AMD-0002-09_97_02-Painting-Hydraulic-Structures.pdf

Solicitation No. W912DS-16-R-0015

SECTION TABLE OF CONTENTS

DIVISION 09 - FINISHES

SECTION 09 97 02

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 WORK PERFORMANCE

1.4 QUALIFICATIONS

1.4.1 Qualified Paint Applicator

1.4.1.1 Certification Test Procedure

1.4.1.2 Certification Criteria

1.4.2 Coating Thickness Gage Qualification

1.5 SAMPLING AND TESTING

1.6 QUALITY CONTROL PERSONNEL

1.7 SAFETY AND HEALTH PROVISIONS

1.7.1 Abrasive Blasting

1.7.1.1 Hoses And Nozzles

1.7.1.2 Workers Other Than Blasters

1.7.2 Cleaning with Compressed Air

1.7.3 Cleaning with Solvents

1.7.3.1 Ventilation

1.7.3.2 Personal Protective Equipment

1.7.4 Paint Application

1.7.4.1 Ventilation

1.7.4.2 Explosion Proof Equipment

1.7.4.3 Further Precautions

1.7.4.4 Ignition Sources

1.7.5 Health Protection

1.7.5.1 Air Sampling

1.7.5.2 Respirators

1.7.5.3 Protective Clothing and Equipment

1.8 MEDICAL STATUS

1.9 CHANGE IN MEDICAL STATUS

1.10 ENVIRONMENTAL PROTECTION

1.10.1 Visible Emissions Monitoring

1.10.2 Air Quality Monitoring

1.10.2.1 PM-10 Monitoring

1.10.2.2 TSP Monitoring

1.11 PAINT PACKAGING, DELIVERY, AND STORAGE

PART 2 PRODUCTS

2.1 SPECIAL PAINT FORMULAS

2.2 PAINT FORMULATIONS

2.2.1 Formula V-766e, Vinyl-Type White (or Gray) Impacted Immersion

Coating

2.2.2 Formula VZ-108d, Vinyl-Type Zinc-Rich Impacted Immersion Coating

2.2.3 Formula V-102e, Vinyl-Type Ready-Mixed Aluminum Impacted

Immersion Coating

2.3 INGREDIENTS FOR SPECIAL PAINT FORMULAS

2.3.1 Pigments and Suspending Agents

2.3.1.1 Aluminum Powder

SECTION TABLE OF CONTENTS 09 97 02 Page 1 AMENDMENT 0002

2.3.1.2 Carbon Black

2.3.1.3 Zinc Dust

2.3.1.4 Iron Oxide

2.3.1.5 Titanium Dioxide

2.3.1.6 Suspending Agent E

2.3.1.7 Suspending Agent F

2.3.2 Resins, Plasticizer, and Catalyst

2.3.2.1 Diisodecyl Phthalate

2.3.2.2 Vinyl Resin, Type 3

2.3.2.3 Vinyl Resin, Type 4

2.3.2.4 Ortho-phosphoric Acid

2.3.3 Solvent and Thinners

2.3.3.1 Methanol

2.3.3.2 Methyl Ethyl Ketone

2.3.3.3 Methyl Isobutyl Ketone

2.3.3.4 Methyl Isoamyl Ketone

2.3.3.5 Toluene

2.3.4 Silane B

2.4 TESTING

2.4.1 Chromatographic Analysis

2.4.2 Vinyl Paints

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

3.1.2 Ferrous Surfaces Subject to Atmospheric Exposures

3.1.3 Ferrous Surfaces Subject to Severe Exposure

3.1.4 Galvanized, Aluminum, Aluminum Alloy, or Copper Surfaces

3.2 PAINT APPLICATION

3.2.1 General

3.2.2 Mixing and Thinning

3.2.3 Atmospheric and Surface Conditions

3.2.4 Time Between Surface Preparation and Painting

3.2.5 Method of Paint Application

3.2.6 Coverage and Film Thickness

3.2.6.1 Measurement on Ferrous Metal

3.2.7 Progress of Painting Work

3.2.8 Contacting Surfaces

3.2.9 Drying Time Prior to Immersion

3.2.10 Protection of Painted Surfaces

3.2.11 Vinyl Paints

3.2.11.1 General

3.2.11.2 Vinyl Zinc-Rich Primer

3.2.11.3 Vinyl Paints

3.3 PAINT SYSTEMS APPLICATION

3.3.1 Fabricated and Assembled Items

3.3.2 Surface Preparation

3.3.3 System No. 3-A-Z

3.4 INSPECTION

3.5 PAINTING SCHEDULES

-- End of Section Table of Contents --

SECTION TABLE OF CONTENTS 09 97 02 Page 2 AMENDMENT 0002

SECTION 09 97 02

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM D1045 (2014) Sampling and Testing Plasticizers Used in Plastics

