SOW-TWGC_Attach_10_Coating_Repair_Plan.pdf

Attachment 10 – Coating Repair Plan

This attachment includes most of the construction transmittal 09 90 00-16 for Onsite Coating Repair

Plan. The Plan included coating product data for the Gates (Tainter and Bulkhead) as well as mechanical components (Hydraulic cylinder, etc.) and Bulkhead Gate Hoist. Product data that is not applicable to the Thrust Washer Cover Gap has been removed from the transmittal in this attachment.

In addition, the Plan includes references to specification section 09 90 00, which is included in this attachment.

FOLSOM DAM AUXILIARY SPILLWAY

CONTROL STRUCTURE PROJECT

Submittal

Section 09 90 00

Painting and Coating

Section 09 97 01.3.5

Metalizing: Hydraulic Structures

SD-01 Preconstruction

Coating Work Plan; G

TABLE OF CONTENTS

ONSITE FIELD COATING REPAIR PLAN

1. NOTE-***VARIATION TO CONTRACT SPECIFICATIONS***

2. SCOPE

3. DEFINTIONS

4. MOBILIZATION AND DEMOBILIZATION

5. GENERAL DEFFECTS AND DAMAGE

6. PRE-SURFACE PREPARATION - POST-PROCESSING FOR ALL REPAIR TYPES

7. SURFACE PREPARATION - POST-PROCESSING MAJOR DEFECTIVE REPAIRS

8. SURFACE PREPARATION - POST-PROCESSING MINOR DAMAGE REPAIRS

9. GENERAL COATING APPLICATION- FOR ALL REPAIR TYPES

10. APPLICATON METHOD - MAJOR DEFECTIVE REPAIRS

11. APPLICATON METHOD -MINOR DAMAGE REPAIRS

12. GENERAL COATING INITIAL CURE FOR ALL REPAIR TYPES

13. GENERAL IN-PROCESS REPAIRS

14. GENERAL PROTECTION OF PAINTED SURFACES

15. GENERAL INSPECTIONS AND TESTING

16. GENERAL DOCUMENTATION/REPORTS (TRACKING NON-COMPLIANCE AND CORRECTIONS)

17. SAFETY

18. SPECIFIC PRODUCT DATA

19. ATTACHMENTS

Submittal 09 90 00-16

Folsom Dam Auxiliary Spillway, Control Structure 1667

09 90 00 - 1

CONFORMED AS BUILT

SECTION TABLE OF CONTENTS

DIVISION 09 - FINISHES

SECTION 09 90 00

PAINTING AND COATING

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 GENERAL INFORMATION

1.4 QUALITY ASSURANCE

1.4.1 Contract Errors, Omissions, and Other Discrepancies

1.4.2 Corrective Action Procedures

1.4.3 Implement Corrective Action (CA)

1.4.4 Coating Work Plan

1.5 QUALIFICATIONS

1.5.1 Qualifications of Certified Protective Coatings Specialist (PCS)

1.5.2 Qualifications of QC Specialist Coating Inspector

1.5.3 Qualifications of Individuals Performing Abrasive Blasting

1.5.4 Qualifications of Coating Contractors, SSPC QP 1

1.5.5 Pre-Installation Conference

1.6 SAFETY AND HEALTH PROVISIONS

1.6.1 Abrasive Blasting

1.6.1.1 Hoses and Nozzles

1.6.1.2 Workers Other Than Blasters

1.6.2 Cleaning with Compressed Air

1.6.3 Cleaning with Solvents

1.6.4 Ventilation

1.6.5 Emergency Equipment

1.6.6 Personal Protective Equipment

1.6.7 Paint Application

1.6.7.1 Ventilation

1.6.7.2 Explosion Proof Equipment

1.6.7.3 Further Precautions

1.6.7.4 Ignition Sources

1.6.8 Health Protection

1.6.8.1 Respirators

1.6.8.2 Protective Clothing and Equipment

1.7 MEDICAL STATUS

1.8 CHANGE IN MEDICAL STATUS

1.9 PAINT PACKAGING, DELIVERY, AND STORAGE

PART 2 PRODUCTS

2.1 ABRASIVE BLASTING MATERIAL

2.2 PROTECTIVE COATINGS

2.2.1 Shop and Factory Finishing

2.2.2 Coating Systems

2.3 ABRASIVE SAMPLE COLLECTION AND SHIPPING KIT

2.3.1 Test Kit for Measuring Chloride, Sulfate and Nitrate Ions on

Steel and Coated Surfaces

2.4 ABRASIVE

2.4.1 Non-metallic Abrasive

09 90 00 - 2

2.4.2 Metallic Abrasive

2.4.2.1 New and Remanufactured Steel Grit

2.4.2.2 2.5.2.2 Recycled Steel Grit

2.5 SPECIAL PAINT FORMULAS

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

3.2 ABRASIVE BLASTING (AB)

3.2.1 Disposal of Used Abrasive

3.2.2 Mechanical Cleaning (MC)

3.3 COATING AND ABRASIVE SAMPLE COLLECTION AND TESTING

3.3.1 Abrasive Sample Collection

3.3.2 Abrasive Sample Test Reports

3.3.3 Pre-Application Testing for Surface Cleanliness

3.4 MIXING AND APPLICATION OF COATING SYSTEMS

3.4.1 Mixing Primer and Intermediate Coat Materials

3.4.1.1 Mixing Topcoat Material

3.4.1.2 3.4.1.2 Pot Life

