09 97 02.pdf

Braddock and Charleroi L/D's, Painting Tainter Gates

SECTION TABLE OF CONTENTS

DIVISION 09 - FINISHES

SECTION 09 97 02

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 GENERAL REQUIREMENTS

1.3.1 Painting

1.3.1.1 Charleroi Locks and Dam

1.3.1.2 Braddock Locks and Dam

1.3.2 Existing Lead Paint

1.3.3 Access Hatches

1.3.4 Removal and Reinstallation of End Shields and Debris Shields

1.3.5 Removal of Magnesium Anodes

1.3.6 Electric Gate Heaters

1.3.7 Existing Paint Systems

1.3.8 Exposure Monitoring

1.4 QUALIFICATIONS

1.4.1 Certified Professional

1.4.2 Certified Laboratory

1.4.3 Qualified Painting Contractor

1.4.4 Qualified Paint Applicator

1.4.4.1 Test Plate

1.4.4.2 Certification Test Procedure

1.4.4.3 Certification Criteria

1.4.5 Coating Thickness Gage Qualification

1.5 SAFETY AND HEALTH PROVISIONS

1.5.1 Abrasive Blasting

1.5.1.1 Hoses And Nozzles

1.5.1.2 Workers Other Than Blasters

1.5.2 Cleaning with Compressed Air

1.5.3 Cleaning with Solvents

1.5.3.1 Ventilation

1.5.3.2 Personal Protective Equipment

1.5.4 Mixing Polyurethane Resin Formulations

1.5.4.1 Exhaust Ventilation

1.5.4.2 Personal Protective Equipment

1.5.4.3 Medical Precautions

1.5.4.4 Emergency Equipment

1.5.5 Paint Application

1.5.5.1 Ventilation

1.5.5.2 Explosion Proof Equipment

1.5.5.3 Further Precautions

1.5.5.4 Ignition Sources

1.5.6 Health Protection

1.5.6.1 Air Sampling

1.5.6.2 Respirators

1.5.6.3 Protective Clothing and Equipment

SECTION 09 97 02 Page 1 W911WN-09-B-0006 Revised by Amendment No. 2

1.6 MEDICAL STATUS

1.7 CHANGE IN MEDICAL STATUS

1.8 ENVIRONMENTAL PROTECTION

1.8.1 Waste Classification, Handling, and Disposal

1.8.2 Containment

1.8.2.1 Special Provisions

1.8.3 Air Quality Monitoring

1.8.3.1 TSP Monitoring

1.8.4 Water Quality

1.9 PAINT PACKAGING, DELIVERY, AND STORAGE

PART 2 PRODUCTS

2.1 MOISTURE CURE POLYURETHANE COATINGS

2.1.1 Performance Requirements

2.1.2 Primer

2.1.3 Intermediate Coat

2.1.4 Top Coat

2.1.4.1 Top Coat for Gate Structure Not Subject to Immersion

2.1.4.2 Top Coat for Gate Structure Subject to Immersion

2.2 SEAL COATING FOR METALLIZED SURFACES

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

3.1.2 Non-Metallized Ferrous Surfaces Subject to Severe Exposure

3.1.3 Top Compartment of Bottom Unit of Movable-Crest Tainter Gates

3.1.4 High Pressure Water Jetting

3.1.5 Metallized Surfaces

3.2 PAINT APPLICATION

3.2.1 General

3.2.2 Mixing and Thinning

3.2.3 Atmospheric and Surface Conditions

3.2.4 Time Between Surface Preparation and Painting

3.2.5 Method of Paint Application

3.2.6 Coverage and Film Thickness

3.2.6.1 Measurement on Ferrous Metal

3.2.7 Progress of Painting Work

3.2.8 Curing Time Prior to Immersion

3.2.9 Protection of Painted Surfaces

3.2.10 Proprietary Paint Systems

3.3 PAINT SYSTEMS APPLICATION

3.3.1 Surface Preparation

3.3.2 Systems No. LRP35.1

3.3.3 Protection of Nonpainted Items and Cleanup

3.4 INSPECTION

3.5 PAINTING SCHEDULES

3.5.1 Finish Colors

3.6 SURFACES NOT TO BE PAINTED

-- End of Section Table of Contents --

SECTION 09 97 02 Page 2

SECTION 09 97 02

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN SOCIETY OF SAFETY ENGINEERS (ASSE/SAFE)

ASSE/SAFE Z87.1 (2003) Standard for Occupational and Educational Eye and Face Protection

ASTM INTERNATIONAL (ASTM)

ASTM B 117 (2007a) Standing Practice for Operating Salt Spray (Fog) Apparatus

ASTM D 2247 (2002) Testing Water Resistance of Coatings in 100% Relative Humidity

ASTM D 2794 (1993; R 2004) Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact)

ASTM D 4060 (2007) Abrasion Resistance of Organic Coatings by the Taber Abraser

ASTM D 4417 (2003) Field Measurement of Surface Profile of Blast Cleaned Steel

ASTM D 4541 (2002) Pull-Off Strength of Coatings Using Portable Adhesion Testers

ASTM D 522 (1993a; R 2008) Mandrel Bend Test of Attached Organic Coatings

ASTM D 7091 (2005) Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nondestructive Coatings Applied to Non-Ferrous Metals

ASTM G 53 (1996) Operating Light- and Water-Exposure Apparatus (Fluorescent UV-Condensation Type) for Exposure of Nonmetallic Materials

INTERNATIONAL SAFETY EQUIPMENT ASSOCIATION (ISEA)

ISEA Z358.1 (2004) Emergency Eyewash and Shower

SECTION 09 97 02 Page 3

Equipment

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2007; AMD 1 2008) National Electrical Code - 2008 Edition

