Revised_09_97_13.27_Amendment_0006.pdf

C-17 Type III Fuel System & Ramp Expansion FJRP159073 145th Airlift Wing, North Carolina Air National Guard

Section 09 97 13.27 Page 1

SECTION 09 97 13.27

EXTERIOR COATING OF STEEL STRUCTURES

10/16

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 C920 (2014a) Standard Specification for

Elastomeric Joint Sealants

ASTM D1200 (2010; R 2014) Viscosity by Ford Viscosity

Cup

ASTM D1640 (2014) Standard Test Methods for Drying, Curing, or Film Formation of Organic Coatings

ASTM D3276 (2007) Painting Inspectors (Metal Substrates)

ASTM D3925 (2002; R 2015) Sampling Liquid Paints and

Related Pigmented Coatings

ASTM D4285 (1983; R 2012) Indicating Oil or Water in

Compressed Air

ASTM D7127 (2013) Measurement of Surface Roughness of

Abrasive Blast Cleaned Metal Surfaces using a Portable Stylus Instrument

ASTM E11 (2017) Standard Specification for Woven Wire

Test Sieve Cloth and Test Sieves

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 9001 (2008; Corr 1 2009) Quality Management

Systems- Requirements

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC 7 (2007; E 2004) Brush-Off Blast Cleaning

SSPC AB 2 (2015; E 2016) 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

Section 09 97 13.27 Page 2

SSPC Guide 6 (2015) Guide for Containing Surface Preparation Debris Generated During Paint Removal Operations

SSPC PA 1 (2016) Shop, Field, and Maintenance Coating of Metals

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

SSPC QP 1 (2012; E 2012) Standard Procedure for

Evaluating Painting Contractors (Field Application to Complex Industrial Structures)

SSPC QP 5 (2012) Standard Procedure for Evaluating the

Qualifications of Coating and Lining Inspection Companies

SSPC QS 1 (2015) Standard Procedure for Evaluating a

Contractor's Advanced Quality Management System

SSPC SP 1 (2015) Solvent Cleaning

SSPC SP 10 (2007) Near-White Blast Cleaning

SSPC SP COM (2004) Surface Preparation Commentary for

Steel and Concrete Substrates

SSPC VIS 1 (2002; E 2004) Guide and Reference

Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-A-22262 (1993; Rev B; Am 2 1996) Abrasive Blasting

Media Ship Hull Blast Cleaning

MIL-DTL-24441 (2009; Rev D) Paint, Epoxy-Polyamide, General

Specification for

MIL-DTL-24441/19 (2009; Rev C) Paint, Epoxy-Polyamide, Zinc

Primer, Formula 159, Type III

MIL-DTL-24441/31 (2009; Rev B) Paint, Epoxy-Polyamide, White, Formula 152, Type IV

MIL-PRF-85285 (2012; Rev E) Coating: Polyurethane Aircraft and Support Equipment

MIL-STD-161 (2005; Rev G; Notice 1 2010) Identification

Methods for Bulk Petroleum Products Systems Including Hydrocarbon Missile Fuels

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

Section 09 97 13.27 Page 3

FED-STD-595 (Rev C; Notice 1) Colors Used in Government Procurement

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

29 CFR 1910-SUBPART Z Toxic and Hazardous Substances

29 CFR 1910.1000 Air Contaminants

29 CFR 1910.134 Respiratory Protection

29 CFR 1926.59 Hazard Communication

NORTH ATLANTIC TREATY ORGANIZATION (NATO)

AFLP-3747 (2013; Rev 9) Guide Specifications (Minimum

Quality Standards) for Aviation Turbine Fuels (F-24, F-27, F-34, F-35, F-37, F-40 And F-44)

1.2 DEFINITIONS

Definitions are provided throughout this Section, generally in the paragraph where used, and denoted by capital letters.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:

SD-03 Product Data

Joint Sealant Product Data; G

Coating System Product Data; G

SD-05, Design Data

Containment System

SD-06 Test Reports

Joint Sealant Qualification Test Reports

Coatings Qualification Test Reports

Metallic Abrasive Qualification Test Reports

Coating Sample Test Reports

Abrasive Sample Test Reports

Inspection Report Forms

Daily Inspection Reports

Section 09 97 13.27 Page 4

Recycled Metallic Abrasive Field Test Reports (Daily and Weekly)

SD-07 Certificates

Contract Errors, Omissions, and Other Discrepancies

Corrective Action Procedures

Coating Work Plan

Qualifications of Certified Industrial Hygienist (CIH)

