Technical Specifications - Amendment 0004.pdf

McNary Powerhouse Turbine Draft Tube Slot Filler W912EF25BA002 MNTDTSF352071 Amend-0004

SECTION TABLE OF CONTENTS

DIVISION 09 - FINISHES

SECTION 09 97 02.01 28

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALIFICATIONS

1.3.1 Qualified Shop Painting Contractor

1.3.2 Qualified Coating Applicator

1.3.2.1 Test Plate

1.3.2.2 Certification Test Procedure

1.3.2.2.1 Independent Third Party Test Agency

1.3.2.3 Certification Criteria

1.3.3 Coating Thickness Gage Qualification

1.3.4 Certified Coating Inspector

1.4 DELIVERY, STORAGE, AND HANDLING

1.5 AMBIENT CONDITIONS

PART 2 PRODUCTS

2.1 PRODUCT SAMPLES

2.2 SPECIAL PAINT FORMULAS

2.3 PAINT FORMULATIONS

2.3.1 Formula C-200A, Coal Tar-Epoxy (Black) Paint

2.3.2 Formula VZ-108D

2.3.3 Formula V-766E

2.4 INGREDIENTS FOR SPECIAL PAINT FORMULAS

2.4.1 Pigments and Suspending Agents

2.4.1.1 Carbon Black

2.4.1.2 Zinc Dust

2.4.1.3 Iron Oxide

2.4.1.4 Titanium Dioxide

2.4.1.5 Suspending Agent E

2.4.1.6 Suspending Agent F

2.4.2 Resins, Plasticizer, and Catalyst

2.4.2.1 Plasticizer

2.4.2.2 Vinyl Resin, Type 3

2.4.2.3 Vinyl Resin, Type 4

2.4.2.4 Ortho-phosphoric Acid

2.4.3 Solvent and Thinners

2.4.3.1 Methanol

2.4.3.2 Methyl Ethyl Ketone

2.4.3.3 Methyl Isobutyl Ketone

2.4.3.4 Methyl Isoamyl Ketone

2.4.3.5 Toluene

2.4.4 Silane B

2.5 TESTING

2.5.1 Chromatographic Analysis

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G4EDHCMP

Line

2.5.2 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 Severe Exposure

3.2 PAINT APPLICATION

3.2.1 General

3.2.2 Mixing and Thinning of Coatings other than the Vinyl

Formulations

3.2.3 Time between Surface Preparation and Painting

3.2.4 Method of Paint Application

3.2.5 Coverage and Film Thickness

3.2.6 Coating Thickness Measurement on 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 Repair of Vinyl Coating Defects

3.2.12 Coal Tar-Epoxy (Black) Paint (Formula C-200A)

3.2.12.1 Mixing

3.2.12.2 Application

3.2.12.3 Subsequent Coats

3.2.12.4 Repair of Coal Tar-Epoxy (Black) Paint (Formula C-200A)

Defects

3.2.12.5 Ambient Temperature

3.3 PAINT SYSTEMS APPLICATION

3.3.1 Surface Preparation

3.3.2 System No. 5-E-Z

3.3.3 Epoxy Polysiloxane System

3.3.4 System No. 6-A-Z

3.3.5 Intersections of Coating Systems

3.4 IDENTIFICATION PAINTING

3.4.1 Data Label Stenciling

3.5 INSPECTION

3.6 PAINTING SCHEDULES

3.7 TOUCH-UP PAINTING

-- End of Section Table of Contents --

SECTION 09 97 02.01 28

SECTION 09 97 02.01 28

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 D153 (1984; R 2014) Specific Gravity of Pigments

ASTM D281 (2012; R 2016) Standard Test Method for Oil Absorption of Pigments by Spatula Rub-Out

ASTM D520 (2000; R 2011) Zinc Dust Pigment

ASTM D561 (1982; R 2014) Carbon Black Pigment for Paint

ASTM D740 (2011) Methyl Ethyl Ketone

ASTM D841 (2019) Standard Specification for Nitration Grade Toluene

ASTM D1045 (2019) Standard Test Methods for Sampling and Testing Plasticizers Used in Plastics

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

ASTM D1153 (2012) Methyl Isobutyl Ketone

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

ASTM D1210 (2005; R 2014) Fineness of Dispersion of Pigment-Vehicle Systems by Hegman-Type Gage

ASTM D2917 (2007; R 2013) Methyl Isoamyl Ketone

ASTM D3465 (2014) Standard Test Method for Purity of Monmeric Plasticizers by Gas Chromatography