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH (NIOSH)

NIOSH 98-119 (1998; 4th Ed) Supplement 2 to NIOSH Manual of Analytical Methods

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC Guide 6 (2004) Guide for Containing Debris Generated During Paint Removal Operations

SSPC QP 1 (1998; E 2004) Standard Procedure for Evaluating Painting Contractors (Field Application to Complex Industrial Structures)

SSPC SP 1 (1982; E 2004) Solvent Cleaning

SSPC SP 12 (2002) Surface Preparation and Cleaning of Metals by Waterjetting Prior to Recoating

SSPC SP 5 (2007) White Metal Blast Cleaning

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2008) Safety and Health Requirements Manual

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

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1910.134 Respiratory Protection

29 CFR 1910.146 Permit-required Confined Spaces

29 CFR 1910.20 Access to Employee Exposure and Medical Records

29 CFR 1910.94 Ventilation

29 CFR 1926 Safety and Health Regulations for Construction

29 CFR 1926.62 Lead

40 CFR 117 Determination of Reportable Quantities for Hazardous Substances

40 CFR 122 EPA Administered Permit Programs: The National Pollutant Discharge Elimination System

SECTION 09 97 02 Page 4

40 CFR 261 Identification and Listing of Hazardous Waste

40 CFR 262.22 Number of Copies

40 CFR 263 Standards Applicable to Transporters of Hazardous Waste

40 CFR 302 Designation, Reportable Quantities, and Notification

40 CFR 355 Emergency Planning and Notification

40 CFR 50 National Primary and Secondary Ambient Air Quality Standards

40 CFR 58 Ambient Air Quality Surveillance

49 CFR 171 General Information, Regulations, and Definitions

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Safety and Health Provisions; G, RE

An Accident Prevention Plan in accordance with the requirements of Section 01 of EM 385-1-1. The plan shall include, but is not limited to, each of the topic areas listed in Appendix A therein and the specified requirements; each topic shall be developed in a concise manner to include management and operational aspects.

Confined Spaces; G, RE

Detailed written standard operating procedures for confined spaces in accordance with 29 CFR 1910.146 and EM 385-1-1, Section 6I. The procedures shall include:

a. Certificates of calibration for all testing and monitoring equipment. The certificates of calibration shall include: type of equipment, model number, date of calibration, firm conducting calibration, and signature of individual certifying calibration.

b. Methods of inspection of personal protective equipment prior to use.

c. Work practices and other engineering controls designed to reduce airborne hazardous chemical exposures to a minimum.

d. Specification of the design and installation of ventilation systems which shall provide adequate oxygen content and provide for the dilution of paint solvent vapor, lead, and other toxic

SECTION 09 97 02 Page 5 particulates within the confined space. In addition, include plans to evaluate the adequacy of air flow patterns.

Respirators; G, RE

A comprehensive written respiratory protection program in accordance with 29 CFR 1910.134, 29 CFR 1926.62, and Section 05.E of EM 385-1-1.

Certified Laboratory; G, RE

An Airborne Sampling Plan detailing the NIOSH 98-119, Factory Mutual, or Underwriters Laboratories approved equipment, equipment calibration procedures, sampling methods, sampling to be performed, and analytical procedures to be used based on the type of work to be performed and anticipated toxic contaminants to be generated. Include the name of the accredited laboratory, listed by the American Industrial Hygiene Association (AIHA), to be used to conduct the analysis of any collected air samples.

Government-Approved Independent Third Party Test Agency; G, RE

Prior to testing or certification or applicator qualifications, a statement of qualifications and experience for the test agnecy.

Ventilation; G, RE

A plan to provide ventilation assessment.

Medical Status; G, RE

A Medical Surveillance Plan and a statement from the examining physician indicating the name of each employee evaluated and any limitations which will preclude the employee from performing the work required. The statement shall include the date of the medical evaluation, the physician's name, signature, and telephone number.

Lead-Based Paint Removal; G, RE

A Worker Protection Plan in accordance with the requirements of 29 CFR 1926.62. The plan shall address all necessary aspects of worker protection and shall include activities emitting lead, means to achieve compliance, alternative technologies considered, air monitoring program, implementation schedule, work practice program, administrative controls, multiContractor site arrangements, and jobsite inspections.

Environmental Protection; G, RE

An Environmental Compliance Plan. The plan shall incorporate the submittals for Water Quality Plan, Ambient Air Monitoring Plan, and Visible Emissions Monitoring Plan. The submitted plan shall also address all aspects of establishing and demarcating regulated areas, ventilation/containment system performance verification, and reporting of accidental releases.

Containment; G, RE

SECTION 09 97 02 Page 6

A plan for containing debris generated during paint removal operations. The plan shall include drawings, load-bearing capacity calculations, and wind load calculations. When the design is such that the spent abrasive is allowed to accumulate in quantities greater than 1,000 pounds, and/or impart a significant wind load on the structure, the Contractor shall have the drawings approved by a registered structural engineer. The drawings and calculations shall be stamped with the engineer's seal. Also identify the type and placement of water booms, methods for anchoring the booms, and the procedures for removing debris.

Water Quality; G, RE

A Water Quality Plan for all job sites where lead-containing or other hazardous paint will be removed. The plan shall include provisions for halting work if spills or emissions are observed entering into bodies of water or found in areas where storm water runoff could carry the debris into bodies of water or storm sewers. The plan shall also address cleanup and reporting procedures.

SD-04 Samples

Proprietary Paints and Thinners; G, RE

Proprietary paints are any which do not follow the complete specification requirements of Federal, Military, and Steel Structures Painting Council specifications but meet the performance requirements specified in these specifications.