Qualifications Of Individuals Performing Abrasive Blasting

Qualifications of Certified Protective Coatings Specialist (PCS)

Qualifications of Coating Inspection Company

Qualifications of QC Specialist Coating Inspector

Qualifications of Testing Laboratory for Coatings

Qualifications of Testing Laboratory for Abrasive

Qualifications of Coating Contractors

Joint Sealant Materials

Coating Materials

Coating System Component Compatibility

Non-metallic Abrasive

Metallic Abrasive

SD-08 Manufacturer's Instructions

Joint Sealant Instructions

Coating System Instructions

SD-11 Closeout Submittals

Disposal of Used Abrasive

Inspection Logbook; G

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

Section 09 97 13.27 Page 5

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 (CA)

CA shall be included in the Quality Control Plan.

1.4.2.1 Corrective Action Procedures

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 CA, and for tracking and documenting each step.

1.4.2.2 Implement Corrective Action

The Contractor shall 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.

1.4.3 Coating Work Plan

This work plan shall be considered as part of the Quality Control Plan.

Provide procedures for reviewing contract documents immediately after award 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 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

Section 09 97 13.27 Page 6 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.

1.4.4 Design Data

1.4.4.1 Containment System

Submit complete design drawings and calculations for the scaffolding and containment system, including an analysis of the loads which will be added to the structure by the containment system and waste materials. A registered engineer shall approve calculations and scaffold system design.

1.4.5 Test Reports

1.4.5.1 Joint Sealant Qualification Test Reports

Submit test results from independent laboratory of representative samples of joint sealant material. Samples must have been tested within the last three years. Submit results as required in paragraph QUALITY ASSURANCE PROVISIONS of ASTM C920. Note that testing in accordance with QUALITY ASSURANCE PROVISIONS is a pre-qualification requirement.

1.4.5.2 Coatings Qualification Test Reports

Submit test results from independent laboratory of representative samples of each coating material. U.S. Department of Defense laboratories are considered to be independent laboratories for purposes of compliance with "QUALIFICATION INSPECTION" requirements herein. Samples must have been tested within the last three years. Submit results for epoxy materials as required in paragraph QUALIFICATION INSPECTION of MIL-DTL-24441, and as revised by paragraph COATING SYSTEM herein. Submit results for polyurethane materials as required in paragraph QUALIFICATION INSPECTION of MIL-PRF- 85285, and as revised by paragraph COATING SYSTEM herein. Note that requirement for QUALIFICATION INSPECTION is a pre-qualification requirement, and involves the same testing required for listing in the Qualified Products List of the respective material. See appropriate Military Specification for specific test requirements.

1.4.5.3 Metallic Abrasive Qualification Test Reports

Submit results for abrasive as required in paragraph 4 REQUIREMENTS of SSPC AB 3. Submit test results from independent laboratory of representative

Section 09 97 13.27 Page 7 samples of each abrasive to be used on the jobsite. Samples must have been tested within the last three years. Note that this testing is for the purpose of prequalifying the abrasive.

1.4.5.4 Recycled Metallic Abrasive Field Test Reports (Daily and Weekly)

Submit test results from independent laboratory of daily and weekly Quality Control testing required by SSPC AB 2, as modified in paragraph ABRASIVE.

1.4.6 Qualifications

1.4.6.1 Qualifications of Certified Industrial Hygienist (CIH)

Submit name, address, telephone number, FAX number, and e-mail address of the independent third party CIH. Submit documentation that hygienist is certified by the American Board of Industrial Hygiene in comprehensive practice, including certification number and date of certification/recertification. Provide evidence of experience with hazards involved in industrial coating application work.

1.4.6.2 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.

1.4.6.3 Qualifications of Coating Inspection Company

Submit documentation that the coating inspection company that will be performing all coating inspection functions is certified by SSPC to the requirements of SSPC QP 5 prior to contract award, and shall remain certified while accomplishing any coating inspection functions. The coating inspection company must remain so certified for the duration of the project.

If a coating inspection company's certification expires, the firm will not be allowed to perform any inspection functions, and all surface preparation and coating application work must stop, until the certification is reissued.

Requests for extension of time for any delay to the completion of the project due to an inactive certification will not be considered and liquidated damages will apply. Notify the Contracting Officer of any change in coating inspection company certification status.

1.4.6.4 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.

1.4.6.5 Qualifications Of Individuals Performing Abrasive Blasting

Section 09 97 13.27 Page 8

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.

1.4.6.6 Qualifications of Testing Laboratory for Coatings

the independent third party laboratory selected to perform testing of coating samples for compliance with specification requirements. Submit documentation that laboratory is regularly engaged in testing of paint samples for conformance with specifications, and that persons performing analyses are qualified.