ASTM D1152 (2006; R 2012) Methanol (Methyl Alcohol)

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

ASTM D1153 (2012) Methyl Isobutyl Ketone

ASTM D1210 (2005; R 2010) Fineness of Dispersion of Pigment-Vehicle Systems by Hegman-Type Gage

ASTM D153 (1984; R 2008) Specific Gravity of Pigments

ASTM D281 (2012) Oil Absorption of Pigments by Spatula Rub-Out

ASTM D2917 (2007; R 2013) Methyl Isoamyl Ketone

ASTM D304 (2011) n-Butyl Alcohol (Butanol)

ASTM D3721 (2005; R 2011) Synthetic Red Iron Oxide Pigment

ASTM D520 (2000; R 2011) Zinc Dust Pigment

ASTM D4417 (2014) Field Measurement of Surface Profile of Blast Cleaned Steel

ASTM D561 (1982; R 2008) Carbon Black Pigment for Paint

ASTM D7091 (2013) Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nondestructive Coatings Applied to Non-Ferrous Metals

ASTM D740 (2011) Methyl Ethyl Ketone

ASTM D841 (2013) Nitration Grade Toluene

SECTION 09 97 02 Page 1 AMENDMENT 0002

ASTM D962 (1981; R 2014) Aluminum Powder and Paste Pigments for Paints

ASTM E1347 (2006; R 2011) Color and Color Difference Measurement by Tristimulus (Filter) Colorimetry

INTERNATIONAL SAFETY EQUIPMENT ASSOCIATION (ISEA)

ANSI/ISEA Z87.1 (2015) Occupational and Educational Personal Eye and Face Protection Devices

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3-4 2014; AMD 4-6 2014) National Electrical Code

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC Paint 27 (1982; E 2004) Basic Zinc Chromate-Vinyl Butyral Wash Primer

SSPC SP 1 (2015) Solvent Cleaning

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

SSPC SP 6 (2007) Commercial Blast Cleaning

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FED-STD-595 (Rev C; Notice 1) 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 1910.94 Ventilation

29 CFR 1926 Safety and Health Regulations for Construction

40 CFR 58 Ambient Air Quality Surveillance

40 CFR 60 Standards of Performance for New Stationary Sources

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

SECTION 09 97 02 Page 2 AMENDMENT 0002 that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals (Prefabrication Submittals)

Preparation and Painting Management Program; G

The Contractor shall review the specified preparation and painting work tasks and methods and shall develop a detailed Preparation and Painting Management Program that identifies the work procedures and safety and health measures to be used during the course of the work under this contract. The program plan shall address the various sources of hazardous substances and the methods to be undertaken to address these hazards. The Contractor shall not begin any preparation and painting work until the Safety and Health Plan has been reviewed and approved by the Contracting Officer.

Quality Control (Inspections)

The Contractor shall develop a plan for documentation and submittal of all quality control requirements. Submittals shall be made on a daily basis and shall include but are not limited to:

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

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

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

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

Equipment List

A list of equipment items to be used in the work, including brand names, model, capacity, performance characteristics, quantities and other pertinent information.

SD-04 Samples

Special Paint Formulas; G

The Contractor shall submit samples of all special paint formula and proprietary paints. For products that are specified to be applied in accordance with the manufacturer's recommendations the Contractor shall submit the paint producer's product data sheet or other written instructions for those products.

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Solvent and Thinners; G

Samples shall be submitted of the thinners which are those solvents used to reduce the viscosity of the paint.

SD-07 Certificates

Qualified Paint Applicator; G

Documentation of certification shall be submitted for all paint applicators.

Coating Thickness Gage Qualification; G

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

1.3 WORK PERFORMANCE

Work shall be performed in accordance with the requirements of 29 CFR 1910 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.

1.4 QUALIFICATIONS

Qualifications and experience shall comply with the following.

1.4.1 Qualified Paint Applicator

Documentation of certification shall be submitted for all paint applicators. Prior to the initiation of any work all paint applicators shall be tested and certified as meeting the requirements of the qualified paint applicator. Certification shall be administered by the government approved independent third party Test Agency. Applicators failing the certification test shall not be permitted to apply any paint on the project.

1.4.1.1 Certification Test Procedure

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

1.4.1.2 Certification Criteria

The paint applicator shall be evaluated based on the conformance of the

SECTION 09 97 02 Page 4 AMENDMENT 0002 applied paint system to the requirements of the specifications.

Deficiencies in the coatings, improper mixing or improper application methods are basis for failure. The Test Agency shall be the sole judge as to the acceptability of each paint applicators performance.