Samples of polyurethane coating shall be submitted within 30 days of receipt of Notice to Proceed to permit adequate time for testing by the Government. To receive consideration, a statement from the supplier that the paint is appropriate as to type, color, and gloss and is a premium grade of paint shall be furnished. The following information shall also be furnished:

a. Test results indicating acceptable performance under the exposure conditions specified.

b. A list of projects at which the paints have been in service for at least 5 years, along with names, addresses, and telephone numbers of points of contact for the project owner or operator.

c. Special surface preparation, application, or environmental requirements for proper performance under the specified exposure conditions.

Solvent and Thinners; G, RE

Samples of the thinners or solvents used to reduce the viscosity of the paint.

SD-06 Test Reports

TSP Monitoring; G, RE

Reports of the TSP monitoring tests.

SECTION 09 97 02 Page 7

Certified Laboratory; G, RE

Reports of airborne sampling tests.

Inspection; G, RE

Records of inspections and operations performed. Submittals shall be made on a daily basis.

SD-07 Certificates

Qualifications; G, RE

Certification for all job sites. Submittal of the qualifications and experience of any additional qualified and competent persons employed to provide on-site environmental, safety, and health shall also be provided. Acceptance of this submission must be obtained prior to the submission of other required environmental, safety, and health submittal items.

Qualified Painting Contractor; G, RE

A copy of their current SSPC QP 1 certification.

Coating Thickness Gage Qualification; G, RE

Documentation of manufacturer's certification shall be submitted for all coating thickness gages.

1.3 GENERAL REQUIREMENTS

1.3.1 Painting

The following surfaces of the tainter gates and bulkheads at Charleroi Locks and Dam and tainter gates at Braddock Locks and Dam shall be painted. Areas to be metallized and painted are indicated on the sketches attached to Section 09 97 01.00 10 METALLIZING; HYDRAULIC STRUCTURES.

1.3.1.1 Charleroi Locks and Dam

a. Non-Overflow Gates (Gates Nos. 3 and 4. All ferrous surfaces shall be blast cleaned to white metal grade and painted with the paints specified. The bottom and upstream faces of the gates shall be metallized as specified in Section 09 97 01.00 10 METALLIZING;

HYDRAULIC STRUCTURES.

b. Movable-Crest Gates (Gates Nos. 1, 2 and 5). All ferrous surfaces of the top units, all exterior ferrous surfaces of the bottom units, and the interior bottom compartment shall be blast cleaned to white metal grade and painted with the paints specified. The exterior bottom and upstream faces of the gates shall be metallized as specified in Section 09 97 01.00 10 METALLIZING; HYDRAULIC STRUCTURES. The interior top compartments of the bottom units of the movable-crest gates shall be spot cleaned and touchup painted in those areas where the existing paint is deteriorated. The areas to be touchup painted will be marked on the surface by the Contracting Officer prior to beginning surface preparation.

c. Bulkhead Units. All ferrous surfaces of the bulkhead units at

SECTION 09 97 02 Page 8

Charleroi Locks and Dam shall be blast cleaned to white metal grade and painted with the paints specified.

1.3.1.2 Braddock Locks and Dam

a. Water Quality Gate (Gate No. 1) and Non-Overflow Gates (Gates Nos.

2, 3 and 4). The bottom and upstream faces of the gates shall be metallized as specified in Section 09 97 01.00 10 METALLIZING;

HYDRAULIC STRUCTURES. The metallized surfaces, and any adjacent surfaces on which the existing paint coating is damaged by the cleaning and metallizing operations shall be cleaned and painted with the paints specified.

1.3.2 Existing Lead Paint

The paint system used at various times for touchup on the interior of the bottom units and repair of portions of the interior of the top units of the moveable-crest tainter gates at Charleroi Locks and Dam is known to include one coat of red lead primer (FS TT-P-86, Type I) and two coats of linseed -tung oil, phenolic aluminum paint. The actual amount of such touchup is unknown. The blast media and debris from all areas shall be tested as specified in Section 02 42 00 DISPOSAL OF MATERIALS, paragraph WASTE

CLASSIFICATION, HANDLING, AND DISPOSAL.

Although the vinyl paint system applied to the gates at Charleroi Locks and Dam when last painted does not contain lead, samples of the paint from similar gates have been found to contain lead. This lead is believed to be an impurity in the zinc-rich vinyl first coat.

Initial exposure monitoring, to determine if the OSHA Action Level or Permissible Exposure Limit for lead exposure are exceeded, shall be performed when performing surface preparation for the removal of paint in each area. This monitoring shall be as specified in paragraph WORKER PROTECTION PER OSHA CONSTRUCTION INDUSTRY STANDARD, subparagraph Exposure Monitoring. The safety and health requirements of this section are applicable to all work performed on the interior of the bottom units of the moveable-crest gates. The remaining areas are not anticipated to result in lead exposure above the Permissible Exposure Limit, however, the applicability of the specific safety and health requirements of this section to the work in these areas will be determined by the results of the initial monitoring. Payment for application of safety and health provisions for lead exposure to areas which are not anticipated to have lead exposure above the Permissible Exposure Limit, but which is required because testing indicates exposure above the Permissible Exposure Limit, will be made in accordance with Section 00700 CONTRACT CLAUSES, paragraph Changes. Environmental protection requirements of this section shall apply regardless of the results of exposure monitoring.

1.3.3 Access Hatches

The gratings in the bottom of the movable-crest gates at Charleroi Locks and Dam may be removed for access and cleaning and painting and reinstalled upon completion of the work. New stainless steel cap screws shall be used for reinstallation of the gratings.