3.4.1.3 Application Conditions and Recoat Windows

3.4.1.4 Test Kit for Identifying Amine Blush on Epoxy Surfaces

3.4.1.5 Amine Blush Testing of Epoxy Coat Prior to Overcoating

3.5 COATING APPLICATION

3.5.1 3.5.1 General Requirements

3.5.2 Mixing and Application Procedures

3.5.3 Application of Primer

3.5.4 Application of Stripe Coat

3.5.5 Application of Intermediate Coat

3.5.6 Non-skid for Stairs and Top

3.5.7 Application of Topcoat

3.5.8 Procedure for Holiday and Spot Repairs of Newly Applied Coating

3.6 ENVIRONMENTAL CONDITIONS

3.7 LIGHTING

3.8 INSPECTION

3.8.1 Coating Inspector

3.8.2 Field Inspection

3.8.2.1 Inspection Requirements

3.8.2.2 Inspection Report Forms

3.8.2.3 Daily Inspection Reports

3.8.2.4 Inspection Logbook

3.8.2.5 Inspection Equipment

3.9 FINAL CLEANUP

-- End of Section Table of Contents --

09 90 00 - 3

SECTION 09 90 00

PAINTING AND COATING

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 D 3276 (2007) Painting Inspectors (Metal Substrates)

ASTM D 7127 (2005) Measurement of Surface Roughness of

Abrasive Blast Cleaned Metal Surfaces using a Portable Stylus Instrument

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 9001 (2008; R 2008; Cor 1 2009) Quality

Management Systems- Requirements

INTERNATIONAL SAFETY EQUIPMENT ASSOCIATION (ISEA)

ISEA Z358.1 (2004) Emergency Eyewash and Shower Equipment

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2008; AMD 1 2008) National Electrical Code

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC Painting Manual (2002) Good Painting Practice, Steel

Structures Painting Manual, Volume 1, Edition 4

SSPC AB 1 (1991; E 2004; E 2007) Mineral and Slag

Abrasives

SSPC AB 2 (1996; E 2004) Cleanliness of Recycled Ferrous Metallic Abrasive

SSPC AB 3 (2003; E 2004) Ferrous Metallic Abrasive

SSPC Guide 12 (1998; E 2004) Guide for Illumination of

Industrial Painting Projects

09 90 00 - 4

SSPC Guide 6 (2004) Guide for Containing Surface Preparation 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 QP 3 (2006; E 2004) Standard Procedure for

Evaluating Qualifications of Shop Painting Applicators

SSPC QP 5 (1999; E 2004) Standard Procedure for

Evaluating the Qualifications of Coating and Lining Inspection Companies

SSPC SP 1 (1982; E 2004) Solvent Cleaning

SSPC SP 10 (2007) Near-White Blast Cleaning

SSPC SP 11 (1987; E 2004) Power Tool Cleaning to Bare

Metal

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-A-22262 (1996; Rev B; Am 2) Abrasive Blasting

Media Ship Hull Blast Cleaning

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FED-STD-313 (Rev D; Am 1) Material Safety Data, Transportation Data and Disposal Data for Hazardous Materials Furnished to Government Activities

FED-STD-595 (Rev C) Colors Used in Government

Procurement

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-SUBPART I Personal Protective Equipment

29 CFR 1910.20 Access to Employee Exposure and Medical Records

29 CFR 1910.94 Ventilation

09 90 00 - 5

29 CFR 1926 Safety and Health Regulations for Construction

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-01 Preconstruction Submittals

Safety and Health Provisions; G

An Accident Prevention Plan in accordance with the requirements of Section 01 of EM 385-1-1.

Safety Plan; G

A Safety Plan shall be submitted in accordance with paragraph titled "GENERAL INFORMATION" of this section.

Coating Work Plan; G

SD-03 Product Data

Material, Equipment, and Fixture Lists

Material, Equipment, and Fixture Lists shall be submitted in accordance with paragraph titled "GENERAL INFORMATION" of this section.

Abrasive Blasting Material Inorganic Zinc Coating Inhibitive Polyamide Epoxy Aliphatic Polyurethane

Manufacturer's catalog data shall be submitted for the above.

SD-04 Samples color chips; G

Manufacturer's Standard Color or Government selected color samples shall be submitted in accordance with paragraph titled "GENERAL INFORMATION" of this section.