1.4.6.7 Qualifications of Testing Laboratory for Abrasive

the independent third party laboratory selected to perform testing of abrasive for compliance with specification requirements. Submit documentation that laboratory has experience in testing samples of abrasive for conformance with specifications, and that persons performing analyses are qualified.

1.4.6.8 Qualifications of Coating Contractors

All Contractors and Subcontractors that perform surface preparation or coating application shall be certified to either ISO 9001 or SSPC QP 1 and SSPC QS 1 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. If a Contractor's or Subcontractor's certification expires, the firm will not be allowed to perform any work until the certification is reissued. Requests for extension of time for any delay to the completion of the project due to an inactive certification will not be considered and liquidated damages will apply. Notify the Contracting Officer of any change in Contractor certification status.

1.4.6.9 Joint Sealant Materials

Provide manufacturer's certification of conformance to contract requirements.

1.4.6.10 Coating Materials

Provide manufacturer's certification of conformance to contract requirements.

1.4.6.11 Coating System Component Compatibility

Provide certification from each manufacturer of components of the coating system, epoxy primer, epoxy intermediate, and polyurethane topcoat, that the supplied coating material is suitable for use in the specified coating system. Each manufacturer shall identify the specific products, including manufacturer's name, which their product may be used with. The certification shall provide the name of the manufacturer that will provide

Section 09 97 13.27 Page 9 technical support for the entire system. When all coating materials are manufactured by one manufacturer, this certification is not required.

1.4.6.12 Non-metallic Abrasive

Provide manufacturer's certification that the materials are currently approved by the Naval Sea Systems Command and listed on the Qualified Products Lists (QPL) for the specified materials.

1.4.6.13 Metallic Abrasive

Provide manufacturer's certification of conformance to contract requirements and provide copies of test results.

1.4.7 Protective Coating Specialist (PCS)

The PCS shall be considered a QC Specialist and shall report to the QC Manager, as specified in Section 01 45 00.00 20 QUALITY CONTROL. The PCS shall approve all submittals prior to submission to the QC Manager for approval or submission to the government for approval.

1.4.8 Pre-Application Meeting

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.

1.5 PRODUCT DATA

1.5.1 Joint Sealant Instructions

Submit manufacturer's printed instructions including detailed application procedures, minimum and maximum application temperatures, and curing procedures. Include materials safety data sheets (MSDS) for materials to be used at the job site in accordance with 29 CFR 1926.59.

1.5.2 Coating System Instructions

Submit manufacturer's printed instructions including detailed mixing and application procedures, number and types of coats required, minimum and maximum application temperatures, and curing procedures. Include materials safety data sheets (MSDS) for materials to be used at the job site in accordance with 29 CFR 1926.59.

1.6 DELIVERY AND STORAGE

Ship, store, and handle materials in accordance with SSPC PA 1, and as modified in this Section. Maintain temperature in storage spaces between 40 and 85 degrees F, and air temperature more than 5 degrees F above the dew-point at all times. Inspect materials for damage prior to use and return

Section 09 97 13.27 Page 10 non-compliant materials to manufacturer. Remove materials with expired shelf life from government property immediately and notify the Contracting Officer.

If materials are approaching shelf life expiration and an extension is desired, samples may be sent to the manufacturer, along with complete records of storage conditions, with a request for shelf life extension. If the manufacturer finds the samples and storage data suitable for shelf life extension, the manufacturer may issue an extension, referencing the product evaluation and the review of storage records. Products may not be extended longer than allowed in the product specification.

1.7 COATING HAZARDS

Ensure that employees are trained in all aspects of the safety plan.

Specified coatings may have potential health hazards if ingested or improperly handled. The coating manufacturer's written safety precautions shall be followed throughout mixing, application, and curing of the coatings. During all cleaning, cleanup, surface preparation, and paint application phases, ensure that employees are protected from toxic and hazardous chemical agents which exceed concentrations in 29 CFR 1910.1000.

Comply with respiratory protection requirements in 29 CFR 1910.134. The CIH shall approve work procedures and personal protective equipment.

1.8 JOB SITE REFERENCES

Make available to the Contracting Officer at least one copy each of ASTM

D3276, ASTM D3925, ASTM D4285, ASTM D7127, SSPC SP COM, SSPC SP 1, SSPC 7,

SSPC SP 10, SSPC PA 1, SSPC PA 2, SSPC Guide 6, SSPC VIS 1, SSPC QP 1, SSPC QS 1, and an SSPC Certified Contractor Evaluation Form at the job site.