1.3.4 Removal and Reinstallation of End Shields and Debris Shields

The side frames of the bottom units of the movable-crest tainter gates at Charleroi Locks and Dam are enclosed with 3/8-inch steel plates bolted to

SECTION 09 97 02 Page 9 the structural members of the side frames. The bottom area of the non-overflow crest gates at Charleroi Locks and dam are enclosed with 1/4-inch steel plates bolted to the structural members on the downstream face. These plates must be removed to permit cleaning and painting of these portions of the gate structure. The plates shall be carefully removed, cleaned and painted, and replaced. New cap screws shall be furnished for reinstallation of the end shields. Cap screws for bolting the plates to the side frames shall be stainless steel conforming to the requirements of paragraph SCREWS, and shall be painted after installation.

1.3.5 Removal of Magnesium Anodes

Magnesium anodes are attached to the upstream face of the skin plate and the bottom of the gates at Charleroi Locks and Dam. The anodes on the skin plate are protected by protective shields welded to the gate above the anodes. The Contractor shall carefully remove the anodes from each gate prior to cleaning the gate and dispose of the anodes in accordance with Federal, State and local laws and regulations. All mounting studs and protection angles shall be completely removed, and the remaining weld surfaces shall be ground flush with the adjacent surface.

1.3.6 Electric Gate Heaters

Electric gate heaters are provided in the top compartment of the bottom unit of the moveable-crest tainter gates at Charleroi Locks and Dam as shown on reference Drawing No. 037-L4-56/9.1. The gate heater units and the cables connecting them shall be protected during surface preparation and painting operations. Any damage to the gate heaters or cables caused by the Contractor's operations shall be repaired to the satisfaction of the Contracting Officer at no additional cost to the Government. The Contractor shall coordinate lock-out of the gate heaters with the Lockmaster in accordance with EM 385-1-1, Section 12.

1.3.7 Existing Paint Systems

In general, and except for the areas mentioned in paragraph Existing Lead Paint, the tainter gates at Charleroi Locks and Dam are painted with vinyl paint systems. The gates and bulkhead units have been painted at various times with the following systems:

a. Original paint applied at time of construction - These areas were painted at the time of construction with five coats of Corps of Engineers formula V-766 vinyl paint. The original paint remains on the interior of the bottom unit of the movable-crest tainter gates and areas of the top unit and non-overflow tainter gates which were touch-up painted in 1981-82 as described in subparagraph b. The specified average dry film thickness was 7.5 mils.

b. The following areas were painted in 1981-82 with three coats of Corps of Engineers formula V-766e vinyl paint, with alternating coats of white and gray and two coats of Corps of Engineers formula V-102d aluminum vinyl paint:

Moveable-Crest tainter gates - all exterior surfaces of the bottom unit, including trunnion arms

Moveable-Crest tainter gates - upstream face of skinplate of the top unit

SECTION 09 97 02 Page 10

Non-overflow tainter gates - upstream face of skin plate and surfaces of the downstream skin plate and framing below the bottom girder

Other areas of the top unit of the moveable-crest tainter gates and the non-overflow tainter gates where the existing vinyl paint system was deteriorated - The entire gate surface, including existing vinyl paint which was not removed, received the two coats of aluminum vinyl paint. The specified total dry film thickness was 6.0 mils.

c. Upstream face of skin plate of movable-crest and non-overflow tainter gates - These areas were painted in 1985 with one coat of Corps of Engineers formula VZ-108d zinc-rich vinyl paint and four coats of Corps of Engineers formula V-766e vinyl paint with alternating coats of white and gray, specified average dry film thickness of 7.5 mils.

d. Bulkhead units - The bulkhead units were painted in 1987 with one coat of Corps of Engineers formula VZ-108d zinc-rich vinyl paint and three coats of Corps of Engineers formula V-766e vinyl paint with alternating coats of white and gray, specified total dry film thickness of 7.0 mils.

The tainter gates at Braddock Locks and Dam were coated with one of two systems. Areas subject to immersion were metallized with 85-15 Zinc-Aluminum with a specified thickness of 14 to 16 mils and painted with three coats of micaceous iron oxide aliphatic polyurethane with a specified average dry film thickness of 9 mils. Areas not subject to immersion were painted with a system consisting of moisture cure zinc-rich polyurethane base coat, micaceous iron oxide aromatic polyurethane intermediate coat and micaceous iron oxide aliphatic polyurethane top coat with a specified average dry film thickness of 9 mils.

The average film thickness was as specified, however, the actual thickness of the existing paint coating may vary considerably from this.

1.3.8 Exposure Monitoring

Personal air samples shall be collected to determine lead exposures of employees performing tasks involving lead exposure. Full shift air samples shall be collected for each job classification in the exposure area. Where initial monitoring indicates that lead exposures are below the Action Level, and where work activities and conditions will remain the same as at the time of initial sampling, additional monitoring need not be repeated for that work activity. Where initial monitoring indicates that lead exposures are at or above the Action Level, additional representative exposure monitoring shall be conducted at the frequencies established in 29 CFR 1926.62 d. For example, quarterly if the results are above the PEL. Representative monitoring shall be conducted at the beginning of work on each gate, and when changes occur (e.g. an increase in the number of blasters in an area). The range of exposures for lead removal and cleanup activities shall be determined. All air samples shall be collected and analyzed according to NIOSH 7082 Method, or equivalent. All samples shall be analyzed by laboratories accredited by the American Industrial Hygiene Association for metals analysis. All exposed employees shall be notified in writing of the monitoring results within five days after receiving the results.

SECTION 09 97 02 Page 11

1.4 QUALIFICATIONS

Qualifications and experience shall comply with the following.