New and Remanufactured Steel Grit; G

SD-06 Test Reports

Daily Inspection Reports; G

Abrasive Sample Test Reports; G

Recycled Metallic Abrasive Field Test Reports (Daily and Weekly); G

09 90 00 - 6

Inspection reports shall be submitted for protective coating systems in accordance with paragraph titled, "Field Inspection," of this section.

SD-07 Certificates

Corrective Action Procedures

Qualifications of QC Specialist Coating Inspector; G Qualifications of Individuals Performing Abrasive Blasting; G Qualifications of Individuals Performing painting; G Qualifications of Certified Protective Coatings Specialist (PCS); G

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.

Qualifications of Coating Contractors; G

A copy of their current SSPC QP 1 certification.

Abrasive Blasting Material Inorganic Zinc Coating Inhibitive Polyamide Epoxy Aliphatic Polyurethane

Certificates shall be submitted for above items showing conformance with the referenced standards contained in this section.

SD-08 Manufacturer's Instructions

Protective Coatings

Manufacturer's instructions shall be submitted for Protective

Coatings including details of thinning, mixing, handling, and application.

Manufacturer's Material Safety Data Sheets (MSDS)

Submit manufacturer's Material Safety Data sheets for coatings, solvents, and other potentially hazardous materials, as defined in

FED-STD-313.

SD-10 Operation and Maintenance Data coating systems

Preprinted maintenance instructions for all coating systems shall be provided.

1.3 GENERAL INFORMATION

A Safety Plan shall be submitted for protective coating systems in accordance with OSHA regulations.

09 90 00 - 7

Material, Equipment, and Fixture Lists shall be submitted for manufacturer's style or catalog numbers, specification and drawing reference numbers and warranty information for the Protective Coatings Systems fabrication site.

Submit three color chips 75 millimeter by 100 millimeter, 3 inch by 4 inch or manufacture pull-down of each finish color and gloss as scheduled.

1.4 QUALITY ASSURANCE

1.4.1 Contract Errors, Omissions, and Other Discrepancies

Submit all errors, omissions, and other discrepancies in contract documents the Contracting Officer within 30 days of contract award for all work covered in this Section, other than the work that will not be uncovered until a later date. All such discrepancies shall be addressed and resolved, and the Coating Work Plan modified, prior to beginning the Initial and Follow-Up phases of work. Discrepancies that become apparent only after work is uncovered shall be identified at the earliest discoverable time and submitted for resolution. Schedule time (Float) should be built into the project schedule at those points where old work is to be uncovered or where access is not available during the first 30 days after award, to allow for resolution of contract discrepancies.

1.4.2 Corrective Action Procedures

Within 30 days following Notice to Proceed, develop procedures for determining the root cause of each non-compliance, developing a plan to eliminate the root cause so that the non-compliance does not recur, and following up to ensure that the root cause was eliminated. Develop Corrective Action Request (CAR) forms for initiating Corrective Action (CA), and for tracking and documenting each step.

1.4.3 Implement Corrective Action (CA)

Take action to identify and eliminate the root cause of each non-compliance so as to prevent recurrence. These procedures shall apply to non-compliance in the work, and to non-compliance in the QC System.

Corrective actions shall be appropriate to the effects of the non-compliance encountered. Each CAR shall be serialized, tracked in a Log to completion and acceptance by the Contracting Officer, and retained in project records. The Corrective Action Log, showing status of each CAR, shall be submitted to the Contracting Officer monthly. A CAR may be initiated by either the Contractor or the Contracting Officer. The Contracting Officer must approve each CAR at the root cause identification stage, the plan for elimination stage, and the close out stage after verification that the root cause has been eliminated.

1.4.4 Coating Work Plan

Provide procedures for reviewing contract documents immediately after Notice to Proceed to identify errors, omissions, and discrepancies so that any such issues can be resolved prior to project planning and development of detailed procedures.

Provide procedures for verification of key processes during Initial Phase to ensure that contract requirements can be met. Key processes shall include surface preparation, coating application and curing, inspection, and documentation, and any other process that might adversely impact

09 90 00 - 8 orderly progression of work.

Provide procedures for all phases of coating operations, including planned work, rework, repair, inspection, and documentation. Address mobilization and setup, surface preparation, coating application, coating initial cure, tracking and correction of noncompliant work, and demobilization.

Coordinate work processes with health and safety plans and confined space entry plans. For each process, provide procedures that include appropriate work instructions, material and equipment requirements, personnel qualifications, controls, and process verification procedures. Provide procedures for inspecting work to verify and document compliance with contract requirements, including inspection forms and checklists, and acceptance and rejection criteria.

Provide procedures for correcting noncompliant work. Detailed procedures are required in advance to avoid delays in meeting overcoat windows as well as to avoid delays in production. Provide procedures for repairing defects in the coating film, such as runs, drips, sags, holidays, overspray, as well as how to handle correct coating thickness noncompliance, any other areas of repair or rework that might be adversely affected by delays in preparing and approving new procedures.