PART 2 PRODUCTS

2.1 DESIGN CONDITIONS

Components shall be suitable for use with AFLP-3747 Jet A (F-24) turbine fuel with a specific gravity of 0.775 to 0.84, a viscosity 1.5 cSt at 100 degrees F, and a Reid Vapor Pressure 0.05 psia. Components shall be ASME Class 150 (275 psi at 100 degrees F) unless otherwise noted. Components to be suitable for outdoor, unsheltered location, and to function normally in ambient temperatures between 0 and 100 degrees F.

2.2 JOINT SEALANT

TT-S-00230, Type II, Class B.

2.3 COATING SYSTEM

Alternate systems or products will not be considered. All primer, intermediate coat and topcoat materials shall be supplied by one supplier.

The entire coating system is intended to be applied in the field.

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.

Adjust all shop preparation to avoid conflicts with final surface preparation requirements.

Section 09 97 13.27 Page 11

The Military specification epoxy and polyurethane products specified in this Section do not require approval for listing on the QPL prior to contract award, as indicated in paragraph 3.2 of MIL-DTL-24441 and paragraph 3.1 of MIL-PRF-85285. Testing of products by an independent laboratory to the QUALIFICATION INSPECTION requirements of MIL-DTL-24441 and MIL-PRF-85285 prior to contract award is required. See specific submittal requirements in paragraph QUALITY ASSURANCE.

2.3.1 Zinc-Rich Epoxy Primer Coat

Epoxy polyamide, MIL-DTL-24441/19 (Formula 159, Type III).

2.3.2 Epoxy Intermediate Coat

Epoxy polyamide, MIL-DTL-24441/31 (Formula 152, Type IV, White (Tinted)).

Tint to approximately FED-STD-595 color number 27778 parchment using pigment dispersions prepared for epoxy paint tinting. Manufacturer shall tint material and appropriately label. All other requirements of this Military Specification apply.

2.3.3 Polyurethane Topcoat

Polyurethane coating topcoat of MIL-PRF-85285, Type II, Beige FED-STD-595 color number 27769 in gloss.

Modify paragraph 3.6.4 of MIL-PRF-85285, Viscosity and Pot Life, as follows:

The viscosity of the admixed coating, when tested in accordance with ASTM D1200 through a No. 4 Ford cup, shall be as follows:

Time from mix (minimum) Maximum time through a No. 4 Ford cup

Initially 30 seconds

2 hours 60 seconds

4 hours No gel

Modify paragraph 3.7.1 of MIL-PRF-85285, Drying Time, as follows:

When applied by spray techniques and when tested in accordance with ASTM D1640, the coating shall be set-to-touch within four hours and dry-hard within eight hours (see 4.6 and table I).

2.4 COLOR IDENTIFICATION OF FUEL HANDLING AND STORAGE FACILITIES

Piping, conduit, and tank identification shall be in accordance with MIL- STD-161G. Mark direction of fluids in accordance with MIL-STD-161G.

2.5 COATING SAMPLE COLLECTION AND SHIPPING KIT

Provide a kit that contains one quart can for the base of each coating material, an appropriately sized can for each activator, dipping cups for

Section 09 97 13.27 Page 12 each component to be sampled, a shipping box sized for the samples to to be shipped, and packing material. Mark cans 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.

2.6 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.

2.7 TEST KITS

2.7.1 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.

2.7.2 Test Kit for Identifying Amine Blush on Epoxy Surfaces

After coating and/or primer has hardened and prior to applying the next coat, test for unreacted amines using the AMINE BLUSH CHECK, manufactured by Elcometer, Rochester Hills, Michigan, or equal. To be considered for approval as an "equal" test kit it shall meet the following requirements:

a. Be a completely self-contained field test kit with all materials, supplies, tools and instructions to perform tests and indicate the presence of unreacted amines;

http://www.chlor-rid.com/

Section 09 97 13.27 Page 13

b. Use an identifiable, consistent, uniform, pre-packaged, factory pre-measured indicating solution;

c. Kit contains no mercury or lead and is environmentally friendly;

d. Kit contains a solution of an unreacted amine for the purpose of "self checking" the indicator solution;

2.8 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.

Interpret MIL-A-22262 to include the meaning that abrasive material contains a maximum one percent by weight of any toxic substance listed in either Table Z-1, Z-2, or Z-3 or 29 CFR 1910-SUBPART Z, with the exception of inert or nuisance dust materials, arsenic, beryllium, cadmium, cobalt, lead, mercury, rhodium, silver, tellurium, thallium, and uranium.