1.4.2 Coating Thickness Gage Qualification

Documentation of certification shall be submitted for all coating thickness gages. Magnetic flux thickness gages as described in ASTM D7091 shall be used to make all coating thickness measurements on ferrous metal substrates. Gages shall have an accuracy of +/- 3 percent or better. Gages to be used on the job shall be certified by the manufacturer as meeting these requirements.

1.5 SAMPLING AND TESTING

The Contractor shall allow at least 30 days for sampling and testing.

Sampling may be at the site of fabrication or source of supply. The Contractor shall notify the Contracting Officer when the paint and thinner are available for sampling. Sampling of each batch shall be witnessed by the Contracting Officer unless otherwise specified or directed. A 1-quart sample of paint and thinner shall be submitted for each batch proposed for use. The sample shall be labeled to indicate formula or specification number and nomenclature, batch number, batch quantity, color, date made, and applicable project contract number. Testing will be performed by the Government. Costs for retesting rejected material will be deducted from payments to the Contractor at the rate of $250.00 for each sample retested.

1.6 QUALITY CONTROL PERSONNEL

The painting (sub)contractor's Quality Control personnel shall have received formal training in paint inspection and testing of the specified paint system and methods of applications proposed. All quality control personnel shall have a minimum of 2 years experience in inspection and testing of paint systems. The Contractor shall present to the Contracting Officer credentials for each quality control person who will be inspecting the painting operations, showing the individual is versed in inspection techniques.

1.7 SAFETY AND HEALTH PROVISIONS

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

1.7.1 Abrasive Blasting

The Contractor shall comply with the requirements in Section 06.H of

EM 385-1-1.

1.7.1.1 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

SECTION 09 97 02 Page 5 AMENDMENT 0002 used. Hose lengths shall be joined together by approved couplings of a material and type designed to prevent erosion and weakening of the couplings. The couplings and nozzle attachments shall fit on the outside of the hose and shall be designed to prevent accidental disengagement.

1.7.1.2 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 ANSI/ISEA Z87.1and 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.

1.7.2 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.

1.7.3 Cleaning with Solvents

1.7.3.1 Ventilation

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

1.7.3.2 Personal Protective Equipment

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

1.7.4 Paint Application

1.7.4.1 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.

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1.7.4.2 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.

1.7.4.3 Further Precautions

a. Workers must wear nonsparking safety shoes.

b. Place and ground solvent drums, taken into the spraying area, on nonferrous surfaces. Maintain metallic bonding between containers and drums when materials are being transferred.

c. Inspect insulation on all power and lighting cables 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.

1.7.4.4 Ignition Sources

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

1.7.5 Health Protection

1.7.5.1 Air Sampling

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

1.7.5.2 Respirators

During all spray painting operations, spray painters shall use approved SCBA or SAR (air line) respirators, unless valid air sampling has demonstrated contaminant levels to be consistently within concentrations that are compatible with air-purifying respirator Assigned Protection Factor (APF). Persons with facial hair that interferes with the sealing surface of the facepiece to faceseal or interferes with respirator valve function shall not be allowed to perform work requiring respiratory protection. Air-purifying chemical cartridge/canister half- or full-facepiece respirators that have a particulate prefilter and are suitable for the specific type(s) of gas/vapor and particulate

SECTION 09 97 02 Page 7 AMENDMENT 0002 contaminant(s) may be used for nonconfined space painting, mixing, and cleaning (using solvents). These respirators may be used provided the measured or anticipated concentration of the contaminant(s) in the breathing zone of the exposed worker does not exceed the APF for the respirator and the gas/vapor has good warning properties or the respirator assembly is equipped with a NIOSH-approved end of service life indicator for the gas(es)/vapor anticipated or encountered. Where paint contains toxic elements such as lead, cadmium, chromium, or other toxic particulates that may become airborne during painting in nonconfined spaces, air-purifying half- and full-facepiece respirators or powered air-purifying respirators equipped with appropriate gas vapor cartridges, in combination with a high-efficiency filter, or an appropriate canister incorporating a high-efficiency filter, shall be used.

1.7.5.3 Protective Clothing and Equipment

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

1.8 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 1910.1020. The evaluation shall include:

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

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

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

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

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

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

(4) Determination of baseline values of biological indices for later comparison to changes associated with exposure to paint systems and thinners or blast media, which include: liver function tests to include SGOT, SGPT, GGPT, alkaline phosphates, bilirubin, complete urinalysis, EKG (employees over age 40), blood urea nitrogen (bun), serum creatinine, pulmonary function test, FVC, and FEV, chest x-ray (if medically indicated), blood lead and ZPP

SECTION 09 97 02 Page 8 AMENDMENT 0002

(for individuals where it is known there will be an exposure to materials containing lead), other criteria that may be deemed necessary by the Contractor's physician, and Physician's statements for individual employees that medical status would permit specific task performance.