If a procedure is based on a proposed or approved request for deviation, the deviation shall be referenced. Changes to procedures shall be noted by submittal number and date approved, clearly delineating old requirements and new requirements, so that the records provide a continuous log of requirements and procedures.

1.5 QUALIFICATIONS

1.5.1 Qualifications of Certified Protective Coatings Specialist (PCS)

Submit name, address, telephone number, FAX number, and e-mail address of the independent third party PCS. Submit documentation that specialist is certified by SSPC: The Society for Protective Coatings (SSPC) as a PCS, including certification number and date of certification/recertification.

If the PCS is employed by the same coating inspection company to which the coating inspector is employed, this does not violate the independent third-party requirements. The PCS shall remain certified during the entire project, and the Contracting Officer shall be notified of any change in certification status within 10 days of the change. The PCS shall not be the designated coating inspector.

1.5.2 Qualifications of QC Specialist Coating Inspector

Submit documentation that each coating inspector is employed, and qualified to SSPC QP 5, Level III, by the selected coating inspection company. Each inspector shall remain employed by the coating inspection company while performing any coating inspection functions.

1.5.3 Qualifications of Individuals Performing Abrasive Blasting

Submit name, address, and telephone number of each person that will be performing abrasive blasting. Submit documentation that each blaster is qualified by SSPC to the SSPC C-7 Dry Abrasive Blaster Qualification Program. Each blaster shall remain qualified during the entire period of abrasive blasting, and the Contracting Officer shall be notified of any change in qualification status.

09 90 00 - 9

1.5.4 Qualifications of Coating Contractors, SSPC QP 1

All Contractors and Subcontractors that perform surface preparation or coating application shall be certified to field apply either ISO 9001 or SSPC QP 1 and SSPC QP 3 prior to contract award, and shall remain certified while accomplishing any surface preparation or coating application. The painting Contractors and painting Subcontractors must remain so certified for the duration of the project. Notify the Contracting Officer of any change in Contractor certification status.

1.5.5 Pre-Installation Conference

After approval of submittals but prior to the initiation of coating work, Contractor representatives, including at a minimum, project superintendent and QC manager, paint foreman, coating inspector, and PCS shall have a pre-application coating preparatory meeting. This meeting shall be in addition to the pre-construction conference. Specific items addressed shall include: corrective action requirements and procedures, coating work plan, safety plan, coordination with other Sections, inspection standards, inspection requirements and tools, test procedures, environmental control system, safety plan, and test logs. Notify Contracting Officer at least ten days prior to meeting.

1.6 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.

Protect adjacent materials and equipment against damage from spillage, dripping, and spatter of coating materials. Facility materials and equipment must be left clean and with all damaged surfaces corrected.

Provide signs to indicate newly painted surfaces.

Provide forced ventilation for interior spaces during application and drying of coatings to prevent the buildup of toxic or explosive concentrations of solvent vapors.

1.6.1 Abrasive Blasting

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

1.6.1.1 Hoses and Nozzles

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

09 90 00 - 10

1.6.1.2 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.

1.6.2 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.

1.6.3 Cleaning with Solvents

Sources of ignition shall not be permitted in the vicinity of solvent cleaning if there is any indication of combustible gas or vapor present.

Submit Confined Space Procedures and including requirements for toxic materials and air sampling in confined spaces, as specified below.

Representative air samples shall be collected from the breathing zone of workers involved in the cleaning process to determine the specific solvent vapor concentrations. Personal protective equipment shall be provided where required by 29 CFR 1910.146 and in accordance with

29 CFR 1910-SUBPART I.

Dispose of rags that are used to wipe up coating materials, solvents, and thinners by drenching them with water and placing in a covered metal container.

1.6.4 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).

1.6.5 Emergency Equipment

Provide fire extinguishers of the required quantity and correct type to combat flammable liquid fires.

In addition to the requirements of Section 05 of EM 385-1-1, provide an eyewash station in accordance with ISEA Z358.1, paragraph (6).

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

1.6.6 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.

Personnel shall be protected in accordance with 29 CFR 1910-SUBPART I.

09 90 00 - 11

1.6.7 Paint Application

1.6.7.1 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.

1.6.7.2 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.

1.6.7.3 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 slack to prevent undue stress or chafing.

1.6.7.4 Ignition Sources

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

09 90 00 - 12 storage, paint mixing, or paint application.

1.6.8 Health Protection

1.6.8.1 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 harmful elements such as zinc, or other hazardous 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.

1.6.8.2 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.

1.7 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 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

09 90 00 - 13 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), 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.

1.8 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 physician's reevaluation statement.

