Specification Section 09 97 02.pdf

Tionesta Outflow Left Bank Long-Term Repair

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 QUALIFICATIONS

1.3.1 Qualified Painting Contractor

1.3.2 Coating Inspector Qualifications

1.3.3 Coating Thickness Gage Qualification

1.4 DELIVERY, STORAGE, AND HANDLING

1.5 AMBIENT CONDITIONS

PART 2 PRODUCTS

2.1 SPECIAL PAINT FORMULAS

2.2 PAINT FORMULATIONS

2.2.1 Formula C-200a, Coal Tar-Epoxy (Black) Paint

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

3.1.2 Ferrous Surfaces Subject to Severe Exposure

3.2 PAINT APPLICATION

3.2.1 General

3.2.2 Mixing and Thinning

3.2.3 Time Between Surface Preparation and Painting

3.2.4 Method of Paint Application

3.2.5 Coverage and Film Thickness

3.2.5.1 Dry Film Thickness Measurement on Ferrous Metal

3.2.6 Progress of Painting Work

3.2.7 Contacting Surfaces

3.2.8 Drying Time Prior to Immersion

3.2.9 Protection of Painted Surfaces

3.2.10 Coal Tar-Epoxy (Black) Paint (Formula C-200a)

3.2.10.1 Mixing

3.2.10.2 Application

3.2.10.3 Subsequent Coats

3.2.10.4 Ambient Temperature

3.2.10.5 Safety

3.3 PAINT SYSTEMS APPLICATION

3.3.1 Surface Preparation

3.3.2 System No. 6

3.3.3 Protection of Nonpainted Items and Cleanup

3.4 INSPECTION

3.5 PAINTING SCHEDULES

3.5.1 Colors and Tints

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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.

ASTM INTERNATIONAL (ASTM)

ASTM D7091 (2013) 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

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC PA 17 (2012; E 2012) Procedure for Determining Conformance to Steel Profile/Surface Roughness/Peak Count Requirements

SSPC PA 2 (2015; E 2017) Procedure for Determining Conformance to Dry Coating Thickness Requirements

SSPC SP 1 (2015) Solvent Cleaning

SSPC SP 5/NACE No. 1 (2007) White Metal Blast Cleaning

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. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Manufacturer's Product Data Sheet; G,RO

SD-06 Test Reports

Inspection Reports

SD-07 Certificates

Qualified Painting Contractor; G,RO

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Coating Inspector Qualifications; G,RO

Coating Thickness Gage Qualification

1.3 QUALIFICATIONS

Qualifications and experience shall comply with the following.

1.3.1 Qualified Painting Contractor

Provide a certified SSPC QP 1 Painting Contractor. Submit a copy of the SSPC QP 1 Certificate.

1.3.2 Coating Inspector Qualifications

Submit documentation of certification for all coating inspectors. The documentation shall include the inspector identification numbers, date of qualification, and expiration date. Submit one of the following certificates:

SSPC Protective Coating Inspector Level 2

National Association of Corrosion Engineers (NACE) Certified Paint Inspector Level 2

1.3.3 Coating Thickness Gage Qualification

Submit Coating Thickness Gage Qualification documentation of manufacturer's certification for all coating thickness gages. Type 2 gages as described in ASTM D7091 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.

1.4 DELIVERY, STORAGE, AND HANDLING

Process and package paints 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 not larger than 5 gal, 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.

1.5 AMBIENT CONDITIONS

Paint shall be applied in accordance with the manufacturers written instructions and only to surfaces that are a minimum of 5 degrees above the dew point temperature and that are completely free of moisture as determined by sight and touch. Paint shall not be applied to surfaces upon which there is detectable frost or ice. Except as otherwise specified, the temperature of the surfaces to be painted and of air in contact therewith shall be not less than 45 degrees F during paint application nor shall paint be applied if the

SECTION 09 97 02 Page 4 surfaces can be expected to drop to 32 degrees F or lower before the film has cured. During periods of inclement weather, painting may be continued by enclosing the surfaces and utilizing climate control equipment (e.g.

dehumidification, heaters, etc.), provided the minimum temperatures and surface dryness requirements prescribed previously are maintained until the coating has cured. Paint shall not be applied to surfaces heated by direct sunlight or other sources to temperatures that will cause detrimental blistering, pinholing, or porosity of the film.