1.9 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 the Contractor shall obtain a physicians statement as described in paragraph MEDICAL STATUS prior to allowing the employee to return to those work tasks. The Contractor shall notify the Contracting Officer in writing of any negative changes in employee medical status and the results of the physicians reevaluation statement.

1.10 ENVIRONMENTAL PROTECTION

Comply with the following environmental protection criteria:

1.10.1 Visible Emissions Monitoring

The time of emissions shall be measured in accordance with 40 CFR 60, App A, Mtd 22. Visible emissions shall be monitored for not less than 15 minutes of every hour. Visible emissions for each hour shall be calculated by extrapolation. In no case shall visible emissions extend greater than 150 feet in any direction horizontal from the containment. In no case shall visible emissions be observed in the area of any sensitive receptor. If such emissions occur the job shall be shut down immediately and corrective action taken. The foreman shall be notified whenever visible emissions exceed 40 seconds in a 1 hour period. The foreman shall be notified and the job shall be shut down and corrective action taken whenever visible emissions exceed 75 seconds in a 2 hour period. Total observed visible emissions from the containment shall not exceed 1 percent of the work day. Shutdown and corrective action shall be taken by the Contractor to prevent such an occurrence. The Contractor shall document each time that the work is halted due to a violation of the visible emissions criteria. Documentation shall include the cause for shutdown and the corrective action taken to resolve the problem.

1.10.2 Air Quality Monitoring

1.10.2.1 PM-10 Monitoring

The Contractor shall perform PM-10 monitoring. The positioning of air monitoring equipment shall be in accordance with 40 CFR 58, App E, Subpart (8). In addition, a minimum of two PM-10 monitors shall be used at the project site, one down wind from the project and one in the area of greatest public access (e.g., playground, school yard, or homeowner's yard). When the project is in an area where there are critical receptors nearby, monitoring shall be conducted throughout the entire period that abrasive blasting and cleanup operations are performed. Otherwise, monitoring shall be performed 4 of the first 8 days and on a regular basis thereafter for a sum total of 25 percent of the time surface preparation and debris cleanup are performed. Failure to meet air quality regulatory limits shall require air monitoring to be repeated immediately after corrective actions have been taken. The Contractor shall also conduct preproject PM-10 monitoring. The preproject PM-10 monitoring shall be

SECTION 09 97 02 Page 9 AMENDMENT 0002 conducted a minimum of 2 weeks prior to the beginning of the project. The monitoring shall continue for a minimum of 3 days to establish background levels. A report of the results shall be submitted to the Contracting Officer within 48 hours and shall include:

a. Name and location of jobsite.

b. Date of monitoring.

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

d. Identification and serial number of monitoring units.

e. Drawing showing specific location of monitoring units.

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

g. Wind direction and velocity.

h. A flow chart verifying the rate of air flow across the filter throughout the sampling period.

i. Name and address of laboratory.

j. Laboratory test procedure.

k. Laboratory test results.

l. Signatures of field and laboratory technicians conducting the work.

1.10.2.2 TSP Monitoring

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

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

Failure to meet air quality regulatory limits shall require air monitoring to be repeated immediately after corrective actions have been taken. The Contractor shall also conduct preproject TSP monitoring. The preproject TSP monitoring shall be conducted a minimum of 2 weeks prior to the beginning of the project. The monitoring shall continue for a minimum of 3 days to establish background levels. A report of the results shall be submitted to the Contracting Officer within 48 hours and shall include:

a. Name and location of jobsite.

b. Date of monitoring.

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

d. Identification and serial number of monitoring units.

SECTION 09 97 02 Page 10 AMENDMENT 0002

e. Drawing showing specific location of monitoring units.

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

g. Wind direction and velocity.

h. A flow chart verifying the rate of air flow across the filter throughout the sampling period.

i. Name and address of laboratory.

j. Laboratory test procedure.

k. Laboratory test results.

l. Signatures of field and laboratory technicians conducting the work.

1.11 PAINT PACKAGING, DELIVERY, AND STORAGE

Paints shall be processed and packaged to ensure that within a period of one year from date of manufacture, they will not gel, liver, or thicken deleteriously, or form gas in the closed container. Paints, unless otherwise specified or permitted, shall be packaged in standard containers not larger than 5 gallons, with removable friction or lug-type covers.

