take and record ambient, surface, and dew point temperatures before applying each coat. Submit daily report of same to MSCREP. All temperature and dew point readings shall be taken and recorded hourly while painting is in progress. No painting shall take place when temperature and/or dew point readings are outside of the manufacturer’s recommended ranges.

7.6.3 Drying (curing) time between coats shall be as specified by the paint manufacturer as well as minimum and maximum times for undocking (allowing for final cure of coating system).

7.6.4 After applying each coat, take and record dry film thickness (DFT) reading in presence of designated MSCREP. Readings shall be taken at a minimum of (5) five readings per 1000 square feet of surface area.

7.6.5 No painting shall be accomplished from sunset to 0800 (8 AM) the following morning without prior approval, in writing, of the MSCREP.

7.6.6 All areas to be coated will be blown down with dry, oil free air prior to coating.

7.6.7 No painting will begin or take place without a manufacturer's representative in attendance.

7.7 Upon completion of blasting and painting and after appropriate curing time has been allowed, wash down decks with contractor furnished fresh water to remove any and all of the residue caused by work on this item.

7.8 Remove all protective masking, sheeting, tape, covers, plugs and chutes, and dispose of in accordance with all Federal, State and local regulations.

7.8.1 Clean all areas, spaces, and machinery onboard contaminated by sandblasting grit, dust, and water to the satisfaction of the MSCREP.

7.9 Manufacturer's Representative

7.9.1 The Government shall provide a manufacturer’s representative. The representative shall provide technical supervision and quality assurance assistance during the performance of this work item.

8.0 GENERAL REQUIREMENTS: None Additional.

Enclosure 2.2.1

Military Sealift Fleet Support Command (MSFSC)

Standard Work Item for Repetitive Repair Requirements

Item No. 13

22 March 2010

UNDERWATER HULL PRESERVATION

1. ABSTRACT

This standard item provides requirements for underwater hull preservation. This item includes UNIVERSAL REQUIREMENTS, which apply to all work covered in this standard work item, and menu-type COMPONENT REQUIREMENTS that detail the work required for specific underwater hull preservation applications. This standard item will be incorporated into a MSFSC vessel work package by reference.

2. References:

Note: Reference documents include a mix of public and private information. To the maximum extent possible, all reference information is included in the reference folder which is provided with the MSFSC Standard Work Item package. Private documents, such as SOLAS, ASME or SSPC, are not provided but are considered to be common ship repair industry documents which are available through subscription to the publishing organizations.

SSPC (Society for Protective Coatings)

SP – Surface Preparation Standards and Specifications

PA – Paint Application Standards, Guides and Specifications

3. ITEM LOCATION/DESCRIPTION

Locations are as specified in the base item.

4. GOVERNMENT FURNISHED MATERIAL/ EQUIPMENT/ SERVICE: None

5. Notes: None

6. QUALITY ASSURANCE REQUIREMENTS: None

7. STATEMENT OF WORK REQUIRED

A. Universal Requirements

All areas of the underwater hull shall be maintained in a wet condition until the high pressure water washing has been accomplished.

Provide and erect all necessary staging and/or provide suitable alternative means (scissor lift, manlifts, etcetera) required for proper working conditions and inspection.

Immediately upon drydocking the entire hull from the keel to six inches (6") above the Deep Load Line including, but not limited to, appendages such as sea chests, strainer plates, thruster tunnel(s), bilge keels, struts and rudder(s) shall be high pressure water washed to remove all marine growth (slime, grass, tube worms, barnacles, etcetera), peeling, blistered and flaking paint and salts. Equipment utilized shall maintain a minimum discharge pressure of 2,500 to 3,000 psi. Accomplish the requirements of SSPC-SP1, Solvent Cleaning, Accomplish the requirements of Surface Preparation Standard SSPC-SP1, Solvent Cleaning, to remove all dirt, oil, grease, soluble salts or other organic matter. Biodegradable cleaners or other eco-friendly methods/agents shall be used to the greatest extent possible. Upon completion of all cleaning chloride testing shall be performed at random locations. If contamination is found, additional tests shall be made as necessary to determine the extent of contamination and to prove the success of remediation. The maximum allowable contamination concentrations shall be less than 10 ug/cm2 of chloride contaminants as determined by field or laboratory analysis using reliable, reproducible test equipment.