PART 2 PRODUCTS

Submit Manufacturer's Product Data Sheet for each type of paint used; for products that are specified to be applied in accordance with the manufacturer's recommendations, submit the paint manufacturer's product data sheet or other written instructions for those products.

2.1 SPECIAL PAINT FORMULAS

Special paints shall have the composition as indicated in the formulas listed herein. Where so specified, certain components of a paint formulation shall be packaged in separate containers for mixing on the job. If not specified or otherwise prescribed, the color shall be that naturally obtained from the required pigmentation.

2.2 PAINT FORMULATIONS

Special paint formulas shall comply with the following:

2.2.1 Formula C-200a, Coal Tar-Epoxy (Black) Paint

The paint shall conform to SSPC Paint 16 manufactured with Type 1 pitch. In addition to standard labeling, container labels shall include the term, Corps of Engineers Formula C-200a.

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

The sheet pile wall and all components are categorized as being "subject to severe exposure" and are subject to extended periods of immersion.

3.1.1 General Requirements

Clean surfaces to be painted before applying paint or surface treatments.

Remove deposits of grease or oil in accordance with SSPC SP 1, prior to mechanical cleaning. Solvent cleaning shall be accomplished with mineral spirits or other low toxicity solvents or degreaser having a flash point above 100 degrees F, that is compatible with the coating being used. Use clean cloths and clean fluids to avoid leaving a thin film of greasy residue on the surfaces being cleaned. Protect items not to be prepared or coated from damage by the surface preparation methods. Machinery shall be protected against entry of blast abrasive and dust into working parts.

Cleaning and painting shall be so programmed that dust or other contaminants from the cleaning process do not fall on wet, newly painted surfaces, and surfaces not intended to be painted shall be suitably protected from the effects of cleaning and painting operations. Welding of, or in the vicinity of, previously painted surfaces shall be conducted in a manner to prevent weld spatter from striking the paint and to otherwise reduce coating damage to a minimum; paint damaged by welding operations

SECTION 09 97 02 Page 5 shall be restored to original condition. Surfaces to be painted that will be inaccessible after construction, erection, or installation operations are completed shall be painted before they become inaccessible.

3.1.2 Ferrous Surfaces Subject to Severe Exposure

Ferrous surfaces subject to extended periods of immersion or as otherwise required shall be dry blast-cleaned to SSPC SP 5/NACE No. 1. The blast profile, unless otherwise specified, shall be 1.5 to 2.5 mils as measured by ASTM D4417, Method C, SSPC PA 17 to be used for the amount of testing.

Appropriate abrasive blast media shall be used to produce the desired surface profile and to give an angular anchor tooth pattern. If recycled blast media is used, an appropriate particle size distribution shall be maintained so that the specified profile is consistently obtained. Steel shot or other abrasives that do not produce an angular profile shall not be used. Weld spatter not dislodged by blasting shall be removed with impact or grinding tools and the areas reblasted prior to painting. Surfaces shall be dry at the time of blasting. Blast cleaning to SSPC SP 5/NACE No. 1 shall be completed as necessary.

Within 8 hours after blast cleaning, and in any case prior to the deposition of any detectable moisture, contaminants, or corrosion, all ferrous surfaces shall be cleaned of dust and abrasive particles by brush, vacuum cleaner, and/or blown down with clean, dry, compressed air, and given the first coat of paint. The surfaces, if shop blasted, shall be shop coated with the first and second coats of the specified paint system except that moisture cure urethane and epoxy zinc-rich primed surfaces shall receive an extra single spray coat of the zinc primer at the time painting is started, as specified in the paint system instructions. The shop coating shall be maintained in good condition by cleaning and touching up of areas damaged during the construction period. If pinpoint or general rusting appears, surfaces shall be reblasted and repainted at no added cost to the Government. Prior to the application of subsequent coats, soiled areas of the shop coating shall be thoroughly cleaned and all welds or other unpainted or damaged areas shall be cleaned and coated in a manner to make them equivalent to adjacent, undamaged paint surfaces.