Containers for vinyl-type paints shall be lined with a coating resistant to solvents in the formulations and capable of effectively isolating the paint from contact with the metal container. Each container of paint or separately packaged component thereof shall be labeled to indicate the purchaser's order number, date of manufacture, manufacturer's batch number, quantity, color, component identification and designated name, and formula or specification number of the paint together with special labeling instructions, when specified. Paint shall be delivered to the job in unbroken containers. Paints that can be harmed by exposure to cold weather shall be stored in ventilated, heated shelters. All paints shall be stored under cover from the elements and in locations free from sparks and flames.

PART 2 PRODUCTS

2.1 SPECIAL PAINT FORMULAS

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

2.2 PAINT FORMULATIONS

Special paint formulas shall comply with the following:

2.2.1 Formula V-766e, Vinyl-Type White (or Gray) Impacted Immersion Coating

The ingredients for this formula are shown in the table below.

SECTION 09 97 02 Page 11 AMENDMENT 0002

INGREDIENTS PERCENT BY MASS

Vinyl Resin, Type 3 5.6

Vinyl Resin, Type 4 11.6

Titanium Dioxide and (for Gray) Carbon Black

13.0

Diisodecyl Phthalate 2.9

Methyl Isobutyl Ketone 32.0

Toluene 34.7

Ortho-Phosphoric Acid 0.2

Total 100.0

a. The dispersion of pigment shall be accomplished by means of pebble mills or other approved methods to produce a fineness of grind (ASTM D1210) of not less than 7 on the Hegman scale. Grinding in steel-lined or steel-ball mills will not be permitted. No grinding aids, antisettling agents, or any other materials except those shown in the formula will be permitted. The paint shall show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods. The ortho-phosphoric acid shall be measured accurately and diluted with at least four parts of ketone to one part of acid and it shall be slowly incorporated into the finished paint with constant and thorough agitation.

b. The viscosity of the paint shall be between 60 and 90 seconds using ASTM D1200 and a No. 4 Ford cup.

c. The white and gray paints shall be furnished in the volume ratio designated by the purchaser. The gray paint shall contain no pigments other than those specified. Enough carbon black shall be included to produce a dry paint film having a reflectance of 20-24 (ASTM E1347).

The resulting gray color shall approximate color 26231 of FED-STD-595.

2.2.2 Formula VZ-108d, Vinyl-Type Zinc-Rich Impacted Immersion Coating

The ingredients for this formula are shown in the table below.

INGREDIENTS PERCENT BY

WEIGHT

POUNDS GALLONS

COMPONENT A

Vinyl Resin, Type 3

16.6 109.2 9.65

Methyl Isobutyl Ketone

80.6 528.9 79.30

SECTION 09 97 02 Page 12 AMENDMENT 0002

INGREDIENTS PERCENT BY

WEIGHT

POUNDS GALLONS

Suspending Agent E

0.7 4.6 0.28

Suspending Agent F

0.4 2.7 0.19

Methanol 0.5 3.3 0.50

Synthetic Iron Oxide

1.2 7.9 0.19

Total 100.0 656.6 90.11

COMPONENT B

Silane B 100.0 4.1 0.47

COMPONENT C

Zinc Dust 100.0 550.0 9.42

Total Volume 100.00 (mixed paint)

a. The iron oxide and suspending agents shall be dispersed into the vehicle (Component A) to a fineness of grind of not less than 4 on the Hegman scale (ASTM D1210). Grinding in steel-lined containers or using steel-grinding media shall not be permitted. The sole purpose of the iron oxide pigment is to produce a contrasting color. A red iron oxide-type 3 vinyl resin vehicle paste may be used in place of dry iron oxide provided compensating adjustment are made in the additions of Type 3 resin and methyl isobutyl ketone. The finished product with zinc dust added shall produce a paint which has a red tone upon drying and a reflectance of not more than 16 (ASTM E1347).

b. VZ-108d paint shall be supplied as a kit. Each kit shall consist of

4.5 gallons (33.1 pounds) of Component A in a 5-gallon lug closure type pail, 27.5 pounds of zinc dust (Component C) packaged in a 1-gallon plastic pail, and 3 fluid ounces of silane (Component B) packaged in a glass bottle of suitable size having a polyethylene lined cap. The bottle of silane shall be placed on the zinc dust in the 1-gallon pail. In addition to standard labeling requirements, each container of each component shall be properly identified as to component type and each container label of Component A shall carry the following: MIXING AND APPLICATION INSTRUCTIONS: WARNING - THIS PAINT WILL NOT ADHERE TO STEEL SURFACES UNLESS COMPONENT B IS ADDED. Remove the 3 ounces of bottled Component B (silane) from the Component C (zinc dust) container and add to the base paint Component A) with thorough stirring. Then sift the zinc dust into the base paint while it is being vigorously agitated with a power-driven stirrer and continue the stirring until the zinc dust has been dispersed. The mixed paint shall at some point be strained through a 30-60 mesh screen to prevent zinc dust slugs from reaching the spray gun nozzle. The paint shall be stirred continuously during application at a rate that will prevent settling. If spraying is interrupted for longer than 15 minutes, the entire length of the hose shall be whipped vigorously to redisperse the zinc. If the spraying is to be interrupted for more than 1 hour, the

SECTION 09 97 02 Page 13 AMENDMENT 0002 hose shall be emptied by blowing the paint back into the paint pot.