1.4.1 Certified Professional

Utilize a qualified and competent person as defined in Section 01 of EM 385-1-1 to develop the required safety and health submittal and to provide on-site safety and health services during the contract period. The person shall be a Certified Industrial Hygienist (CIH), an Industrial Hygienist (IH), or a Certified Safety Professional (CSP) with a minimum of 3 years of demonstrated experience in similar related work. Certify that the Certified Industrial Hygienist (CIH) holds current and valid certification from the American Board of Industrial Hygiene (ABIH), that the IH is considered board eligible by written confirmation from the ABIH, or that the CSP holds current and valid certification from the American Board of Certified Safety Professionals. The CIH, IH, or CSP may utilize other qualified and competent persons, as defined in EM 385-1-1, to conduct on-site safety and health activities as long as these persons have a minimum of 2 years of demonstrated experience in similar related work and are under the direct supervision of the CIH, IH, or CSP. For lead containing jobsites, the competent and qualified person shall have successfully completed an EPA or state accredited lead-based paint abatement Supervisor course specific to the work to be performed and shall possess current and valid state and/or local government certification, as required.

1.4.2 Certified Laboratory

Provide documentation which includes the name, address, and telephone number of the laboratories to be providing services. In addition, the documentation shall indicate that each laboratory is an EPA National Lead Laboratory Accreditation Program (NLLAP) accredited laboratory and that each is rated proficient in the NIOSH/EPA Environmental Lead Proficiency Analytical Testing Program (ELPAT)and will document the date of current accreditation. Certification shall include accreditation for heavy metal analysis, list of experience relevant to analysis of lead in air, and a Quality Assurance and Quality Control Program.

1.4.3 Qualified Painting Contractor

The Contractor shall be a certified SSPC-QP 1 Painting Contractor.

1.4.4 Qualified Paint Applicator

Documentation of certification shall be submitted for all paint applicators. Prior to the initiation of any work all paint applicators shall be tested and certified as meeting the requirements of the qualified paint applicator. Certification shall be administered by the CQC System Manager, if not employed by the prime contractor, or by a Government-approved independent third party Test Agency. Applicators failing the certification test shall not be permitted to apply any paint on the project.

1.4.4.1 Test Plate

The test plate shall consist of a 6 by 6 feet steel plate with a 3/8 inch minimum thickness. The test plate shall have at least six bolts, three with bolt heads exposed and three with threads exposed, a 12-inch wide

SECTION 09 97 02 Page 12 flange and a 6-inch diameter pipe each 18 inches long welded perpendicular to the test panel and a 6-inch deep T-beam with sealed ends welded horizontal across the test panel one foot up from the bottom all within the area to be painted on one side. Bolts shall be 1 inch minimum diameter.

1.4.4.2 Certification Test Procedure

Certification testing of paint applicators shall be conducted at the job site in coordination with the Contracting Officer. Supply the fabricated test plates to be used for the tests and shall provide crane service, rigging, and any other work necessary to provide accessibility for the certification testing and inspection. In preparation, clean and prepare the test plates in accordance with the requirements of the contracted work. Abrasive blasting shall be performed with the blast media to be used in the contract. The paints to be applied shall be the Contractor supplied materials and shall be those previously tested and approved for use on the contract. Paints shall be applied as specified in the contract. The painter being tested shall mix and thin the paints to be used in the test and shall set up and adjust the application equipment for use. Each painter shall apply each of the types of paint comprising the specified system. The test plate shall be painted in a near vertical position.

1.4.4.3 Certification Criteria

The paint applicator shall be evaluated based on the conformance of the applied paint system to the requirements of the specifications.

Deficiencies in the coatings, improper mixing or improper application methods are basis for failure. The CQC System Manager, if not employed by the prime contractor, or the Government-approved independent third party Test Agency shall be the sole judge as to the acceptability of each paint applicators performance.

1.4.5 Coating Thickness Gage Qualification

Documentation of certification shall be submitted for all coating thickness gages. Magnetic flux thickness gages as described in ASTM D 7091 shall be used to make all coating thickness measurements on ferrous metal substrates. Gages shall have an accuracy of +/- 3 percent or better.

Gages to be used on the job shall be certified by the manufacturer as meeting these requirements.

1.5 SAFETY AND HEALTH PROVISIONS

Work shall be performed in accordance with the requirements of 29 CFR 1910, 29 CFR 1926, EM 385-1-1, and other references as listed herein. Matters of interpretation of the standards shall be submitted to the Contracting Officer for resolution before starting work. Where the regulations conflict, the most stringent requirements shall apply. Paragraph SAFETY AND HEALTH PROVISIONS supplements the requirements of EM 385-1-1, paragraph (1). In any conflict between Section 01 of EM 385-1-1 and this paragraph, the provisions herein shall govern.

1.5.1 Abrasive Blasting

Comply with the requirements in Section 06.H of EM 385-1-1.

1.5.1.1 Hoses And Nozzles

In addition to the requirements in Section 20 of EM 385-1-1, hoses and hose

SECTION 09 97 02 Page 13 connections of a type to prevent shock from static electricity shall be used. Hose lengths shall be joined together by approved couplings of a material and type designed to prevent erosion and weakening of the couplings. The couplings and nozzle attachments shall fit on the outside of the hose and shall be designed to prevent accidental disengagement.

1.5.1.2 Workers Other Than Blasters

Workers other than blasting operators working in close proximity to abrasive blasting operations shall be protected by utilizing MSHA/NIOSH-approved half-face or full-face air purifying respirators equipped with high-efficiency particulate air (HEPA) filters, eye protection meeting or exceeding ASSE/SAFE Z87.1 and hearing protectors (ear plugs and/or ear muffs) providing a noise reduction rating of at least 20 dBA or as needed to provide adequate protection.