3.2 PAINT APPLICATION

3.2.1 General

The finished coating shall be free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, dry spray/overspray, cracking, blisters and variations in color, texture, and gloss. Application of initial or subsequent coatings shall not commence until the Contracting Officer's Representative has verified that atmospheric conditions and the surfaces to be coated are satisfactory. Each paint coat shall be applied in a manner that will produce an even, continuous film of uniform thickness. Edges, corners, crevices, seams, joints, welds, rivets, corrosion pits, and other surface irregularities shall be stripe coated with the striping extending a minimum of 1 inch on either side of surface irregularity. Spray equipment shall be equipped with traps and separators and where appropriate, mechanical agitators, pressure gauges, pressure regulators, and screens or filters. Air caps, nozzles, and needles shall be as recommended by the spray equipment manufacturer for the material being applied. Airless-type spray equipment may be used only on broad, flat, or otherwise simply configured surfaces, except that it may be employed for general painting if the spray gun is equipped with dual or adjustable tips of proper types and orifice sizes.

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3.2.2 Mixing and Thinning

Paints shall be thoroughly mixed, strained where necessary, and kept at a uniform composition and consistency during application. Dry-powder pigments specified to be added at the time of use shall, with the aid of powered stirrers, be incorporated into the vehicle or base paint in a manner that will produce a smooth, homogeneous mixture free of lumps and dry particles. Where necessary to suit conditions of the surface temperature, weather, and method of application, the paint may be thinned immediately prior to use. Thinning shall generally be limited to the addition of not more than 1 pint per gal of the proper thinner; this general limitation shall not apply when more specific thinning instructions are provided. Paint that has been stored at low temperature, shall be brought up to at least 70 degrees F before being mixed and thinned, and its temperature in the spray tank or other working container shall not fall below 60 degrees F during the application. Paint that has deteriorated in any manner to a degree that it cannot be restored to essentially its original condition by customary mixing methods shall not be used and shall be removed from the work site. Paint and thinner that is more than 1 year old shall be resampled and resubmitted for testing to determine its suitability for application. Moisture cure urethane paint shall be resampled and resubmitted for testing to determine its suitability for application whenever the paint is more than six months old as indicated by the date of manufacture on the container.

3.2.3 Time Between Surface Preparation and Painting

Surfaces that have been cleaned and/or otherwise prepared for painting shall be primed as soon as practicable after such preparation has been completed but, in any event, prior to any deterioration of the prepared surface.

3.2.4 Method of Paint Application

Unless otherwise specified, paint shall be applied by brush, roller, or spray to ferrous and nonferrous metal surfaces. Paints with suspended metallics are not to be applied by use of rollers. Striping shall be directed toward ensuring adequate coverage of edges, corners, crevices, pits, rivets, bolts, welds, and similar surface irregularities. Other methods of application to metal surfaces shall be subject to the specific approval of the Contracting Officer or designated representative.

3.2.5 Coverage and Film Thickness

Film thickness or spreading rates shall be as specified hereinafter. Where no spreading rate is specified, the paint shall be applied at a rate consistent with the manufacturer's written instructions. In any event, the combined coats of a specified paint system shall completely hide base surface and the finish coats shall completely hide undercoats of dissimilar color.

3.2.5.1 Dry Film Thickness Measurement on Ferrous Metal

Where dry film thickness requirements are specified for coatings on ferrous surfaces, measurements shall be made with a gage qualified in accordance with paragraph Coating Thickness Gage Qualification. They shall be calibrated and used in accordance with ASTM D7091. Prior to each use the Base Metal Reading (BMR) shall be established for the gage as specified in

SECTION 09 97 02 Page 7 the test method. Accuracy of the gage shall be verified using plastic shims as specified by the test method both prior to and following each set of measurements. Frequency of measurements shall be as recommended for field measurements by SSPC PA 2, except that measurements shall be performed on all areas of the structure being coated. Thickness measurements shall be reported as the mean for each spot determination.