Thinning will not normally be required when ambient temperatures are below about 80 degrees F, but when the ambient and steel temperatures are higher, methyl isoamyl ketone (MIAK) or methyl isobutyl ketone (MIBK) should be used. If paint is kept covered at all times, its pot life will be about 8 days.

2.2.3 Formula V-102e, Vinyl-Type Ready-Mixed Aluminum Impacted Immersion Coating

The ingredients for this formula are shown in the table below.

INGREDIENTS PERCENT BY MASS

Vinyl Resin, Type 3 18.2

Aluminum Powder 8.3

Diisodecyl Phthalate 3.1

Methyl Isobutyl Ketone 33.8

Toluene 36.6

Total 100.0

a. Furnish with the aluminum pigment mixed into the vehicle.

b. The viscosity of the paint shall be between 60 and 90 seconds using ASTM D1200 and a No. 4 Ford cup. The paint shall show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods.

2.3 INGREDIENTS FOR SPECIAL PAINT FORMULAS

The following ingredient materials and thinners apply only to those special paints whose formulas are shown above in detail.

2.3.1 Pigments and Suspending Agents

2.3.1.1 Aluminum Powder

For vinyl paint aluminum powder shall conform to ASTM D962, Type 1, Class B.

2.3.1.2 Carbon Black

Carbon black shall conform to ASTM D561, Type I or II.

2.3.1.3 Zinc Dust

Zinc dust pigment shall conform to ASTM D520, Type II.

2.3.1.4 Iron Oxide

Iron oxide, (Dry) synthetic (red), shall conform to ASTM D3721. In addition, the pigment shall have a maximum oil absorption of 24 and a specific gravity of 4.90 to 5.20 when tested in accordance with ASTM D281

SECTION 09 97 02 Page 14 AMENDMENT 0002 and ASTM D153, Method A, respectively. When the pigment is dispersed into specified vinyl paint formulation, the paint shall have color approximating FED-STD-595 color 10076 (dark red paint), and shall show no evidence of incompatibility or reaction between pigment and other components after 6 months storage.

2.3.1.5 Titanium Dioxide

Titanium dioxide in vinyl paint Formula V-766e shall be one of the following: Kronos 2160 or 2101, Kronos, Inc.; Ti-Pure 960, E.I. Dupont DeNemours and Co., Inc.

2.3.1.6 Suspending Agent E

Suspending Agent E shall be a light cream colored finely divided powder having a specific gravity of 2 to 2.3. It shall be an organic derivative of magnesium aluminum silicate mineral capable of minimizing the tendency of zinc dust to settle hard without increasing the viscosity of the paint appreciably. MPA-14, produced by RHEOX, Inc., has these properties.

2.3.1.7 Suspending Agent F

Suspending Agent F shall be a light cream colored finely divided powder having a specific gravity of approximately 1.8. It shall be an organic derivative of a special montmorillonite (trialkylaryl ammonium hectorite).

Bentone 27, produced by RHEOX, Inc., has these properties.

2.3.2 Resins, Plasticizer, and Catalyst

2.3.2.1 Diisodecyl Phthalate

Diisodecyl Phthalate shall have a purity of not less than 99.0 percent, shall contain not more than 0.1 percent water, and shall have an acid number (ASTM D1045) of not more than 0.10.

2.3.2.2 Vinyl Resin, Type 3

Vinyl resin, Type 3, shall be a vinyl chloride-acetate copolymer of medium average molecular weight produced by a solution polymerization process and shall contain 85 to 88 percent vinyl chloride and 12 to 15 percent vinyl acetate by weight. The resin shall have film-forming properties and shall, in specified formulations, produce results equal to Vinylite resin VYHH, as manufactured by the Union Carbide Corporation.

2.3.2.3 Vinyl Resin, Type 4

Vinyl resin, Type 4, shall be a copolymer of the vinyl chloride-acetate type produced by a solution polymerization process, shall contain (by weight) 1 percent interpolymerized dibasic acid, 84 to 87 percent vinyl chloride, and 12 to 15 percent vinyl acetate. The resin shall have film-forming properties and shall, in the specified formulations, produce results equal to Vinylite resin VMCH, as manufactured by the Union Carbide Corporation.