2.8.1 Non-metallic Abrasive

Conform to MIL-A-22262, Type I (Inorganic materials). 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.

2.8.2 Metallic Abrasive

2.8.2.1 New and Remanufactured Steel Grit

Conform to the chemical and physical properties of SSPC AB 3 Class 1 (Steel) only. 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.

2.8.2.2 Recycled Steel Grit

Section 09 97 13.27 Page 14

Conform to the chemical and physical properties of SSPC AB 2

2.9 WHITE ALUMINUM OXIDE NON-SKID GRIT

Size #60, dust free (washed and dry), minimum 99 percent pure, having the following sieve analysis when tested in accordance with ASTM E11 using a 2.2 pound sample:

Sieve # Percent Retained

40 0

50 15-40

60 60-85

PART 3 EXECUTION

Perform all work, rework, and repair in accordance with approved procedures in the Coating Work Plan.

3.1 COATING AND ABRASIVE SAMPLE COLLECTION AND TESTING

Sample and test materials delivered to the jobsite. Notify Contracting Officer three days in advance of sampling. The QC Manager and either the PCS or coating inspector shall witness all sampling.

3.1.1 Coating Sample Collection

Provide a sample collection kit as required in paragraph COATING SAMPLE COLLECTION AND SHIPPING KIT. From each lot, obtain a one quart sample of each base material, and proportional samples of each activator based on mix ratio, by random selection from sealed containers in accordance with ASTM D3925. Prior to sampling, mix contents of each sealed container to ensure uniformity. As an alternative to collecting small samples from kits, entire kits may be randomly selected and shipped to laboratory, observing all requirements for witnessing and traceability. For purposes of quality conformance inspection, a lot is defined as that quantity of materials from a single, uniform batch produced and offered for delivery at one time. A batch is defined as that quantity of material processed by the manufacturer at one time and identified by number on the label. Identify samples by designated name, specification number, batch number, project contract number, sample date, intended use, and quantity involved. The QC manager will take possession of the packaged samples, contact the shipping company to arrange for pickup, and relinquish the samples only to the shipping representative for shipment to the approved laboratory for testing as required by the paragraph COATING SAMPLE TEST REPORTS.

3.1.2 Abrasive Sample Collection

Provide a sample collection kit as required in paragraph ABRASIVE SAMPLE COLLECTION AND SHIPPING KIT. For purposes of quality conformance inspection, a lot shall consist of all abrasive materials of the same type from a single, uniform batch produced and offered for delivery at one time.

Section 09 97 13.27 Page 15

Obtain samples of each abrasive lot using the sampling techniques and schedule of MIL-A-22262. The addition of any substance to a batch shall constitute a new lot. Identify samples by designated name, specification number, lot number, project contract number, sample date, intended use, and quantity involved. The QC manager will take possession of the packaged samples, contact the shipping company to arrange for pickup, and relinquish the samples only to the shipping representative for shipment to the approved laboratory for testing as required by the paragraph ABRASIVE SAMPLE TEST

REPORTS.

3.1.3 Coating Sample Test Reports

Submit test results for each lot of coating material delivered to the jobsite. Test samples of primer, intermediate, and topcoat materials for compliance with requirements of Table I. Reject entire lot represented by samples that fail one or more tests, select new lots, and test samples.

3.1.4 Abrasive Sample Test Reports

Submit test results for each lot of abrasive delivered to the jobsite. Test samples of metallic abrasive to the requirements of paragraph REQUIREMENTS of SSPC AB 3, except paragraph 4.1.5 DURABILITY. Test samples of non-metallic abrasive as required in paragraph QUALITY CONFORMANCE INSPECTION of MIL-A-22262. Reject entire lot represented by samples that fail one or more tests, select new lots, and test samples.

3.2 SURFACES TO BE COATED

Coat exterior surfaces of tank, including steel roof, shell, legs, stair, railing, and other exterior appurtenances. Coat exterior steel structure of Metal Building System; see Section 13 34 19 METAL BUILDING SYSTEMS.

3.3 LIGHTING

Provide lighting for all work areas as prescribed in SSPC Guide 12.

3.4 ENVIRONMENTAL CONDITIONS

3.4.1 Containment

Design and provide a containment system for the capture, containment, collection, storage and disposal of the waste materials generated by the work under this Section, to meet the requirements of SSPC Guide 6, Class 3.

Vapor concentrations shall be kept at or below 10 percent of Lower Explosive Limit (LEL) at all times. Containment may be designed as fixed containment for complete structure or portable containment for sections of structure, however, containment shall remain in any one place from beginning of abrasive blasting through initial cure of coating. Waste materials covered by this paragraph shall not include any material or residue from removal of coatings containing lead, chromium, cadmium, PCB, or any other hazardous material.