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

ASTM D4228 (2005; R 2017) Standard Practice for Qualification of Coating Applicators for Application of Coatings to Steel Surfaces

ASTM D4417 (2021) Standard Test Methods for Field

Measurement of Surface Profile of Blast Cleaned Steel

ASTM D7091 (2021) 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 E1347 (2006; R 2020) Standard Test Method for Color and Color Difference Measurement by Tristimulus (Filter) Colorimetry

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC PA 2 (2015; E 2018) Procedure for Determining Conformance to Dry Coating Thickness Requirements

SSPC Paint 16 (2006; R 2015; E 2015) Coal Tar Epoxy-Polyamide Black (or Dark Red) Paint

SSPC Paint 40 (2019) Zinc-Rich Moisture-Cure Polyurethane Primer, Performance-Based

SSPC QP 3 (2010) Standard Procedure for Evaluating Qualifications of Shop Painting Applicators

SSPC SP 1 (2015) Solvent Cleaning

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

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AMS-STD-595A (2017) Colors used in Government Procurement

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-DTL-24441 (2009; Rev D; Notice 1 2021) Paint, Epoxy-Polyamide, General Specification for

MIL-PRF-24635 (2009; Rev E) Coating Systems, Weather Resistant, Exterior Use

1.2 SUBMITTALS

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

submittals having an "I" designation are for information only.

Designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. Submit in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Manufacturer's Safety Data Sheet ; G, ST

SD-04 Samples

Product Samples ; G, CERL

Special Paint Formulas ; G, CERL

Solvent and Thinners ; G, CERL

SD-06 Test Reports

Inspection Reports

SD-07 Certificates

Qualified Shop Painting Contractor ; G, ST

Coating Thickness Gage Qualification ; I, ST

Qualified Coating Applicator ; G, ST

Independent Third Party Test Agency ; G, ST

1.3 QUALIFICATIONS

Qualifications and experience must comply with the following.

1.3.1 Qualified Shop Painting Contractor

The Painting Contractor must be a certified SSPC QP 3 Painting Contractor or hold an American Institute of Steel Construction (AISC) Complex Coating Endorsement 1 (Enclosed) for all off-site (shop) surface preparation or coating application. Submit a copy of the applicable SSPC Certificate or AISC CCE-1 Certificate at the time of bid. The contractor must have been certified prior to award of this contract and must remain certified for the duration of this contract. Submit all renewals if they occur during the contract performance period. Renewals must be achieved prior to expirations occurring. The Painting Contractor must be certified by the Association for Materials Protection and Performance (AAMP) with SSPC QP 3 certification for all shop surface preparation and coating application.

Submit a copy of the applicable SSPC Certificates at the time of bid. The contractor must have been certified prior to award of this contract and must remain certified for the duration of this contract. Submit all renewals if they occur during the contract performance period. Renewals must be achieved prior expirations occurring.

1.3.2 Qualified Coating Applicator

Submit records of qualification tests for each Qualified Coating Applicator .

Prior to the initiation of any work, all coating applicators must be tested and certified as meeting the requirements of ASTM D4228.

Certification must be administered by an authorized government representative or independent third party test agency. Applicators failing the certification procedure will not be permitted to apply any paint on the project.

1.3.2.1 Test Plate

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

SECTION 09 97 02.01 28

G4EDHCMP

Line flange and a 6-inch diameter pipe each 18 inches long welded perpendicular to the test panel and a 6-inch deep T-beam with sealed ends welded horizontal across the test panel one foot up from the bottom all within the area to be painted on one side. Bolts shall be 1 inch minimum diameter. As an alternative, a test plate configuration, as described in ASTM D4228, may be used.

1.3.2.2 Certification Test Procedure

Conduct certification testing of coating applicators in coordination with the Contracting Officer (KO). Supply the fabricated test plates to be used for the tests. The test plate must be painted in a near vertical position.

In preparation, clean and prepare the test plate in accordance with the requirements of the contracted work. Perform abrasive blasting with the blast media to be used in the contract. The paints to be applied are Contractor supplied materials and are those previously tested and approved for use on the contract. Paints must be applied as specified in this contract. The painter being tested must mix and thin the paints to be used in the test and set up and adjust the application equipment for use. Each painter must apply each of the types of paint comprising the specified system. The contractor's QC inspector must be present during the procedure to monitor the actions of the painter being tested.