1.9 PAINT PACKAGING, DELIVERY, AND STORAGE

Materials shall be delivered in their original, unopened containers, processed and packaged to ensure that they are within a period of one year from date of manufacture. Paints, unless otherwise specified or permitted, shall be packaged in standard containers not larger than 5 gallons container. Each container or separately packaged component thereof and 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 ABRASIVE BLASTING MATERIAL

Abrasive blasting materials shall be per SSPC Painting Manual.

Abrasive are required to Meets SSPC AB 1, type I (natural minerals) and type II (slags), class A, except flint minerals are not permitted.

SSPC AB 2 for recycled cleanliness.

SSPC AB 3SSPC-AB3 class I (steel) or II (iron) for angular shaped grit.

09 90 00 - 14

Do not exceed toxicity threshold limit for hazardous materials. Samples must have been tested within the last three years. Note that this testing is for the purpose of qualifying the abrasive.

2.2 PROTECTIVE COATINGS

2.2.1 Shop and Factory Finishing

Shop applied coatings: Manufacturer's standard surface preparation and shop applied permanent coating system that meets the following:

a. 2-year corrosion-free protection without significant defects stored in atmospheric exposure.

b. Color and gloss to be manufacturer's standard unless specified below or in color schedule.

Unexposed interior surfaces of cabinets, enclosures, and equipment to be given the manufacturer's standard permanent coated finish.

2.2.2 Coating Systems

All primer, intermediate coat and topcoat materials shall be supplied by one supplier. The entire coating system may be applied in the field or in the shop. Alternatively, surface preparation may be accomplished in the shop, following all temperature, humidity, and testing requirements listed herein, followed by an application of a hold-primer. Remove all shop-applied primer prior to final field surface preparation and coating system application, except galvanizing. Adjust all shop preparation to avoid conflicts with final surface preparation requirements.

Contractor will supply a 2-year warranty of corrosion-free protection without significant defects stored in atmospheric exposure.

The following two coating systems definitions are to be specified for use on the surfaces listed in the Coating Schedule, of this section, and as directed.

Coating System No. 1 shall consist of inorganic zinc only, no top coat unless specified. Inorganic zinc shall be selected from the following listing. Coatings, thinners, and cleaners shall be the product of one manufacturer.

Coating System No. 2 shall consist of inorganic zinc first coat, inhibitive polyamide epoxy intermediate coat, and aliphatic polyurethane finish coat. Coatings shall be selected from the following listing and all coatings, thinners, and cleaners shall be the product of the same manufacturer. Each successive coating shall be of a contrasting color to provide a visual assurance of complete coverage.

09 90 00 - 15

COATING SYSTEMS

Coating System No. 1 (ZINC PRIMER) - Select one system

Items to be coated:

a. Atmospheric steel surfaces where the appearance of an untopcoated zinc coating is acceptable. Includes steel exposed to view and concealed steel and other ferrous surfaces that will be inaccessible for painting after construction.

Coating Materials & Manufacturer – Zinc

Rich Primers

Number and thickness of coats

Surfaces preparation method

Amercoat 68HS -

PPG Protective & Marine Coatings , One PPG Place, Pittsburgh, PA 15272 Ph: 412-434-3131

2 or more coats, apply at 2 – 3 mils, DFT each coat

Total system, excluding stripe coats:

4 mils DFT, minimum 6 mils DFT, maximum

SSPC SP 1 followed by

SSPC SP 10

Follow manufacturer's Surface preparation and application instructions to apply subsequent coats

Carbozinc 11HS -

Carboline, 350 Hanley Industrial Court, St.

Louis, MO 631441 Ph: 314-644-1000

2 or more coats apply at 2 – 3 mils, DFT each coat

Total system, excluding stripe coats:

4 mils DFT, minimum 6 mils DFT, maximum

SSPC SP 1 followed by

SSPC SP 10

Follow manufacturer's Surface preparation and application instructions to apply subsequent coats

Catha-Coat 303H 302H-

Devoe High Performance Coatings, Strongsville, OH 44115 Ph: 800-654-2616

2 or more coats apply at 2 – 4 3-6 mils, DFT each coat

Total system, excluding stripe coats:

4 6 mils DFT, minimum 8 12 mils DFT, maximum

SSPC SP 1 followed by

SSPC SP 10

Follow manufacturer's Surface preparation and application instructions to apply subsequent coats

Zinc Clad II Plus -

Sherwin-Williams, 101 Prospect Avenue NW, Cleveland, OH 44115 Ph: 216-566-2000

2 or more coats apply at 2 – 4 mils, DFT each coat

Total system, excluding stripe coats:

4 mils DFT, minimum 8 mils DFT, maximum

SSPC SP 1 followed by

SSPC SP 10

09 90 00 - 16

COATING SYSTEMS

Coating System No. 1 (ZINC PRIMER) - Select one system

Items to be coated:

a. Atmospheric steel surfaces where the appearance of an untopcoated zinc coating is acceptable. Includes steel exposed to view and concealed steel and other ferrous surfaces that will be inaccessible for painting after construction.