It is the Contractors responsibility to insure the feasibility and workability of the containment system. The Contractor shall perform his operations and work schedule in a manner as to minimize leakage of the containment system. The containment system shall be properly maintained and shall not deviate from the approved drawings. If the containment system

Section 09 97 13.27 Page 16 fails to function satisfactorily, the Contractor shall suspend all operations, except those required to minimize adverse impact on the environment or government property. Operations shall not resume until modifications have been made to correct the cause of the failure.

3.4.2 Automated Monitoring Requirements

Provide continuous monitoring of temperature, relative humidity, and dew point data at pertinent points on the structure, during surface preparation, coating application, and initial cure. Locate sensors to provide pertinent data for the surface preparation and coat application being performed.

Monitor any heating, cooling, or dehumidification equipment used. Make data available to the Contracting Officer through Internet access. Provide monitoring equipment to perform as follows:

a. Data is collected in the field unit in one minute increments, and available for download (on-site) in a standard format. Contractor shall collect this data and make available to the Contracting Officer;

b. Monitoring equipment shall have backup power such that data collection and transmission to web server will be uninterrupted during the entire period of the dehumidification requirement;

c. Monitoring equipment shall have capability to measure surface temperatures at a minimum of four locations anywhere on a 150 foot diameter by 50 foot high tank;

d. Monitoring equipment shall have capability to measure interior and exterior dry bulb temperature (DB), relative humidity (RH), and dewpoint temperature (DP);

e. Data shall be available continuously through secure Internet connection, using widely available web browsers;

f. Internet accessible data shall be collected and stored in maximum 15 minute increments, and lag time between data collection and online availability shall be no greater than 70 minutes;

g. Internet accessible data shall be available for viewing online in tabular format, and graphical format using selected data;

h. Internet accessible data shall be available for download in user-defined segments, or entire project to date, in a standard format usable by Microsoft Excel and other spreadsheet programs.

i. Internet-based controls shall provide alerts to pre-designated parties through email messaging;

j. Internet-based controls shall monitor data uploads from field unit and issue alert if data not initiated within 60 minutes of last upload;

k. Internet-based controls shall monitor operation of DH equipment and issues alert when power remains off for more than 15 seconds, or if pre-determined temperature, RH, or DP conditions are exceeded.

The requirements listed here were developed around the Munters Exactaire Monitoring System, as this was the only monitoring system having Internet

Section 09 97 13.27 Page 17 connectivity known to be commercially available. There is no requirement for connectivity of the monitoring system to control the DH equipment, therefore, any combination of equipment having the required functionality will be accepted.

3.5 SURFACE PREPARATION

3.5.1 Abrasive Blasting Equipment

Use abrasive blasting equipment of conventional air, force-feed, or pressure type. Maintain a minimum pressure of 95 psig at nozzle. Confirm that air supply for abrasive blasting is free of oil and moisture when tested in accordance with ASTM D4285. Test air quality at each startup, but in no case less often than every five operating hours.

3.5.2 Operational Evaluation of Abrasive

Test abrasive for salt contamination and oil contamination as required by the appropriate abrasive specification daily at startup and every five operating hours thereafter.

3.5.3 Surface Standard

Inspect surfaces to be coated, and select plate with similar properties and surface characteristics for use as a surface standard. Blast clean one or more 1 foot square steel panels as specified in paragraph SURFACE PREPARATION. Record blast nozzle type and size, air pressure at nozzle and compressor, distance of nozzle from panel, and angle of blast to establish procedures for blast cleaning. Measure surface profile in accordance with ASTM D7127. When the surface standard complies with all specified requirements, seal with a clearcoat protectant. Use the surface standard for comparison to abrasive blasted surfaces throughout the course of work.

3.5.4 Pre-Preparation Testing for Surface Contamination

Perform testing, abrasive blasting, and testing in the prescribed order.

3.5.4.1 Pre-Preparation Testing for Oil and Grease Contamination

Inspect all surfaces for oil and/or grease contamination using two or more of the following inspection techniques: 1) Visual inspection, 2) WATER BREAK TEST, 3) CLOTH RUB TEST. Reject oil and/or grease contaminated surfaces, clean in accordance with SSPC SP 1, and recheck for contamination until surfaces are free of oil and grease.

WATER BREAK TEST - Spray atomized mist of distilled water onto surface, and observe for water beading. If water "wets" surface rather than beading up, surface can be considered free of oil or grease contamination. Beading of water (water forms droplets) is evidence of oil or grease contamination.