Provide and maintain adequate lighting of a suitable nature during the course of all water washing, blasting, coating and inspection activities.

Remove all interferences as found necessary to accomplish this work item. Upon completion of work, re-install all interferences.

Upon completion of the HP water washing and prior to the start of surface preparation take and record Dry Film Thickness readings of the existing coatings at a rate of one (1) spot reading per 500 SF. DFT gages shall be calibrated and spot readings shall be taken in accordance with SSPC-PA2, Measurement of Dry Coating Thickness With Magnetic Gages. Prepare a report showing the existing antifouling DFT. Assume that the DFT of the underlying anti-corrosive epoxy is an average of 11 mils. Submit the results of the DFT inspection to the MSCREP within 24 hours of completion.

Prior to initiating surface preparation the contractor shall ensure that the vessel's equipment is protected from damage caused by blasting abrasive, dust or paint. Measures to be taken include, but are not limited to, the following: Plug open ends of pipes, including sea connections, vents and ducts; Install protective covering on all impressed current anodes, reference cells, sacrificial anodes and transducers, propellers, exposed shafting and bow thruster propellers; Grease and wrap all valve stems and exposed portions of hydraulic cylinders. Install filters on all air intake vents. Install stack covers on the main and auxiliary uptakes. Install covers on all fuel tank vents; In the areas to be abrasive blasted and/or coated, record all ship's markings, including information, size and color; Overboard discharges for services which cannot be curtailed, such as reefer cooling water overboard, shall be carried-off by means of temporary scuppers, hoses, etcetera, in order to prevent recontamination of the hull after surface preparation; Protective covering shall be inspected at regular intervals, but not less than at the start of each work shift. Degraded protective covering shall be repaired prior to the restart of work. Contamination of the vessel and its equipment shall be reported to the MSCREP verbally immediately upon its discovery, followed by a written report within four (4) hours of the verbal notification. The contractor shall be responsible for cleaning the contaminated equipment and showing that the contamination has not caused damage to same. Cost to repair equipment damaged by such contamination shall be borne by the Contractor.

Paint material shall be stored within the paint manufacturer's recommended temperature range. When paint material is being applied, ensure that the material's temperature is within the manufacturer's recommended range for application, but in any case not less than 70o F.

Ensure the following conditions are met prior to painting: Surfaces shall be clean, dry and free of oil, grease or residue from abrasive blasting; The edges of the spot blasted areas shall be feathered-in; The surface appearance of the prepared surface shall meet the definition established by the cited surface preparation standard(s); Air and substrate temperatures shall be within the range published by the paint manufacturer; The ambient air and substrate temperatures must register at least 5o F. above the dew point temperature; The relative humidity is within the range set by the manufacturer’s product data sheet. In the event that there is no range established by the manufacturer, the relative humidity shall be no higher than 85 percent; No coating shall be applied at temperatures below 35o F. without prior written approval of the MSCREP; Painting shall not be performed between the hours of sunset and 0800 without prior written approval of the MSCREP; Any overspray shall have been removed prior to the application of the next coat of paint in the system; Material Safety Data Sheets for the product(s) being applied are on the job site and have been reviewed by the personnel involved.

Prior to application of any coating, the area to be painted shall be inspected and approved by the MSCREP and the Paint Representative. Inspection shall include surface preparation including cleanliness, and surface profile as determined by Keane-Tator Comparator (or equal) examination and/or replica tape, DFT readings of prior coats, etcetera, as applicable depending upon the current stage of coating application. This inspection includes not only the initial coat of paint, but all subsequent coats as well.

Regardless whether the surfaces are abrasive blasted or UHP Water Jetted, immediately prior to coating the surface shall be re-tested for non-visual surface contaminates at random locations to ensure that the surfaces have not been re-contaminated. If contamination is found, additional tests shall be made as necessary to determine the extent of contamination and to prove the success of remediation. Results of this testing shall be presented to the MSCREP at time of inspection for coating application.