1.3.2.2.1 Independent Third Party Test Agency

If a government representative is not available to witness the test plate, an independent third party test agency may be used to witness the test plate. The witness from the independent third party test agency must be a NACE certified coating inspector, level 3. Submit the certificates of the third party test agency before the test is performed. The third party test agency must be present at all times during the test plate painting and and must conduct thickness gage checks throughout the test to ensure paint is being applied per the specifications.

1.3.2.3 Certification Criteria

Evaluate the paint applicator based on the conformance of the applied paint system to the requirements of this specification. Deficiencies in the coatings, improper mixing or improper application methods are basis for failure. The authorized Government Representative is the sole judge as to the acceptability of each coating applicator's performance.

1.3.3 Coating Thickness Gage Qualification

Submit Coating Thickness Gage Qualification documentation of manufacturer's certification for all coating thickness gages. Use magnetic flux thickness gages as described in ASTM D7091 to make all coating thickness measurements on ferrous metal substrates. Gages to be used on the job must have an accuracy of 3 percent or better and be certified by the manufacturer as meeting this requirement.

1.3.4 Certified Coating Inspector

Provide a certified coating inspector who is listed as either SSPC-PCI Level 2, or NACE CIP Level 2 for all surface preparation and painting activities. Submit a copy of the applicable SSPC or NACE Certificates.

Submit all renewals if they occur during the contract performance period.

Renewals must be achieved prior expirations occurring.

1.4 DELIVERY, STORAGE, AND HANDLING

Process and package paints to ensure that within a period of one year from date of manufacture, they will not gel, liver, or thicken deleteriously, or form gas in the closed container. Paints, unless otherwise specified or permitted, must be packaged in standard containers not larger than 5 gal , with removable friction or lug-type covers. Containers for vinyl-type paints must 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 must 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 must be delivered to the job in unbroken containers.

Paints that can be harmed by exposure to cold weather must be stored in ventilated, heated shelters. All paints must be stored under cover from the elements and in locations free from sparks and flames.

1.5 AMBIENT CONDITIONS

Paint must be applied in accordance with the manufacturers written instructions or to the special requirements contained herein. Surfaces that are less than 5 degrees F above the dew point temperature must be monitored closely to assure that are completely free of moisture as determined by sight and touch. Paint must not be applied to surfaces upon which there is detectable frost or ice. Except as otherwise specified, paint must not be applied if the temperature of the surfaces to be painted and of air in contact therewith is less than 45 degrees F during paint application nor if the surfaces can be expected to drop to 32 degrees F or lower before the film has dried to a reasonably firm condition. During periods of inclement weather, painting may be continued by enclosing the surfaces and utilizing climate control equipment (e.g. dehumidification, heaters, etc.), provided the minimum temperatures and surface dryness requirements prescribed previously are maintained. Paint must not be applied to surfaces heated by direct sunlight or other sources to temperatures that will cause detrimental blistering, pinholing, or porosity of the film.

PART 2 PRODUCTS

2.1 PRODUCT SAMPLES

Submit product samples of each batch of thinner, solvent, and paint to the Government for testing. Submit manufacturer's Safety Data Sheet (SDS) for each type of paint used; for products that are specified to be applied in accordance with the manufacturer's recommendations, submit the paint manufacturer's product data sheet (PDS) or other written instructions for those products. Allow at least 30 days from time of delivery to CERL for testing of samples of paints and thinners. Sampling may be at the jobsite or source of supply. Coordinate sampling and submission of all samples of paint and thinner with the KO. Standard sample size for liquid paints and thinners is 1-quart ; powders and other additives for multi component paints may be of appropriately smaller size. The sample must 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 at the contractors expense.

2.2 SPECIAL PAINT FORMULAS

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

2.3 PAINT FORMULATIONS

Special paint formulas must comply with the following:

2.3.1 Formula C-200A, Coal Tar-Epoxy (Black) Paint

The paint must conform to SSPC Paint 16 manufactured with Type 1 pitch.

In addition to standard labeling, container labels must include the term, Corps of Engineers Formula C-200A.