Coating Materials & Manufacturer – Zinc

Rich Primers

Number and thickness of coats

Surfaces preparation method

Tnemec-Zinc 90-97

Tnemec Company, 6800 Corporate Drive, Kansas City, MO 64141 Ph: 800-863-6321

2 or more coats apply at 2 – 45 mils, DFT each coat

Total system, excluding stripe coats:

4 mils DFT, minimum 8 mils DFT, maximum

SSPC SP 1 followed by

SSPC SP 10

Follow manufacturer's Surface preparation and application instructions to apply subsequent coats

NOTES:

1. Remove stabilizing or storage treatments on galvanizing by one of following (a) SSPC SP 1 and sweep blasting or (b) manufacturers compatible wash treatment.

2. Galvanizing to be painted shall be lightly sanded or etched.

3. Use of SSPC SSPC SP 11 Power Tool Cleaning to Bare Metal is permitted where abrasive blasting is impractical.

09 90 00 - 17

Coating System No. 2 (Zinc Primer, Epoxy Intermediated Coat, Polyurethane Topcoat) - Select one system

Items to be coated:

a. All mechanical and electrical equipment, unless otherwise identified.

b. Tainter gate hydraulic cylinder body and clevis.

c. Hoisting equipment, unless otherwise identified.

d. Bar grating and plate grating and embedded steel supports.

e. Bollards - paint manufacturer's standard safety yellow.

f. Steel tubing.

g. Steel piping.

h. Miscellaneous metal.

i. Trunnion Girder Interior

Coating Materials & Manufacturer – Zinc

Rich Primers/Epoxy/Polyurethan

System

Number and thickness of coats

Surfaces preparation method

Amercoat 68HS – zinc primer

PPG Protective & Marine Coatings , One PPG Place, Pittsburgh, PA 15272 Ph: 412-434-3131

1 or more prime coats, apply at 2 – 3 mils, DFT each coat

SSPC SP 1 followed by

SSPC SP 10

Amerlock 2/400 – epoxy intermediate coat

1 or more intermediate coats, apply at 6 – 8 mils, DFT each coat, plus stripe coat

Follow manufacturer’s Surface preparation and application instructions to apply subsequent coats

Amershield VOC – polyurethane topcoat

Color and gloss:

FED-STD-595 no.

26622/light gray

1 or more topcoats coats, apply at 3 – 5 mils, DFT each coat

Total system, excluding stripe coats:

11 mils DFT, minimum 16 mils DFT, maximum

09 90 00 - 18

Items to be coated:

a. All mechanical and electrical equipment, unless otherwise identified.

b. Tainter gate hydraulic cylinder body and clevis.

c. Hoisting equipment, unless otherwise identified.

d. Bar grating and plate grating and embedded steel supports.

e. Bollards - paint manufacturer's standard safety yellow.

f. Steel tubing.

g. Steel piping.

h. Miscellaneous metal.

i. Trunnion Girder Interior

Coating Materials & Manufacturer – Zinc

Rich Primers/Epoxy/Polyurethan

System

Number and thickness of coats

Surfaces preparation method

Carbozinc 11HS – zinc primer

Carboline, 350 Hanley Industrial Court, St.

Louis, MO 631441 Ph: 314-644-1000

1 or more coats apply at 2 – 3 mils, DFT each coat

SSPC SP 1 followed by

SSPC SP 10

Carboguard 893 - epoxy intermediate coat

1 or more intermediate coats, apply at 4 – 6 mils, DFT each coat, plus stripe coat

Follow manufacturer’s Surface preparation and application instructions to apply subsequent coats

Carbothane 134 VOC – polyurethane topcoat

Color and gloss:

FED-STD-595 no.

26622/light gray

1 or more topcoats coats, apply at 2 – 3 mils, DFT each coat

Total system, excluding stripe coats:

8 mils DFT, minimum 12 mils DFT, maximum

Catha-Coat 303H

Devoe High Performance Coatings, Strongsville, OH Ph: 800-654-2616

1 or more coats apply at 2 – 4 mils, DFT each coat

09 90 00 - 19

Items to be coated:

a. All mechanical and electrical equipment, unless otherwise identified.

b. Tainter gate hydraulic cylinder body and clevis.

c. Hoisting equipment, unless otherwise identified.

d. Bar grating and plate grating and embedded steel supports.

e. Bollards - paint manufacturer's standard safety yellow.

f. Steel tubing.

g. Steel piping.

h. Miscellaneous metal.

i. Trunnion Girder Interior

Coating Materials & Manufacturer – Zinc

Rich Primers/Epoxy/Polyurethan

System

Number and thickness of coats

Surfaces preparation method

Bar-Rust 235V - epoxy intermediate coat

1 or more intermediate coats, apply at 6 – 8 4-8 mils, DFT each coat, plus stripe coat

Follow manufacturer’s Surface preparation and application instructions to apply subsequent coats

Devthane 378H – polyurethane topcoat

Color and gloss:

FED-STD-595 no.