If surface preparation is performed using abrasive blasting the maximum allowable contamination concentrations shall be less than 10 ug/cm2 of chloride contaminants as determined by field or laboratory analysis using reliable, reproducible test equipment. If UHP Water Jetting is utilized for surface preparation the limits established by NV-2 shall be met.

In areas spot prepared to bare metal, whether prepared by abrasive blasting, water jetting or other means, the edges of the surrounding intact coating shall be feathered-in.

DFT readings of the prior coat of paint shall be presented to the MSC Port Engineer at the time of inspection for coating. Spot readings shall be taken at a rate of five per 1,000 square feet. DFT gages shall be calibrated, spot readings shall be taken and DFT tolerances shall be in accordance with SSPC-PA2, Measurement of Dry Coating Thickness With Magnetic Gages.

Note: All coatings shall be allowed to air dry. The minimum and maximum times to recoat shall be in accordance with the manufacturer's recommendations.

Note: From the keel to the light load line, each coat of antifouling shall be alternately black and red. From the light load line to the deep load line, all anti-fouling coats shall be black.

Cut in the light load line and deep load line. Restore all hull markings (draft marks, plimsol marks, load line grids, bulkhead. markings, etcetera). Remove all protective coverings and re-install all interferences. Remove any paint which has adhered to normally unpainted items including, but not limited to, port lights, anodes, valve stems, etcetera. Anode shields damaged as a result of work performed under this item shall be repaired by the contractor at no additional expense to the government.

The contractor shall prepare a paint report and submit same to the MSCREP within three (3) days of completing the coating application. The report shall include the following data: The date, time and location of each coating application; The air and substrate temperatures, relative humidity and dew point temperature at the time of each coating application; Dry film thickness readings at a rate of five (5)spot readings per 1,000 sq. ft. of surface for each coat of paint. DFT gages shall be calibrated, spot readings shall be taken and tolerances for coating thickness shall be in accordance with SSPC-PA2, Measurement of Dry Coating Thickness With Magnetic Gages; The manufacturer, Product Identification Number and Batch Numbers for each coat of paint applied; Surface profile measurements of the spot abrasive blast cleaned metal substrate; Results of testing for non-visible surface contamination (soluble salts).

Upon completion the entire vessel shall be cleaned of all residues resulting from the surface preparation and painting operations.

B. Underwater Hull Surface Preparation Methods

The specific surface preparation method shall be identified in the base work item. Possible methods include the following:

1) Dry Abrasive Blasting

Accomplish abrasive blasting in accordance with Surface Preparation Standard, SSPC-SP10/NACE 2, Near White Metal Blast Cleaning to the area identified by the base work item. The blast profile achieved shall be angular in nature and within the range set by the manufacturer’s product data sheet for the coating system being applied. Profile shall be determined using a Keane-Tator (or equal) Surface Profile Comparator. Testex (or equal) Replica Tape shall be used at a rate of one (1) reading per 1,000 SF for verification. Replica Tape shall be mounted, identified as to location and included as part of the final paint report.

Prior to the start of abrasive blasting the blast media shall be tested to ensure that it is not contaminated with chlorides, as determined by field or laboratory analysis using reliable, reproducible test equipment.

Whether spot blasting for a maintenance re-coating or performing a full blast to re-new the coating system in its entirety will be identified in the base work item. Where spot blasting has been specified by the base work item, edges of adjacent intact coating shall be feathered-in.

2) Ultra High Pressure Water Jetting

Upon completion of high pressure water washing, accomplish surface preparation using ultra high pressure water jetting to the area identified by the base work item. Water jetting shall be performed in accordance with Surface Preparation Standard SSPC-SP12/NACE 5. All water jetted areas shall be prepared to a WJ-2, NV-2 Condition. No more than a light (L) grade flash rust shall be allowed on the steel at the time of coating application. If heavier flash rust is present, the surface shall be restored to a coatable condition by fresh water pressure washing at 2,500 to 3,000 psi and allowing it to dry or by other suitable means.

Whether spot water jetting for a maintenance re-coating or performing a full blast to re-new the coating system in its entirety will be identified in the base work item. Where spot water jetting has been specified by the base work item, edges of adjacent intact coating shall be feathered-in.

