0606_A_Flght_Deck_non-skid_Renewal_REV_A.docx

USNS WALLY SCHIRRA

(T-AKE 8)

FLIGHT DECK NON-SKID RENEWAL REV A

ABSTRACT:

1.1 This work item describes the removal and reinstallation of the non-skid surface from the Flight Deck and installation of deck markings to be applied to the Flight Deck.

REFERENCES/ENCLOSURES:

1.2 References:

1.2.1 Naval Ships’ Technical Manual (NSTM) Chapter 634 (“Deck Coverings”)

1.2.2 Naval Air Warfare Center Dwg 627928, Visual Landing Aids Installation TAK(E) Class Ships

1.2.3 NAVSEA Dwg 588-7488997 (H), Aviation Support Facilities

1.2.4 Surface Preparation Standard No. 10 (SSPC-SP-10) of the steel structures painting council manual

1.2.5 Surface Preparation Standard, SSPC-SP-12/NACE 5, Surface Preparation and Cleaning of Metals by Water jetting Prior to Recoating

1.2.6 Surface Preparation Standard SSPC-SP11, Power Tool Cleaning To Bare Metal

1.2.7 PPG Product Data Sheets, Amercoat 137, 138G, 229T and 240

1.2.8 Air Capable Ship Aviation Facilities Bulletin No. 1K

1.3 Enclosures:

1.3.1 Tie Down Fitting GO-NO GO Gauge

ITEM LOCATION/DESCRIPTION:

1.4 Location/Quantity:

1.4.1 Location:

a. Flight Deck, Main Deck

1.4.2 Quantity:

a. Approximately 12,500 square feet total.

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

1.5 Government Furnished Equipment (GFE): None.

1.6 Government Furnished Material (GFM):

1.7 Government Furnished Services (GFS):

1.7.1 PPG Coating Representative.

1.7.2 MSC-ATT (Aviation) Representative – (MSC_ATT.fct@navy.mil).

NOTES:

1.8 The Contractor and all subcontractors, regardless of tier, must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs.

1.9 The Contractor and all subcontractors regardless of tier are advised to review the other work items under this contract to determine their effect on the work required under this work item.

1.10 THIS SHIP CONTAINS HIGH VOLTAGE (HV) ELECTRICAL SYSTEMS. OBEY ALL POSTED AND VERBAL INSTRUCTIONS REGARDING SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME APPROACH, WORK ON, OR ENTER A HIGH VOLTAGE AREA WITHOUT PROPER AUTHORIZATION.

1.11 THE T-AKE CLASS ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND WHITE. ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED AND PROVEN OTHERWISE. TEST ALL ELECTRICAL CABLES TO ENSURE THEY ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

1.12 Solvents supplied as GFM are for viscosity control only. Solvents required for equipment clean-up are the responsibility of the contractor.

1.13 Flight Deck markings shall be chalked-in, inspected and approved by the attending NAVAIR Representative prior to painting of the new markings.

QUALITY ASSURANCE REQUIREMENTS: None Additional.

STATEMENT OF WORK REQUIRED:

1.14 WORK AREA PREPARATION:

1.14.1 Prior to start of work and with the assistance of Ship’s Force, conduct an operational test in the presence of the MSCREP of all flight deck aviation electronic and electrical gear, lighting, perimeter lights, recessed deck lights, flood and spot lights, including sprinklers, in the vicinity of flight deck areas identified for work, to demonstrate satisfactory operation. Document performance of test results noting “as-found” conditions. All deficiencies shall be submitted to the MSCREP for review.

1.14.2 Provide and erect all material and equipment to create a containment around the entire work area to ensure proper protection from weather and the environmental elements. Containment shall be properly ventilated to meet specifications required by paint manufacturer, and shall not vent into the skin of the ship.

1.14.3 Provide and erect all necessary staging required for proper working conditions and inspections.

1.14.4 Provide and maintain adequate lighting of a suitable nature during the course of all surface preparation, coating and inspection activities.

1.14.5 Remove, store and re-install all interferences as required to accomplish the work specified.

1.14.6 Temporarily install drop cloths, masking, division shields, seals, blanks and filtering materials to prevent abrasives and foreign substances from entering lights, machinery, piping, hatches, fork truck guards, deck drains, ventilation systems, tank vents, valve stems, motor shafts, seals and temporary openings during blasting and painting operations.