2.3.2.4 Ortho-phosphoric Acid

Ortho-phosphoric acid shall be a chemically pure 85-percent grade.

SECTION 09 97 02 Page 15 AMENDMENT 0002

2.3.3 Solvent and Thinners

2.3.3.1 Methanol

Methanol (methyl alcohol) shall conform to ASTM D1152.

2.3.3.2 Methyl Ethyl Ketone

Methyl ethyl ketone (MEK) shall conform to ASTM D740.

2.3.3.3 Methyl Isobutyl Ketone

Methyl isobutyl ketone (MIBK) shall conform to ASTM D1153.

2.3.3.4 Methyl Isoamyl Ketone

Methyl isoamyl ketone (MIAK) shall conform to ASTM D2917.

2.3.3.5 Toluene

Toluene shall conform to ASTM D841.

2.3.4 Silane B

Silane B for Formula VZ-108d shall be N-beta-(aminoethyl)-gamma-aminopropyltrimethoxy silane. Silane A-1120, produced by the C.K. Witco Corporation, and Silane Z-6020, produced by Dow Corning Corporation, are products of this type.

2.4 TESTING

2.4.1 Chromatographic Analysis

Solvents in vinyl paints and thinners shall be subject to analysis by programmed temperature gas chromatographic methods and/or spectrophotometric methods, employing the same techniques that give reproducible results on prepared control samples known to meet the specifications. If the solvent being analyzed is of the type consisting primarily of a single chemical compound or a mixture or two or more such solvents, interpretation of the test results shall take cognizance of the degree of purity of the individual solvents as commercially produced for the paint industry.

2.4.2 Vinyl Paints

Vinyl paints shall be subject to the following adhesion test. When V-766 formulations are tested, 5 to 7 mils (dry) shall be spray applied to mild steel panels. The steel panels shall be essentially free of oil or other contaminants that may interfere with coating adhesion. The test panels shall be dry blast cleaned to a White Metal grade which shall be in compliance with SSPC SP 5/NACE No. 1. The surface shall have an angular profile of 2.0 to 2.5 mils as measured by ASTM D4417, Method C. When VZ-108 is tested, the coating shall be mixed in its proper proportions and then spray applied to a dry film thickness of 1.5 to 2.5 mils above the blast profile. The VZ-108 shall be top coated with a V-766 known to pass this test. In all cases, the complete system shall have a total dry film thickness of 5 to 7 mils above the blast profile. After being air dried for 2 hours at room temperature, the panel shall be dried in a vertical position for 16 hours at 120 degrees F. After cooling for 1 hour, the

SECTION 09 97 02 Page 16 AMENDMENT 0002 panel shall be immersed in tap water at 85 to 90 degrees F for 48 to 72 hours. Immediately upon removal, the panel shall be dried with soft cloth and examined for adhesion as follows: With a pocket knife or other suitable instrument, two parallel cuts at least 1 inch long shall be made 1/4 to 3/8 inch apart through the paint film to the steel surface. A third cut shall be made perpendicular to and passing through the end of the first two. With the tip of the knife blade, the film shall be loosened from the panel from the third cut between the parallel cuts for a distance of 1/8 to 1/4 inch. With the panel being held horizontally, the free end of the paint film shall be grasped between the thumb and forefinger and pulled vertically in an attempt to remove the film as a strip from between the first two cuts. The strip of paint film shall be removed at a rate of approximately 1/10 inch per second and shall be maintained in a vertical position during the process of removal. The adhesion is acceptable if the strip of paint breaks when pulled or if the strip elongates a minimum of 10 percent during its removal. Paints not intended to be self-priming shall exhibit no delamination from the primer.

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. Lubricant on the exterior surfaces of bolted connection nuts shall be removed with proper solvents.

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.

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. Surfaces to be painted that will be inaccessible after fabrication or assembly operations are completed shall be painted before they become inaccessible.

3.1.2 Ferrous Surfaces Subject to Atmospheric Exposures

Ferrous surfaces that are to be continuously in exterior or interior atmospheric exposure and other surfaces as directed shall be cleaned by means of dry blasting to a commercial grade. Cleaning and priming shall be done in the shop unless otherwise directed or permitted. Commercial blast cleaning shall conform to the requirements of SSPC SP 6. Welds and adjoining surfaces within a few inches (centimeters) thereof shall be cleaned of weld flux, spatter, and other harmful deposits by blasting, power impact tools, power wire brush, or such combination of these and other methods as may be necessary for complete removal of each type of deposit. The combination of cleaning methods need not include blasting when preparation of the overall surfaces is carried out by the power tool method. However, brush scrubbing and rinsing with clean water, after

SECTION 09 97 02 Page 17 AMENDMENT 0002 mechanical cleaning is completed, will be required unless the latter is carried out with thoroughness to remove all soluble alkaline deposits.