26622/light gray

1 or more topcoats coats, apply at 2 – 3 3-4 mils, DFT each coat

Total system, excluding stripe coats:

10 mils DFT, minimum 15 mils DFT, maximum

Zinc Clad II Plus

Sherwin-Williams, 101 Prospect Avenue NW, Cleveland, OH 44115 Ph: 216-566-2000

1 or more coats apply at 2 – 4 mils, DFT each coat

09 90 00 - 20

Items to be coated:

a. All mechanical and electrical equipment, unless otherwise identified.

b. Tainter gate hydraulic cylinder body and clevis.

c. Hoisting equipment, unless otherwise identified.

d. Bar grating and plate grating and embedded steel supports.

e. Bollards - paint manufacturer's standard safety yellow.

f. Steel tubing.

g. Steel piping.

h. Miscellaneous metal.

i. Trunnion Girder Interior

Coating Materials & Manufacturer – Zinc

Rich Primers/Epoxy/Polyurethan

System

Number and thickness of coats

Surfaces preparation method

Macropoxy 646-100 -epoxy intermediate coat

1 or more intermediate coats, apply at 5 – 8 mils, DFT each coat, plus stripe coat

Follow manufacturer’s Surface preparation and application instructions to apply subsequent coats

Hi-Solids Polyurethane

– polyurethane topcoat

Color and gloss:

FED-STD-595 no.

26622/light gray

1 or more topcoats coats, apply at 3 – 4 mils, DFT each coat

Total system, excluding stripe coats:

10 mils DFT, minimum 16 mils DFT, maximum

Tnemec-Zinc 90-97

Tnemec Company, 6800 Corporate Drive, Kansas City, MO 64141 Ph: 800-863-6321

1 or more coats apply at 2 – 4 mils, DFT each coat

09 90 00 - 21

Items to be coated:

a. All mechanical and electrical equipment, unless otherwise identified.

b. Tainter gate hydraulic cylinder body and clevis.

c. Hoisting equipment, unless otherwise identified.

d. Bar grating and plate grating and embedded steel supports.

e. Bollards - paint manufacturer's standard safety yellow.

f. Steel tubing.

g. Steel piping.

h. Miscellaneous metal.

i. Trunnion Girder Interior

Coating Materials & Manufacturer – Zinc

Rich Primers/Epoxy/Polyurethan

System

Number and thickness of coats

Surfaces preparation method

Hi-Build Epoxoline II, series 69L - epoxy intermediate coat

1 or more intermediate coats, apply at 6 – 8 mils, DFT each coat, plus stripe coat

Follow manufacturer’s Surface preparation and application instructions to apply subsequent coats

Endura-Shield II, series 1075 – polyurethane topcoat

Color and gloss:

FED-STD-595 no.

26622/light gray

1 or more topcoats coats, apply at 2 – 3 mils, DFT each coat

Total system, excluding stripe coats:

10 mils DFT, minimum 15 mils DFT, maximum

NOTES:

1. Remove stabilizing or storage treatments on galvanizing by one of following (a) SSPC SP 1 and sweep blasting or (b) manufacturers compatible wash treatment.

2. Galvanizing to be painted shall be lightly sanded or etched.

3. Use of SSPC SSPC SP 11 Power Tool Cleaning to Bare Metal is permitted where abrasive blasting is impractical.

2.3 ABRASIVE SAMPLE COLLECTION AND SHIPPING KIT

Provide a kit that contains one suitable plastic bag or container for each sample to be collected. Mark containers for the appropriate component.

Provide shipping documents, including either pre-paid shipping or a shipper number that can be used by the QC Manager to arrange pickup, addressed to the approved coating testing laboratory.

09 90 00 - 22

2.3.1 Test Kit for Measuring Chloride, Sulfate and Nitrate Ions on Steel and Coated Surfaces

Provide test kits called CHLOR*TEST CSN Salts, as manufactured by CHLOR*RID International Inc. of Chandler, Arizona (www.chlor-rid.com) or equal. An "equal" test kit shall meet the following requirements:

a. Kit contains all materials, supplies, tools and instructions for field testing and on-site quantitative evaluation of chloride, sulfate and nitrate ions;

b. Kit extract solution is acidic, factory pre-measured, pre-packaged, and of uniform concentration;

c. Kit components and solutions are mercury free and environmentally friendly;

d. Kit contains new materials and solutions for each test extraction;

e. Extraction test container (vessel, sleeve, cell. etc.) creates a sealed, encapsulated environment during salt ion extraction;

f. Test extract container is suitable for testing the following steel surfaces: horizontal (up/down configuration), vertical, flat, curved, smooth, pitted, and rough; g. All salt ion concentrations are directly measured in micrograms per square centimeter.