1.14.7 Prior to initiating surface preparation, ensure the vessels equipment is protected from damage caused by blasting, water jetting, dirt, dust, paint or other foreign matter. Measures to be taken but are NOT limited to are:

a. Plug open ends of pipes, vents, and ducts. (vents shall not be plugged without Ship’s Force approval)

b. Wrap all valve stems and exposed portions of hydraulic cylinders. Install filters, if required, on all air intake vents. Install covers on all fuel tank vents.

c. In areas to be abrasive blasted or water-jetted and coated, record all ships markings, including information size and color.

d. Install protective coverings on all port-lights, windows, light globes and landing light lenses to prevent damage to inadvertent water-jetting or other means of non-skid removal.

e. Mask all normally unpainted surfaces.

f. Protect running rigging (cargo falls, lifts, cranes, etc.) and mooring lines which cannot be stowed or removed for the duration of non-skid removal.

g. Sprinklers shall be covered with sheet metal disks to prevent damage during surface preparation and coating.

h. Prove all deck drains on Flight Deck are free and clear in the presence of the MSCREP before non-skid removal.

1.14.8 Prior to the start of productive work, protective coverings shall be inspected and approved by the MSCREP.

a. Deficiencies noted during this inspection shall be corrected and the MSCREP shall be given the opportunity to inspect and approve the corrective measures before work begins. Protective covering shall be inspected at regular intervals, but not less than the start of each work shift. Degraded covering shall be repaired prior to restart of work.

1.14.9 Contamination of the vessel and its equipment shall be reported to the MSCREP verbally immediately upon discovery. The Contractor shall be responsible for cleaning the contaminated equipment and showing that the contamination has not caused damage. Cost to repair equipment damage due to contamination shall be the Contractor's responsibility. All cleaning and repairs shall be to the satisfaction of the MSCREP.

1.15 SURFACE PREPARATION:

1.15.1 Areas to be surface prepared for coating shall include:

a. The entire flight deck inside the coaming (fish plate) and vertically 6" up the deck house, including all structure and protective guards inside this perimeter.

b. The entire flight deck coaming (fish plate), and surface from the coaming to the exterior edge of the deck, including all structure and protective guards inside this area.

c. The hanger and truck tunnel door troughs and grating.

1.15.2 Accomplish the requirements of SSPC, Protective Coating Society (formerly the Steel Structures Painting Council) SSPC-SP1, Solvent Cleaning, using biodegradable detergent to remove all oil, grease, dirt and soluble salts from the surface of the specified decks.

1.15.3 Final wash-down shall be made with clean, fresh water at 2,500 to 3,000 PSI. Upon completion of all water washing, chloride testing shall be performed at a rate of no less than one (1) test per 500 Square Feet of surface.

a. The maximum allowable contamination concentrations shall be less than 10 ug/cm2 of chloride contaminants and less than 20 ug/cm2 of soluble sulfate contaminates as determined by field or laboratory analysis using reliable, reproducible test equipment.

b. If contamination is found, additional water wash shall be performed. Additional tests shall be made as necessary to determine the extent of contamination and to prove the success of remediation.

1.15.4 Vacuum blast the entire flight deck area including deck tie down fittings to a SSPC-SP-10 Near White Metal with a 3-4.5 mil surface profile.

a. Blasting material recovery shall meet the local pollution control district regulations.

1.15.5 All areas being vacuum blasted may, with the MSCREP written approval, be prepared using ultra high pressure water jetting in lieu of vacuum blasting at no additional cost to the Government.

a. If allowed, water jetting shall be performed in accordance with SSPC-SP12/NACE 5.

b. All water jetted areas shall be prepared to a WJ-2 Condition. Non-visible surface cleanliness shall meet the definitions of NV-2 in Table A1.

1.15.6 The hanger and truck tunnel door trough grating shall be removed from the ship and taken to the shop for SSPC-SP-10 grit blasting to white metal.

1.15.7 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 pressure washed at 2,500 to 3,000 PSI and allowed to air dry in order to restore the surface to a paint-able condition.

1.15.8 Open abrasive blasting will not be permitted.

1.15.9 Accomplish the requirements of SSPC-SP-11 Power Tool Clean to Bare Metal those areas inaccessible to the vacuum-blast machines and approximately 6 inches up all vertical surfaces of bulkheads, deck houses, foundations, fan housings, and other appendages in way of the aforementioned areas to bare metal in accordance with Reference 2.1.6.

1.15.10 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 a rate of no less than one (1) test per 1,000 SF of prepared area.

a. The maximum allowable contamination concentrations for dry abrasive blasted surfaces shall be less than 10 ug/cm2 of chloride contaminants and less than 20 ug/cm2 of soluble sulfate contaminates as determined by field or laboratory analysis using reliable, reproducible test equipment. Results of this testing shall be presented to the MSCREP at the time of inspection for coating application. For UHP water jetted surfaces the requirements of Table A1, NV-2 shall apply.

b. If contamination is found, additional tests shall be made as necessary to determine the extent of contamination and to prove the success of re-mediation.