1.5.2 Cleaning with Compressed Air

Cleaning with compressed air shall be in accordance with Section 20.B.5 of EM 385-1-1 and personnel shall be protected as specified in 29 CFR 1910.134.

1.5.3 Cleaning with Solvents

1.5.3.1 Ventilation

Ventilation shall be provided where required by 29 CFR 1910.146 or where the concentration of solvent vapors exceeds 10 percent of the Lower Explosive Limit (LEL). Ventilation shall be in accordance with 29 CFR 1910.94, paragraph (c)(5).

1.5.3.2 Personal Protective Equipment

Personal protective equipment shall be provided where required by 29 CFR 1910.146 and in accordance with 29 CFR 1910, Subpart I.

1.5.4 Mixing Polyurethane Resin Formulations

1.5.4.1 Exhaust Ventilation

Local exhaust ventilation shall be provided in the area where the curing agent and resin are mixed. This ventilation system shall be capable of providing at least 100 linear fpm of capture velocity measured at the point where the curing agent and resin contact during mixing.

1.5.4.2 Personal Protective Equipment

Exposure of skin and eyes to resin components shall be avoided by wearing appropriate chemically resistant gloves, apron, safety goggles, and face shields meeting or exceeding the requirements of ASSE/SAFE Z87.1.

1.5.4.3 Medical Precautions

Individuals who have a history of sensitivity to polyurethane resin systems shall be medically evaluated before any exposure can occur. Individuals who are medically evaluated as exhibiting a sensitivity to resins shall not conduct work tasks or otherwise be exposed to such chemicals. Individuals who develop a sensitivity shall be immediately removed from further exposure and medically evaluated.

SECTION 09 97 02 Page 14

1.5.4.4 Emergency Equipment

A combination unit, comprised of an eyewash and deluge shower, within close proximity to the polyurethane resin mixing operation shall be provided in accordance with ISEA Z358.1, paragraph (9).

1.5.5 Paint Application

1.5.5.1 Ventilation

When using solvent-based paint in confined spaces, ventilation shall be provided to exchange air in the space at a minimum rate of 5,000 cubic feet per minute per spray gun in operation. It may be necessary to install both a mechanical supply and exhaust ventilation system to effect adequate air changes within the confined space. All air-moving devices shall be located and affixed to an opening of the confined space in a manner that assures that the airflow is not restricted or short circuited and is supplied in the proper direction. Means of egress shall not be blocked. Ventilation shall be continued after completion of painting and through the drying phase of the operation. If the ventilation system fails or the concentration of volatiles exceeds 10 percent of the LEL (except in the zone immediately adjacent to the spray nozzle), painting shall be stopped and spaces evacuated until such time that adequate ventilation is provided. An audible alarm that signals system failure shall be an integral part of the ventilation system. The effectiveness of the ventilation shall be checked by using ventilation smoke tubes and making frequent oxygen and combustible gas readings during painting operations.

Exhaust ducts shall discharge clear of the working areas and away from possible sources of ignition.

1.5.5.2 Explosion Proof Equipment

Electrical wiring, lights, and other equipment located in the paint spraying area shall be of the explosion proof type designed for operation in Class I, Division 1, Group D, hazardous locations as required by the NFPA 70. Electrical wiring, motors, and other equipment, outside of but within 20 feet of any spraying area, shall not spark and shall conform to the provisions for Class I, Division 2, Group D, hazardous locations.

Electric motors used to drive exhaust fans shall not be placed inside spraying areas or ducts. Fan blades and portable air ducts shall be constructed of nonferrous materials. Motors and associated control equipment shall be properly maintained and grounded. The metallic parts of air-moving devices, spray guns, connecting tubing, and duct work shall be electrically bonded and the bonded assembly shall be grounded.

1.5.5.3 Further Precautions

a. Workers shall wear nonsparking safety shoes.

b. Solvent drums taken into the spraying area shall be placed on nonferrous surfaces and shall be grounded. Metallic bonding shall be maintained between containers and drums when materials are being transferred.

c. Insulation on all power and lighting cables shall be inspected to ensure that the insulation is in excellent working condition and is free of all cracks and worn spots. Cables shall be further inspected to ensure that no connections are within 50 feet of the operation, that lines are not overloaded, and that they are suspended with sufficient

SECTION 09 97 02 Page 15 slack to prevent undue stress or chafing.

1.5.5.4 Ignition Sources

Ignition sources, to include lighted cigarettes, cigars, pipes, matches, or cigarette lighters shall be prohibited in area of solvent cleaning, paint storage, paint mixing, or paint application.

1.5.6 Health Protection

1.5.6.1 Air Sampling

Perform air sampling and testing as needed to assure that workers are not exposed to contaminants above the permissible exposure limit. In addition, Provide the Contracting Officer with a copy of the test results from the laboratory within five working days of the sampling date and shall provide results from direct-reading instrumentation on the same day the samples are collected.

1.5.6.2 Respirators

During all spray painting operations, spray painters shall use approved SCBA or SAR (air line) respirators, unless valid air sampling has demonstrated contaminant levels to be consistently within concentrations that are compatible with air-purifying respirator Assigned Protection Factor (APF). Persons with facial hair that interferes with the sealing surface of the facepiece to faceseal or interferes with respirator valve function shall not be allowed to perform work requiring respiratory protection. Air-purifying chemical cartridge/canister half- or full-facepiece respirators that have a particulate prefilter and are suitable for the specific type(s) of gas/vapor and particulate contaminant(s) may be used for nonconfined space painting, mixing, and cleaning (using solvents). These respirators may be used provided the measured or anticipated concentration of the contaminant(s) in the breathing zone of the exposed worker does not exceed the APF for the respirator and the gas/vapor has good warning properties or the respirator assembly is equipped with a NIOSH-approved end of service life indicator for the gas(es)/vapor anticipated or encountered. Where paint contains toxic elements such as lead, cadmium, chromium, or other toxic particulates that may become airborne during painting in nonconfined spaces, air-purifying half- and full-facepiece respirators or powered air-purifying respirators equipped with appropriate gas vapor cartridges, in combination with a high-efficiency filter, or an appropriate canister incorporating a high-efficiency filter, shall be used.