3.2.6 Progress of Painting Work

Where field painting on any type of surface has commenced, the complete painting operation, including priming and finishing coats, on that portion of the work shall be completed as soon as practicable, without prolonged delays. Sufficient time shall elapse between successive coats to permit them to dry properly for recoating, and this period shall be modified as necessary to suit adverse weather conditions. Paint shall be considered dry for recoating when it feels firm, does not deform or feel sticky under moderate pressure of the finger, and the application of another coat of paint does not cause film irregularities such as lifting or loss of adhesion of the undercoat. All coats of all painted surfaces shall be unscarred and completely integral at the time of application of succeeding coats. At the time of application of each successive coat, undercoats shall be cleaned of dust, grease, overspray, or foreign matter by means of airblast, solvent cleaning, or other suitable means. Cement and mortar deposits on painted steel surfaces, not satisfactorily removed by ordinary cleaning methods, shall be brush-off blast cleaned and completely repainted as required. Undercoats of high gloss shall, if necessary for establishment of good adhesion, be scuff sanded, solvent wiped, or otherwise treated prior to application of a succeeding coat. Field coats on metal shall be applied after erection except as otherwise specified and except for surfaces to be painted that will become inaccessible after erection.

3.2.7 Contacting Surfaces

When riveted or ordinary bolted contact is to exist between surfaces of ferrous or other metal parts of substantially similar chemical composition, such surfaces will not be required to be painted, but any resulting crevices shall subsequently be filled or sealed with paint. Contacting metal surfaces formed by high-strength bolts in friction-type connections shall not be painted. Where a nonmetal surface is to be in riveted or bolted contact with a metal surface, the contacting surfaces of the metal shall be cleaned and given three coats of the specified primer. Unless otherwise specified, corrosion-resisting metal surfaces, including cladding therewith, shall not be painted.

3.2.8 Drying Time Prior to Immersion

Minimum drying periods after final coat prior to immersion shall be in accordance with manufacturers written instructions. In absence of manufacturers written instructions the following times shall be observed:

cold-applied coal tar systems at least 7 calendar days. Minimum drying periods shall be increased twofold if the drying temperature is below 65 degrees F and/or if the immersion exposure involves considerable abrasion.

3.2.9 Protection of Painted Surfaces

Where shelter and/or heat are provided for painted surfaces during inclement weather, such protective measures shall be maintained until the paint film has cured and discontinuance of the measures is authorized.

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Items that have been painted shall not be handled, worked on, or otherwise disturbed until the paint coat is fully cured. All metalwork coated in the shop shall be stored out of contact with the ground in a manner and location that will minimize the formation of water-holding pockets;

soiling, contamination, and deterioration of the paint film, and damaged areas of paint on such metalwork shall be cleaned and touched up without delay.

3.2.10 Coal Tar-Epoxy (Black) Paint (Formula C-200a)

3.2.10.1 Mixing

Component B shall be added to previously stirred Component A and thoroughly mixed together with a heavy-duty mechanical stirrer just prior to use. The use of not more than 1 pint of xylene thinner per 1 gal of paint will be permitted to improve application properties and extend pot life. The pot life of the mixed paint, extended by permissible thinning, may vary from 2 hours in very warm weather to 5 or more hours in cool weather. Pot life in warm weather may be extended by precooling the components prior to mixing; cooling the mixed material; and/or by slow, continuous stirring during the application period. The mixed material shall be applied before unreasonable increases in viscosity take place.

3.2.10.2 Application

Spray guns shall be of the conventional type equipped with a fluid tip of approximately 0.09 inch in diameter and external atomization, seven-hole air cap. Material shall be supplied to the spray gun from a bottom withdrawal pot or by means of a fluid pump; hose shall be 1/2 inch in diameter. Atomization air pressure shall not be less than 80 psi. High-pressure airless spray equipment may be used only on broad, simply configured surfaces. Brush application shall be with a stiff-bristled tool heavily laden with material and wielded in a manner to spread the coating smoothly and quickly without excessive brushing. The coverage rate of the material is approximately 110 square feet/gal per coat to obtain 20 mils (dry thickness) in a two-coat system. The paint shall flow together and provide a coherent, pinhole-free film. The direction of the spray passes (or finish strokes if brushed) of the second coat shall be at right angles to those of the first where practicable.