1.15.11 The surfaces shall be inspected and approved by the MSCREP prior to the application of each coat of paint or primer.

1.15.12 After completion of surface prep and prior to paint application, inspect all flight deck tie down fittings for bent or deformed crossbars, cracked welds, crossbar wear, corrosion and pitting. Fabricate a GO-NO-GO gauge in accordance with Encl 2.2.1. NOTE: Before using the GO-NO-GO gauge, verify its throat dimension meets dimensional requirements. Check the cross bar wear of each fitting shown in ref 2.1.3 by attempting to fit the throat of the GO-NO-GO gauge over the bar. Fittings are defective if the throat of the gauge goes over the bar at any position along the crossbar. Mark any fittings that fail the GO-NO-GO examination or have bent or deformed crossbars with a red X. A condition report shall be submitted to the MSC Rep with sketch showing the location of any failed, undersized or suspect fittings. It is anticipated that all tie downs are within specification.

1.16 COATING APPLICATION:

1.16.1 Prior to application of any coating, the area to be painted shall be inspected and approved by the MSCREP and the Paint Representative. This includes not only the initial coat of paint, but all subsequent coats as well. Inspection shall include measuring & recording:

a. Type of surface preparation used

b. Surface cleanliness

c. Surface profile as determined by Keane-Tator Comparator (or equal) examination and/or replica tape

d. Environmental conditions (surface temperature, ambient air temperature, dew point temperature and relative humidity)

e. Over coating interval (curing time) since previous application

f. Dry Film Thickness (DFT) of previous coating taken at a rate of five per 1,000 square feet.

1.16.2 Ensure the following conditions are met prior to painting:

a. Surfaces shall be clean, dry and free of oil, grease or residue from abrasive blasting.

b. Surface appearance meets the definition of SSPC-SP10, Near White Metal Blast Cleaning or SSPC-SP12/NACE 5 Surface Preparation of Steel and Other Hard Materials by High- and Ultra-High Pressure Water Jetting Prior to Recoating, WJ-2 Condition, as applicable.

c. Air and substrate temperatures shall be within the range published by the paint manufacturer, see ref 2.1.7.

Ambient Air temp during application & curing should be between:

· 40°F (4°C) and 110°F (43°C) for the Primer.

· 50°F (10°C) and 100°F (38°C) for the Non Skid.

· 40°F (4°C) and 120°F (49°C) for the Markings.

· Surface temp during application should be between:

· 40°F (4°C) and 120°F (49°C) for the Primer and Markings.

· 40°F (4°C) and 110°F (43°C) for the Non-Skid.

d. During application, the substrate temperature shall be at least 5°F (3°C) above Dew Point.

e. The Relative Humidity is within the range set by the manufacturer, shall not exceed 85%.

1.16.3 No coating shall be applied at temperatures below 40o F without prior written approval of the MSCREP.

1.16.4 No coating shall be applied between the hours of sunset and 0800 without prior written approval of the MSCREP.

1.16.5 All coatings shall be prepared and applied in accordance with the manufacturers requirements outlined in the Product Data Sheets, ref 2.1.7. Random Wet Film Thickness (WFT) readings are to be taken during the application of coatings to verify correct millage are being applied.

1.16.6 PRIMER:

a. Apply the following primer to blasted and power tool cleaned surfaces Primer coats must be applied by spraying in order to obtain a uniform DFT and coverage. Rolling the primer is NOT permitted.. A stripe coat is required between primer coats.

· One (1) full coat of Amercoat 137, (buff) at 5-6 mils DFT.

· One (1) stripe coat of Amercoat 137, (dark gray) at 2-3 mils DFT.

· One (1) stripe coat of Amercoat 137, (buff) at 2-3 mils DFT.