1.5.6.3 Protective Clothing and Equipment

All workers shall wear safety shoes or boots, appropriate gloves to protect against the chemical to be encountered, and breathable, protective, full-body covering during spray-painting applications. Where necessary for emergencies, protective equipment such as life lines, body harnesses, or other means of personnel removal shall be used during confined-space work.

1.6 MEDICAL STATUS

Prior to the start of work and annually thereafter, all Contractor employees working with or around paint systems, thinners, blast media, those required to wear respiratory protective equipment, and those who will be exposed to high noise levels shall be medically evaluated for the

SECTION 09 97 02 Page 16 particular type of exposure they may encounter. Medical records shall be maintained as required by 29 CFR 1910.20. The evaluation shall include:

a. Audiometric testing and evaluation of employees who will work in a noise environment with a time weighted average greater than or equal to 90 dBA.

b. Vision screening (employees who use full-facepiece respirators shall not wear contact lenses).

c. Medical evaluation shall include, but shall not be limited to, the following:

(1) Medical history including, but not limited to, alcohol use, with emphasis on liver, kidney, and pulmonary systems, and sensitivity to chemicals to be used on the job.

(2) General physical examination with emphasis on liver, kidney, and pulmonary system.

(3) Determination of the employee's physical and psychological ability to wear respiratory protective equipment and to perform job-related tasks.

(4) Determination of baseline values of biological indices for later comparison to changes associated with exposure to paint systems and thinners or blast media, which include: liver function tests to include SGOT, SGPT, GGPT, alkaline phosphates, bilirubin, complete urinalysis, EKG (employees over age 40), blood urea nitrogen (bun), serum creatinine, pulmonary function test, FVC, and FEV, chest x-ray (if medically indicated), blood lead and ZPP (for individuals where it is known there will be an exposure to materials containing lead), other criteria that may be deemed necessary by the Contractor's physician, and Physician's statements for individual employees that medical status would permit specific task performance.

(5) For lead-based paint removal, the medical requirements of 29 CFR 1926.62 shall also be included.

1.7 CHANGE IN MEDICAL STATUS

Any employee whose medical status has changed negatively due to work related chemical and/or physical agent exposure while working with or around paint systems and thinners, blast media, or other chemicals shall be evaluated by a physician, and obtain a physicians statement as described in paragraph MEDICAL STATUS prior to allowing the employee to return to those work tasks. Notify the Contracting Officer in writing of any negative changes in employee medical status and the results of the physicians reevaluation statement.

1.8 ENVIRONMENTAL PROTECTION

In addition to the requirements of Section 01 57 20.00 10 ENVIRONMENTAL PROTECTION comply with the following environmental protection criteria.

1.8.1 Waste Classification, Handling, and Disposal

The Contractor is responsible for assuring the proper disposal of all

SECTION 09 97 02 Page 17 hazardous and nonhazardous waste generated during the project. Waste generated from abrasive blasting, lead-containing paints with recyclable steel or iron abrasives shall be disposed of as a hazardous waste or shall be stabilized with proprietary pre-blast additives regardless of the results of 40 CFR 261 App II, Mtd 1311. Where stabilization is preferred, employ a proprietary blast additive, that has been blended with the blast media prior to use. Place hazardous waste in properly labeled, closed containers shielded adequately to prevent dispersion of the waste by wind or water. Any evidence of improper storage shall be cause for immediate shutdown of the project until corrective action is taken. Store nonhazardous waste in closed containers separate from hazardous waste storage areas. All hazardous waste shall be transported by a licensed transporter in accordance with 40 CFR 263 and 49 CFR 171, Subchapter C.

All nonhazardous waste shall be transported in accordance with local regulations regarding waste transportation. In addition to the number of manifest copies required by 40 CFR 262.22, one copy of each manifest will be supplied to the Contracting Officer prior to transportation. All materials shall be tested as required and disposed of in accordance with Section 02 42 00 DISPOSAL OF MATERIALS.

1.8.2 Containment

Contain debris generated during paint removal operations in accordance with the requirements of SSPC Guide 6, Class 1A. Where required the containment air pressure shall be verified by instrument. Where required the minimum air movement velocity shall be 100 fpm for cross-draft ventilation or 60 fpm for downdraft ventilation.

1.8.2.1 Special Provisions

Special containment provisions, as appropriate to the project, include:

a. Emergency movement of containment in the event operation of the gates or use of the emergency bulkhead is required (see also Section

01 30 00.10 GENERAL REQUIREMENTS).

b. Water booms when working over or next to water to contain inadvertent releases.

c. Other provisions required by the Coast Guard, State or local agencies, or as directed by the Contracting Officer.

1.8.3 Air Quality Monitoring

1.8.3.1 TSP Monitoring

Perform TSP monitoring. The positioning of air monitoring equipment shall be in accordance with 40 CFR 58, App E, Subpart (8). In addition, a minimum of two TSP monitors shall be used at the project site, one down wind from the project and one in the area of greatest public access (e.g.

playground, school yard, or homeowner's yard). TSP-lead monitoring shall be conducted in accordance with 40 CFR 50, App B. When the project is in an area where there are critical receptors nearby, monitoring shall be conducted throughout the entire period that abrasive blasting and cleanup operations are performed. Otherwise, monitoring shall be performed 4 of the first 8 days and on a regular basis thereafter for a sum total of 25 percent of the time surface preparation and debris cleanup are performed.