2.4 ABRASIVE

The referenced abrasive specifications have maximum limits for soluble salts contamination; however, this maximum level of contamination does not guarantee that contamination will not be transferred to the steel surface during abrasive blasting. Other factors such as on-site handling and recycling can allow contamination of abrasive. Contractors are cautioned to verify that the chosen abrasive, along with work and storage processes, allow the final surface cleanliness requirements to be achieved.

Successful testing of chlorides in abrasive does not negate the final acceptance testing of steel surfaces.

2.4.1 Non-metallic Abrasive

Conform to MIL-A-22262, Type I (Inorganic materials) except that the gross gamma radioactivity shall not exceed 5 picocuries per gram. Abrasive shall be approved by the Naval Sea Systems Command and listed on the appropriate Qualified Products List (QPL) for the specified materials. Use sampling procedures and testing frequencies as prescribed in MIL-A-22262. Use abrasive that is specifically selected and graded to provide a sharp, angular profile to the specified depth. Do not use ungraded abrasive.

Make adjustments to processes or abrasive gradation to achieve specified surface profile. Recycled non-metallic abrasive shall meet all requirements of the specification each time that it is placed in the blast pot.

2.4.2 Metallic Abrasive

2.4.2.1 New and Remanufactured Steel Grit

Conform to the chemical and physical properties of SSPC AB 3 Class 1

09 90 00 - 23

(Steel), Class 2 (Iron) abrasive shall not be used.

To develop a suitable work mix from new steel abrasive, a minimum of 200 - 400 recycles is required, therefore, it is advantageous for a Contractor to use remanufactured steel grit or grit reclaimed from a previous project.

Such grit shall be considered to conform if it can be traced to new grit conforming to SSPC AB 3 Class 1 and it meets all cleanliness requirements of SSPC AB 3 Class 1 when brought to the current jobsite. Submit one representative sample of this work mix to the laboratory for testing, along with samples of new material. Acceptance and use of this work mix shall not be used to justify any deviation from surface preparation requirements.

2.4.2.2 2.5.2.2 Recycled Steel Grit

Conform to the chemical and physical properties of SSPC AB 2

2.5 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.

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

Surfaces to be painted shall be cleaned before applying paint or surface treatments. Deposits of grease or oil shall be removed in accordance with SSPC SP 1, prior to mechanical cleaning. Solvent cleaning shall be accomplished with mineral spirits or other low toxicity solvents having a flash point above 100 degrees F. Clean cloths and clean fluids shall be used to avoid leaving a thin film of greasy residue on the surfaces being cleaned. Items not to be prepared or coated shall be protected 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 shall be restored to original condition by repair of defective or damaged coated areas. Clean metal surfaces to metal substrate by abrasive blasting SSPC SP 10 or where abrasive blasting is impractical SSPC SP 11. Feather abrupt edges and around repair area by hand or power tool with non-woven pad and roughen or abraded surfaces in accordance with manufacturer's recommendations -achieve a matted or lusterless finish before applying coatings. Surfaces to be painted that will be inaccessible after construction, erection, or installation operations are completed shall be painted before they become inaccessible.

Surfaces to be welded shall be left uncoated. Welded areas shall then be masked and touched up.

09 90 00 - 24

Prepared surfaces shall be coated within 6 hours after completion of surface preparation and before rusting or recontamination occurs. Surfaces not coated within 6 hours or which show rusting or contamination, regardless of the length of time after preparation, shall be reprepared.

Surface preparation and coating operations shall be sequenced so that freshly applied coatings will not be contaminated by dust or foreign matter.

3.2 ABRASIVE BLASTING (AB)

Abrasive blasting shall conform to near-white metal SSPC SP 10 and SSPC Painting Manual. Compressed air used for abrasive blasting shall be free of moisture and oil.

Blast cleaning shall achieve a 1 to 2-mil anchor profile. Measure surface profile in accordance with ASTM D 7127 as indicated by a surface profile comparator, replica tape, or similar device, using Rmax as the measure of profile height. Record all measurements required in this standard.

Measure profile at rate of three test areas for the first 1000 square feet plus one test area for each additional 1000 square feet or part thereof.

When surfaces are reblasted for any reason, retest profile as specified.

Rust and corrosion shall be removed from pits and depressions.

Abrasives:

a. Meets SSPC AB 1, type I (natural minerals) and type II (slags), class A, except flint minerals are not permitted.

b. SSPC AB 2 for recycled cleanliness.

c. SSPC AB 3 class I (steel) or II (iron) for angular shaped grit.

d. Additive stabilizers for leachable toxic metal wastes are allowed, except elemental iron is not permitted.

e. Do not exceed toxicity threshold limit for hazardous materials.

All traces of abrasive residue and dust shall be removed from the surface, leaving it clean and dry.

3.2.1 Disposal of Used Abrasive

Dispose of used abrasive off Government property in accordance with Federal, State, and Local mandated regulations.

3.2.2 Mechanical Cleaning (MC)

Where mechanical cleaning is specified, needle scalers or abrasive disks or wheels shall be…