CLOTH RUB TEST - Rub a clean, white, lint free, cotton cloth onto surface and observe for discoloration. To confirm oil or grease contamination in lightly stained areas, a non-staining solvent may be used to aid in oil or grease extraction. Any visible discoloration is evidence of oil or grease contamination.

Section 09 97 13.27 Page 18

3.5.4.2 Pre-Preparation Testing for Soluble Salts Contamination

Test surfaces for soluble salts, and wash as required, prior to abrasive blasting. Soluble salt testing is also required in paragraph PRE- APPLICATION TESTING FOR SOLUBLE SALTS CONTAMINATION as a final acceptance test of prepared surfaces after abrasive blasting, and successful completion of this phase does not negate that requirement. This phase is recommended since pre-preparation testing and washing are generally more advantageous than attempting to remove soluble salt contamination after abrasive blasting. Effective removal of soluble salts will require removal of any barrier to the steel surface, including rust. This procedure may necessitate combinations of wet abrasive blasting, high pressure water rinsing, and cleaning using a solution of water washing and soluble salts remover. The soluble salts remover shall be acidic, biodegradable, nontoxic, noncorrosive, and after application, will not interfere with primer adhesion. Delays between testing and preparation, or testing and coating application, may allow for the formation of new contamination. Use potable water, or potable water modified with soluble salt remover, for all washing or wet abrasive blasting. Test methods and equipment used in this phase are selected at the Contractor's discretion.

3.5.5 Abrasive Blasting

Abrasive blast steel surfaces to near-white metal in accordance with SSPC SP

10. Prepared surfaces shall conform to SSPC VIS 1 and shall match the prepared test-panels. Provide a 2 to 3 mil surface profile. Reject profile greater than 3 mils, discontinue abrasive blasting, and modify processes and materials to provide the specified profile. Measure surface profile in accordance with ASTM D7127, 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. Following abrasive blasting, remove dust and debris by vacuum cleaning. Do not attempt to wipe surface clean.

3.5.6 Disposal of Used Abrasive

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

3.5.7 Pre-Application Testing For Surface Contamination

3.5.7.1 Pre-Application Testing for Oil and Grease Contamination

Ensure surfaces are free of contamination as described in paragraph PRE- PREPARATION TESTING FOR OIL AND GREASE CONTAMINATION, except that only questionable areas need be checked for beading of water misted onto surface.

3.5.7.2 Pre-Application Testing for Soluble Salts Contamination

Test surfaces for chloride contamination using the Test Kit described in

TEST KIT FOR MEASURING CHLORIDE, SULFATE AND NITRATE IONS ON STEEL AND

COATED SURFACES. Test all surfaces at rate of three tests for the first 1000 square feet plus one test for each additional 2000 square feet or part thereof. On the new structures, perform 30 percent of tests on bare steel at welds, divided equally between horizontal and vertical welds. One or

Section 09 97 13.27 Page 19 more readings greater than 3 micrograms per square centimeter of chlorides or 10 micrograms per square centimeter of sulfates or 5 micrograms per square centimeter of nitrates is evidence of soluble salt contamination.

Reject contaminated surfaces, wash as discussed in paragraph PRE-PREPARATION TESTING FOR SOLUBLE SALTS CONTAMINATION, allow to dry, and re-test until all required tests show allowable results. Reblast tested and cleaned areas as required. Label all test tubes and retain for test verification.

3.5.7.3 Pre-Application Testing for Surface Cleanliness

Apply coatings to dust free surfaces. To test surfaces, apply strip of clear adhesive tape to surface and rub onto surface with finger. When removed, the tape should show little or no dust, blast abrasive, or other contaminant. Reject contaminated surfaces and retest. Test surfaces at rate of three tests for the first 1000 square feet plus one test for each additional 1000 square feet or part thereof. Provide two additional tests for each failed test or questionable test. Attach test tapes to Daily Inspection Reports.

3.6 MIXING AND APPLICATION OF SEALANT AND COATING SYSTEM

3.6.1 Preparation of Sealant and Coating Materials for Application

Each of the sealant, primer, intermediate, and topcoat materials is a two-component material supplied in separate containers.

3.6.1.1 Mixing Sealant, Primer and Intermediate Coat Materials

Mix in accordance with manufacturer's instructions, which may differ for each product. Do not mix partial kits, or alter mix ratios. Mix materials in same temperature and humidity conditions specified in paragraph DELIVERY AND STORAGE. Allow mixed material to stand for the required induction time based on its temperature.