3) Sanding

Areas identified by inspection where the anti-fouling coating has either delaminated and peel-off from the anti-corrosive paint or simply worn off, leaving intact anti-corrosive paint, shall be lightly sanded/abraded to establish an anchor pattern in the intact coating.

4) Sandsweeping

If, as determined by inspection, the AF system has generally failed but the underlying anti-corrosive system is intact, the hull shall be sand-swept to remove all antifouling paint and to create an anchor pattern on the surface of the intact anticorrosive paint. The use of a fine grit abrasive and/or reduced air pressure to the blasting equipment is recommended. DO NOT BLOW THROUGH TO BARE METAL. In the event that areas to be sand-swept are taken down to bare metal in spots, those areas shall be spot blasted to near white metal, feathered in and spot coated with epoxy to restore the system integrity at no additional cost to the government.

C. Underwater Hull Preservation Methods

1) Initial Paint System Application

1. If required by the base work item, apply glass flake coating to high turbulence areas such as struts, rudders and sea chests.

2. Apply one (1) full coat of epoxy anti-corrosive paint to the entire underwater hull

3. If called-out by the base work item, apply a stripe coat to weldments and pitted areas.

4. Apply a second full coat of epoxy anti-corrosive paint to the entire underwater hull

5. When the second coat of epoxy is sufficiently cured, i.e. tacky, apply a full coat of black anti-fouling paint to the underwater hull from the keel to the DLL.

6. When the first coat of anti-fouling has cured, apply a second full coat of anti-fouling paint. From the keel to the LLL this second coat shall be red. From the LLL to the DLL, this second coat shall be black.

7. Paint-in all hull markings including draft marks, plimsol marks, load line grids, bulkhead, frame, and tank top markings, bow and stern thruster markings, sea chest and overboard discharge markings, etcetera.

2) Maintenance Recoat of Existing Paint System

1. If required by the base work item, apply glass flake coating to high turbulence areas such as struts, rudders and sea chests.

2. Apply one (1) spot coat of epoxy anti-corrosive paint to the bare metal areas of the underwater hull

3. If called-out by the base work item, apply a stripe coat to weldments and pitted areas.

4. Apply a second spot coat of epoxy anti-corrosive paint to the previously spot coated areas of the underwater hull.

5. When the second coat of epoxy is sufficiently cured, i.e. tacky, apply a spot coat of black anti-fouling paint to the spot coated areas of the underwater hull from the keel to the DLL.

6. When the first coat of anti-fouling has cured, apply a full coat of anti-fouling paint. Using the dry film thickness readings recorded of the existing anti-fouling paint (see Universal Requirements) for guidance, adjust the thickness of the full coat to bring the total AF film up to 11 – 12 mils. From the keel to the LLL this full coat shall be red. From the LLL to the DLL, this full coat shall be black.

7. Paint-in all hull markings including draft marks, plimsol marks, load line grids, bulkhead, frame, and tank top markings, bow and stern thruster markings, sea chest and overboard discharge markings, etcetera.

3) Replacement of Existing Anti-fouling Paint System

1. If required by the base work item, apply glass flake coating to high turbulence areas such as struts, rudders and sea chests.

2. Apply one (1) spot coat of epoxy anti-corrosive paint to the bare metal areas of the underwater hull

3. If called-out by the base work item, apply a stripe coat to weldments and pitted areas.

4. Apply a full coat of epoxy anti-corrosive paint to the previously spot coated areas of the underwater hull as well as those areas sand swept to remove a dead AF system.

5. When the full coat of epoxy is sufficiently cured, i.e. tacky, apply a full coat of black anti-fouling paint to the underwater hull from the keel to the DLL.

6. When the first coat of anti-fouling has cured, apply a second full coat of anti-fouling paint. From the keel to the LLL this full coat shall be red. From the LLL to the DLL, this full coat shall be black.

7. Paint-in all hull markings including draft marks, plimsol marks, load line grids, bulkhead, frame, and tank top markings, bow and stern thruster markings, sea chest and overboard discharge markings, etcetera.