3.2.10.3 Subsequent Coats

Except at the high temperatures discussed later in this paragraph, the drying time between coal tar-epoxy coats shall not be more than 72 hours, and application of a subsequent coat as soon as the undercoat is reasonably firm is strongly encouraged. Where the temperature for substrate or coating surfaces during application or curing exceeds or can be expected to exceed 125 degrees F as the result of direct exposure to sunlight, the surfaces shall be shaded by overhead cover or the interval between coats shall be reduced as may be found necessary to avoid poor intercoat adhesion. Here, poor intercoat adhesion is defined as the inability of two or more dried coats of coal tar-epoxy paint to resist delamination when tested aggressively with a sharp knife. Under the most extreme conditions involving high ambient temperatures and sun-exposed surfaces, the drying time between coats shall not exceed 10 hours, and the reduction of this interval to a few hours or less is strongly encouraged. Where the curing time of a coal tar-epoxy exceeds 72 hours of curing at normal temperatures, 10 hours at extreme conditions, or where the coating develops a heavy blush, it shall be given one of the following treatments before the subsequent coat is applied:

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a. Etch the coating surface lightly by brush-off blasting, using fine sand, low air pressure, and a nozzle-to-surface distance of approximately 3 feet.

b. Remove the blush and/or soften the surface of the coating by wiping it with cloths dampened with 1-methyl-2-pyrrolidone. The solvents may be applied to the surface by fog spraying followed by wiping, but any puddles of solvent shall be mopped up immediately after they form. Apply the subsequent coat in not less than 15 minutes or more than 3 hours after the solvent treatment.

3.2.10.4 Ambient Temperature

Coal tar-epoxy paint shall not be applied when the receiving surface or the ambient air is below 50 degrees F nor unless it can be reasonably anticipated that the average ambient temperature will be 50 degrees F or higher for the 5 calendar day period subsequent to the application of any coat.

3.2.10.5 Safety

Workmen as well as painters shall avoid inhaling atomized particles of coal tar-epoxy paint and contact of the paint with the skin.

3.3 PAINT SYSTEMS APPLICATION

The required paint systems and the surfaces to which they shall be applied are shown in this paragraph, and/or in the drawings. Supplementary information follows.

3.3.1 Surface Preparation

The method of surface preparation and pretreatment shown in the tabulation of paint systems is for identification purposes only. Cleaning and pretreatment of surfaces prior to painting shall be accomplished in accordance with detailed requirements previously described.

3.3.2 System No. 6

Paint shall be spray or brush applied with a minimum of two coats to provide a minimum total thickness at any point of 16 mils. Sheet piles shall be shop coated and may be touched up in the field following final assembly. The specified film thickness shall be attained in any event, and any additional (beyond two) coats needed to attain specified thickness shall be applied at no additional cost to the Government.

3.3.3 Protection of Nonpainted Items and Cleanup

Walls, equipment, fixtures and all other items in the vicinity of the surfaces being painted shall be maintained free from damage by paint or painting activities. Paint spillage and painting activity damage shall be promptly repaired.

3.4 INSPECTION

Inspect and document all work phases and operations on a daily basis.

Submit daily Inspection Reports. As a minimum the daily report shall contain the following:

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a. Inspections performed, including the area of the structure involved and the results of the inspection.

b. Surface preparation operations performed, including the area of the structure involved, the mode of preparation, the kinds of solvent, abrasive, or power tools employed, and whether contract requirements were met.

c. Thinning operations performed, including thinners used, batch numbers, and thinner/paint volume ratios.

d. Application operations performed, including the area of the structure involved, mode of application employed, ambient temperature, substrate temperature, dew point, relative humidity, type of paint with batch numbers, elapsed time between surface preparation and application, elapsed time for recoat, condition of underlying coat, number of coats applied, and if specified, measured dry film thickness or spreading rate of each new coating.

3.5 PAINTING SCHEDULES

SYSTEM NO. 6

Items or surfaces to be coated:

Sheet piling, pile capApply coal tar epoxy to 100% of both sides of sheet piles and wall cap.

SURFACE

PREPARATION

1st COAT 2nd COAT 3rd COAT 4th COAT

White metal blast cleaning

Coal tar epoxy C-200a (black)

Coal tar epoxy C-200a (black)

Coal tar epoxy C-200a (black)

N/A

3.5.1 Colors and Tints

Colors and tints shall match the respective color specimens designated by, or shall otherwise be subject to the approval of, the Contracting Officer.

Where specified or directed, alternate applications of successive undercoats having the same color shall be tinted with approved ingredients, ground in a vehicle compatible with the paint being tinted, in order to ensure that all surfaces are properly coated with the specified number of paint coats.

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