3.6.1.2 Mixing Topcoat Material

Do not mix partial kits, or alter mix ratios. Mix polyurethane coating materials in same temperature conditions specified in paragraph DELIVERY AND STORAGE. The polyurethane coating material is moisture sensitive and any introduction of moisture or water into the material during mixing or application will shorten usable pot life. Use a mixer that does not create a vortex. Do not add solvent without specific written recommendation from the manufacturer. No induction time is required, only thorough agitation of the mixed material.

3.6.1.3 Pot Life

Apply mixed products within stated pot life for each product. Stop applying when material becomes difficult to apply in a smooth, uniform wet film. Add all required solvent at time of mixing. Do not add solvent to extend pot life. Pot life is based on standard conditions at 70 degrees F and 50 percent relative humidity. For every 18 degrees F rise in temperature, pot life is reduced by approximately half, and for every 18 degrees F drop it is approximately doubled. Usable pot life depends on the temperature of the material at the time of mixing and the sustained temperature at the time of application. Other factors such as the shape of the container and volume of mixed material may also affect pot life. Precooling or exterior icing of

Section 09 97 13.27 Page 20 components for at least 24 hours to a minimum of 50 degrees F in hot climates will extend pot life. High humidity at time of mixing and application shortens pot life of the Polyurethane topcoat material.

Following are approximate pot life times:

Sealant As specified by manufacturerEpoxy primer and intermediate materials 4 hours.

Polyurethane topcoat materials 2 hours.

3.6.1.4 Application Conditions and Recoat Windows

The application condition requirements for the coating system are very time and temperature sensitive, and are intended to avoid the delamination problems frequently found on industrial structures. Plan coating application to ensure that specified temperature, humidity, and condensation conditions are met. If conditions do not allow for orderly application of sealant, primer, stripe coat, intermediate coat and topcoat, use appropriate means of controlling air and surface temperatures, as required. Partial or total enclosures, insulation, heating or cooling, or other appropriate measures may be required to control conditions to allow for orderly application of all required coats.

Maintain air and steel surface temperature between 60 and 100 degrees F during application and the first four hours of cure for epoxy coats and the first eight hours of cure for polyurethane coats. Maintain steel surface temperature more than 5 degrees F above the dew-point of the ambient air for the same period.

Use Table entitled "RECOAT WINDOWS" to determine appropriate recoat windows for each coat after the initial coat. Apply each coat during appropriate RECOAT WINDOW of preceding coat. If a RECOAT WINDOW is missed, the minimum and maximum primer and intermediate coat thickness may be adjusted to accommodate a FILL COAT, however, requirements for total epoxy coating thickness and total coating thickness will not be modified. Missing more than one RECOAT WINDOW may require complete removal of coating if maximum total coating thickness requirements cannot be achieved.

If coating is not applied during RECOAT WINDOW, or if surface temperature exceeds 120 degrees F between applications, provide GLOSS REMOVAL, apply next coat within 24 hours. If next planned coat is topcoat, apply FILL COAT if required to fill sanding marks. Sanding marks from GLOSS REMOVAL of intermediate coat reflecting through topcoat will be considered as noncompliant. Apply FILL COAT within 24 hours of GLOSS REMOVAL, then apply topcoat within RECOAT WINDOW of FILL COAT.

RECOAT WINDOWS

EPOXY OVER EPOXY

Temperature degrees F

60-70 71-80 12-36 91-100 101-110 111-120

Section 09 97 13.27 Page 21

RECOAT WINDOWS

RECOAT

WINDOW

(Hrs.)

24-72 18-60 16-48 12-36 8-18 4-6

POLYURETHANE OVER EPOXY

Temperature degrees F

60-70 71-80 12-36 91-100 101-110 111-120

RECOAT

WINDOW

(Hrs.)

24-96 24-72 16-48 12-36 10-24 8-16

POLYURETHANE OVER POLYURETHANE

Temperature degrees F

60-70 71-80 12-36 91-100 101-110 111-120

RECOAT

WINDOW

(Hrs.)

8-48 6-48 4-36 3-24 2-12 1-2

The temperature ranges shown in the table above are for determining recoat windows. Choose recoat window based on the highest surface temperature that was sustained for one or more hours between coats. This applies to the entire time between coats. Measure and record air and surface temperatures on hourly basis to determine appropriate recoat windows. If surface temperature goes above 100 degrees F, measure and record temperatures every half hour.

FILL COAT - Where indicated, apply coat of intermediate coat epoxy, at 2 to 3 mils DFT, then apply next specified full coat within recoat window of FILL COAT.