· One (1) full coat of Amercoat 137, (dark gray) 5-6 mill DFT.

b. Stripe coats shall be applied by brush to all weldments, crevices, corners, edges treads, pitted surfaces, tie-downs and other areas not conducive to proper coverage. Stripe coats shall extend a minimum of 1" from each edge of the area being stripe coated. SSPC-PA1, Paint Application Specification No 1 shall be used for guidance in stripe coating

1.16.7 NON-SKID:

a. Apply one coat of Amercoat 138G Non-Skid.

b. Amercoat 138G must be applied with a nap less phenolic roller in order to obtain the necessary raised ridge profile. Thinning is not permitted.

c. Apply at a rate of approximately 30 square feet per gallon.

d. The surface shall show a uniform pattern of peaks and ridges. The ridge profile shall be continuous and reasonably uniform. Peaks and ridges shall be generally in the same direction (fore-aft preferred), approximately 1/2 to 1 inch apart, and approximately 1/16 to 3/32 inch high. Aggregate shall present a rough, uniformly coarse appearance over the entire surface with no loosely bound clumps of particles.

e. All longitudinal weld seams shall be cross-rolled, perpendicular to the direction of peaks and valleys of the non-skid, 3 to 6 inches minimum on either side of the weld, and welds 8 inches or less apart shall be treated as one weld.

f.

g. Before the start of production application of any non-skid coating, a test patch will be applied. This test patch will be agreeable to the MSCREP and will stand as a "texture and profile" standard for the entire job.

h. Non-skid shall be applied to within approximately 2” of all deck fittings and protrusions and approximately 5” off deck coaming and edges.

1.17 DECK EDGES, TRIM, GUTTERS, AND TIE DOWNS:

1.17.1 Borders around the deck edge, around foundations, tie downs, trough area, and other areas that normally do not receive non-skid coating shall be top-coated with one (1) coat of Amercoat 240 (dark gray), 5-6 mils DTF.

1.17.2 Vertical surfaces shall be top-coated to match the surrounding area. Dado lines shall be cut in straight, level and even.

1.17.3 In shop, spray the grating with at least two (2) coats of Amercoat 240 (dark gray). Each coat should be min of 5-6 mils DFT, for a total of at least 10 mils DFT. Reinstall grating.

1.18 MARKINGS:

1.18.1 Lay out the original Flight Deck markings using Reference 2.1.2 and 2.1.8 as a guide.

1.18.2 MSCREP and MSC-ATT (Aviation) Rep are to inspect, verify and approve the chalk lines prior to application of any paint coating to the markings.

a. This inspection shall be coordinated with the MSCREP no less than 14-days prior.

1.18.3 After approval, apply one (1) coat Amercoat 229T (White) at 2-3 mils DFT to all flight deck markings.

1.19 During the course of all surface preparation and coating operations, the area involved shall be roped off or otherwise barricaded to prevent entry by persons other than those directly involved in the work underway or those inspecting same. Those persons who are allowed in the work area shall wear disposable booties over their shoes to prevent contamination of the surface. New booties shall be put on each time a person enters the area. Such cordoning or barricading shall remain in place until the non-skid and color markings are properly cured.

1.20 Remove all protective coverings, debris and replace all interferences removed in the performance of this item. Upon completion the vessel shall be cleaned of all residues resulting from the surface preparation and painting operations.

1.21 Upon completion of work, ship force shall conduct final operational testing of ALL flight deck aviation line up lights, perimeter lights, recessed deck lights, flood and spot lights, sprinkler heads and drains in the vicinity of the flight deck work completed. Contractor and ship force shall compare "post work" performance test results to the "as-found" conditions previously recorded in para 7.2.2. Contractor shall be responsible for correcting any discrepancies noted between the “as found” and “post work” conditions. All repaired items shall be satisfactorily re-demonstrated to ship force and MSCREP.

1.22 Preparation of Drawings:

1.22.1 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:

a. The location, date and time of each coating application.

b. The air and substrate temperatures, relative humidity and dew point temperature at the time of each coating application.

c. Interval between coatings.

d. 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 and spot readings shall be taken in accordance with SSPC-PA2, Measurement of Dry Coating Thickness With Magnetic Gages.

e. Paint Manufacturer, Product Identification Number, color and Batch Numbers for each coat of paint applied.

f. Surface profile measurements of the metal substrate.

g. Results of testing for nonvisible surface contaminants (soluble salts).

1.23 Manufacturer's Representative:

1.23.1 Coating Representative:

a. A Coating Technical Representative will be in attendance, on the governments’ account, to observe the surface preparation and coating application and to advise the MSCREP as to the quality and the appropriateness of the Contractor's efforts. This representative may perform inspections designated for the MSCREP.

1.23.2 MSC-ATT (Aviation) Representative:

a. A MSC-ATT (Aviation) Representative, on the governments’ account, shall attend the vessel to inspect the alignment and painting of the deck markings and the profile of non-skid for conformance to NAVAIR regulations. The Contractor shall provide a minimum of 48 hours advance notice to the MSCREP in order to arrange attendance of the NAVAIR Representative.

GENERAL REQUIREMENTS: None Additional.

ENCLOSURE 2.2.1 – GO-NO GO Gauge

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