Failure to meet air quality regulatory limits shall require air monitoring to be repeated immediately after corrective actions have been taken. Also

SECTION 09 97 02 Page 18 conduct preproject TSP monitoring. The preproject TSP monitoring shall be conducted a minimum of 2 weeks prior to the beginning of the project. The monitoring shall continue for a minimum of 3 days to establish background levels. A report of the results shall be submitted to the Contracting Officer within 48 hours and shall include:

(1) Name and location of jobsite.

(2) Date of monitoring.

(3) Time of monitoring (i.e., time monitoring begins and ends each day).

(4) Identification and serial number of monitoring units.

(5) Drawing showing specific location of monitoring units.

(6) Drawing showing specific location of paint removal operation and the method of removal or work activity being performed.

(7) Wind direction and velocity.

(8) A flow chart verifying the rate of air flow across the filter throughout the sampling period.

(9) Name and address of laboratory.

(10) Laboratory test procedure.

(11) Laboratory test results.

(12) Signatures of field and laboratory technicians conducting the work.

1.8.4 Water Quality

Conduct operations in such a manner that lead-containing and other hazardous paint debris do not contaminate the water and so that NPDES permits in accordance with EPA regulation 40 CFR 122 are not required for the project. In the event that there are any releases of lead paint debris into the waterways, with reportable quantities of hazardous substances designated pursuant to Section 311 of the Clean Water Act, they shall be reported to the EPA in accordance with 40 CFR 117 and 40 CFR 355. Releases or spills that carry into waterways or storm sewers shall be thoroughly documented. The documentation shall include the time and location of the release, amount of material released, actions taken to clean up the debris, amount of debris recovered, and corrective action taken to avoid a reoccurrence. Releases shall also be reported to the Coast Guard and other state and local authorities as appropriate. If the release is equivalent to 10 pounds or more of lead-containing material in a 24-hour period, it is considered to be a reportable quantity under CERCLA. Comply with

40 CFR 302.

1.9 PAINT PACKAGING, DELIVERY, AND STORAGE

Paints shall be processed and packaged to ensure that within a period of one year from date of manufacture, they will not gel, liver, or thicken deleteriously, or form gas in the closed container. Paints, unless otherwise specified or permitted, shall be packaged in standard containers

SECTION 09 97 02 Page 19 not larger than 5 gallons, with removable friction or lug-type covers.

Each container of paint or separately packaged component thereof shall be labeled to indicate the purchaser's order number, date of manufacture, manufacturer's batch number, quantity, color, component identification and designated name, and formula or specification number of the paint together with special labeling instructions, when specified. Paint shall be delivered to the job in unbroken containers. Paints that can be harmed by exposure to cold weather shall be stored in ventilated, heated shelters.

All paints shall be stored under cover from the elements and in locations free from sparks and flames.

PART 2 PRODUCTS

2.1 MOISTURE CURE POLYURETHANE COATINGS

In general, moisture cure polyurethane coating systems, where specified, shall consist of a zinc-rich single-component moisture cure polyurethane primers, with additional micaceous iron oxide (MIO) coats as specified, single-component moisture cure polyurethane and coal tar resin-based intermediate coats, and single-component moisture cure, micaceous iron oxide, polyurethane top coats. All components shall be the product of the same manufacturer.

The system shall be equivalent to U.S. Bureau of Reclamation Category VIIa coating. Each coating system component (primer, intermediate coat and finish coat) shall have no outer recoat window.

Proprietary accelerator, if required by environmental conditions, shall be of the type recommended by the coating producer.

Thinners shall be only the type recommended by the coating producer.

Thinners containing moisture, alcohol or other hydroxyl bearing solvents will not be permitted.

2.1.1 Performance Requirements

Completed paint systems shall meet the following performance requirements:

TABLE 2

MOISTURE CURE POLYURETHANE SYSTEM PERFORMANCE PROPERTIES

PROPERTY TEST METHOD TEST VALUE

Corrosion Resistance ASTM B 117 Must pass 4000 hours minimum with less than 2 mm creep from scribe. Panels must be 1/8 inch cold rolled steel minimum, having SSPC-SP10 Near White blast with 2.0 - 3.0 mils angular profile.

Accelerated Weathering ASTM G 53 Must pass 3000 hours QUV B bulb with no chalking, cracking, or gloss loss greater than 30 percent.

Forward Impact ASTM D 2794 Must pass minimum 150 lb.

impact

SECTION 09 97 02 Page 20

TABLE 2

MOISTURE CURE POLYURETHANE SYSTEM PERFORMANCE PROPERTIES

PROPERTY TEST METHOD TEST VALUE

Abrasion Resistance ASTM D 4060 Less than 90 mg loss on CS-17 wheel, 1000 gram/load, 1000 cycles.

Relative Humidity ASTM D 2247 Must pass 4000 hours with no Resistance blistering, cracking or delamination of the film

Flexibility ASTM D 522 Must pass 1/2 inch mandrel Conical Mandrel bend with no cracking Bend Test

Adhesion ASTM D 4541 Must pass 500 psi on certified pull test

2.1.2 Primer

The primer shall be a zinc-rich, single component, moisture-cure polyurethane. The primer pigment shall also incorporate a micaceous iron oxide. The primer shall have a minimum solids content of 60% by volume, maximum VOC content of 2.8 pounds per gallon, and minimum zinc content in the dried film of 80%.