Wetting of the surfaces during water-washing operations shall be limited to the weld area required to be treated, and such areas shall be dry before painting. Welds and adjacent surfaces cleaned thoroughly by blasting alone will be considered adequately prepared provided that weld spatter not dislodged by the blast stream shall be removed with impact or grinding tools. All surfaces shall be primed as soon as practicable after cleaning but prior to contamination or deterioration of the prepared surfaces. To the greatest degree possible, steel surfaces shall be cleaned (and primed) prior to lengthy outdoor storage.

3.1.3 Ferrous Surfaces Subject to Severe Exposure

Ferrous surfaces subject to extended periods of immersion or as otherwise required shall be dry blast-cleaned to SSPC SP 5/NACE No. 1. The blast profile, unless otherwise specified, shall be 1.5 to 2.5 mils as measured by ASTM D4417, Method C. Appropriate abrasive blast media shall be used to produce the desired surface profile and to give an angular anchor tooth pattern. If recycled blast media is used, an appropriate particle size distribution shall be maintained so that the specified profile is consistently obtained. Steel shot or other abrasives that do not produce an angular profile shall not be used. Weld spatter not dislodged by blasting shall be removed with impact or grinding tools and the areas reblasted prior to painting. Surfaces shall be dry at the time of blasting. Blast cleaning to SSPC SP 5/NACE No. 1 shall be done in the field and, unless otherwise specifically authorized, after final erection.

Within 8 hours after cleaning, prior to the deposition of any detectable moisture, contaminants, or corrosion, all ferrous surfaces blast cleaned to SSPC SP 5/NACE No. 1 shall be cleaned of dust and abrasive particles by brush, vacuum cleaner, and/or blown down with clean, dry, compressed air, and given the first coat of paint. Upon written request by the Contractor, the Contracting Officer may authorize mill or shop cleaning of assembled or partially assembled components specified to receive one of the vinyl-type paint systems or Systems Nos. 6-A-Z and 21-A-Z employing the epoxy zinc-rich primer. The surfaces, if shop blasted, shall be shop coated with the first and second coats of the specified paint system except that the epoxy zinc-rich primed surfaces shall receive an extra single spray coat of the zinc primer at the time field painting is started, as specified in the paint system instructions. The shop coating shall be maintained in good condition by cleaning and touching up of areas damaged during the construction period. If pinpoint or general rusting appears, surfaces shall be reblasted and repainted at no added cost to the Government. Prior to the field application of subsequent coats, soiled areas of the shop coating shall be thoroughly cleaned and all welds or other unpainted or damaged areas shall be cleaned and coated in a manner to make them equivalent to adjacent, undamaged paint surfaces.

3.1.4 Galvanized, Aluminum, Aluminum Alloy, or Copper Surfaces

Where surfaces are specified to be painted, they shall be first washed with clean mineral spirits and then pretreated with a primer conforming to SSPC Paint 27 in accordance with the following instructions. The pretreatment primer shall be mixed by adding one volume of acid component (diluent) to four volumes of resin component (base solution) slowly and with constant stirring. After mixing, the material shall be used within 8 hours. The pretreatment primer shall be spray applied at a coverage rate of 250 to 300 square feet/gallon (of resin component) to give a dry film thickness of 0.3 to 0.5 mil. Small areas may be coated by brush or swab.

SECTION 09 97 02 Page 18 AMENDMENT 0002

Care shall be exercised in spray application to avoid the deposition of dry particles on the surface. A wet spray shall be maintained at all times by additional thinning with Normal Butanol ASTM D304. The acid component (diluent), over and above the amount prescribed above, shall not be used for thinning purposes. Surfaces shall receive the first coat of paint after at least 1 but not more than 24 hours drying of the pretreatment primer film.

3.2 PAINT APPLICATION

3.2.1 General

The finished coating shall be free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, and variations in color, texture, and gloss. Application of initial or subsequent coatings shall not commence until the Contracting Officer has verified that atmospheric conditions and the surfaces to be coated are satisfactory. Each paint coat shall be applied in a manner that will produce an even, continuous film of uniform thickness. Edges, corners, crevices, seams, joints, welds, rivets, corrosion pits, and other surface irregularities shall receive special attention to ensure that they receive an adequate thickness of paint. Spray equipment shall be equipped with traps and separators and where appropriate, mechanical agitators, pressure gauges, pressure regulators, and screens or filters. Air caps, nozzles, and needles shall be as recommended by the spray equipment manufacturer for the material being applied.