2.3.2 Formula VZ-108D

This formula is for Vinyl-Type Zinc-Rich Impacted Immersion Coating, the ingredients are shown 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

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 (Red)

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. Disperse the iron oxide and suspending agents 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 will not be permitted. The paint must show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods. 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 adjustments are made in the additions of Type 3 resin and methyl isobutyl ketone. The finished product with zinc dust added must produce a paint which has a red tone upon drying and a reflectance of not more than 16 ( ASTM E1347).

b. Supply VZ-108D paint as a kit. Each kit must consist of 4.5 gal (

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-gal plastic pail, and 3 fluid ounces of silane (Component B) packaged in a glass bottle of suitable size having a polyethylene lined cap. Place the bottle of silane on the zinc dust in the 1-gal pail. In addition to standard labeling requirements, identify each container of each component as to component type. Each container label of Component A must 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. At some point strain the mixed paint through a 30-60 mesh screen to prevent zinc dust slugs from reaching the spray gun nozzle. Stir the paint continuously during application at a rate that will prevent settling.

If spraying is interrupted for longer than 15 minutes, vigorously whip the entire length of the hose to redisperse the zinc. If the spraying is to be interrupted for more than 1 hour, empty the hose 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.

2.3.3 Formula V-766E

This formula is for Vinyl-Type White (or Gray) Impacted Immersion Coating, the ingredients are shown below.

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

Plasticizer 2.9

INGREDIENTS PERCENT BY MASS

Methyl Isobutyl Ketone 32.0

Toluene 34.7

Ortho-Phosphoric Acid 0.2

Total 100.0

a. Disperse the pigment 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.

Measure the ortho-phosphoric acid accurately and dilute it with at least four parts of ketone to one part of acid. Add it slowly into the finished paint with constant and thorough agitation.

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

c. Furnish the white and gray paints in the volume ratio designated by the purchaser. The gray paint must contain no pigments other than those specified. Include enough carbon black to produce a dry paint film having a reflectance of 20-24 ( ASTM E1347). The resulting gray color must approximate color 26231 of SAE AMS-STD-595A .

2.4 INGREDIENTS FOR SPECIAL PAINT FORMULAS

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

2.4.1 Pigments and Suspending Agents

2.4.1.1 Carbon Black

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

2.4.1.2 Zinc Dust

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

2.4.1.3 Iron Oxide

Iron oxide, (Dry) synthetic (red), must conform to ASTM D3721. In addition, the pigment must have a maximum oil absorption of 24 and a specific gravity of 4.90 to 5.20 when tested in accordance with ASTM D281 and ASTM D153, Method A, respectively. When the pigment is dispersed into specified vinyl paint formulation, the paint must have color approximating SAE AMS-STD-595A color 10076 (dark red paint), and show no evidence of incompatibility or reaction between pigment and other components after 6 months storage.

2.4.1.4 Titanium Dioxide

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

2.4.1.5 Suspending Agent E

Suspending Agent E must be a light cream colored finely divided powder having a specific gravity of 2 to 2.3. It must 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. M-P-A-14, produced by Elementis Specialties, has these properties.

2.4.1.6 Suspending Agent F

Suspending Agent F must be a light cream colored finely divided powder having a specific gravity of approximately 1.8. It must be an organic derivative of a special montmorillonite (trialkylaryl ammonium hectorite). Bentone 27, produced by Elementis Specialties, has these properties.

2.4.2 Resins, Plasticizer, and Catalyst

2.4.2.1 Plasticizer

The plasticizer must be either Di 2-propyl Heptyl Phthalate (DPHP) or Diisodecyl Phthalate (DIDP). DPHP must have an ester content of not less than 99.5 percent ( ASTM D3465), must contain not more than 0.1 percent water, and must have an acid number ( ASTM D1045) of not more than 0.07.DIDP must have a purity of not less than 99.0 percent, must contain not more than 0.1 percent water, and must have an acid number ( ASTM D1045) of not more than 0.10.

2.4.2.2 Vinyl Resin, Type 3

Vinyl resin, Type 3, must be a vinyl chloride-acetate copolymer of medium average molecular weight produced by a solution polymerization process and must contain (by weight) 85 +/- 1.0 percent vinyl chloride and 15 +/- 1.0 percent vinyl acetate by weight. The resin must have film-forming properties and must, in specified formulations, produce results equal to Vinnol H 15/50, as manufactured by Wacker Chemie AG.

2.4.2.3 Vinyl Resin, Type 4

Vinyl resin, Type 4, must be a vinyl chloride-acetate type produced by a solution polymerization process, must contain 1 percent interpolymerized dicarbonic acid, 84 +/- 1.0 percent vinyl chloride, and 15 +/- 1.0 percent vinyl acetate. The resin must have film-forming properties and must, in the specified formulations, produce results equal to Vinnol H 15/45 M, as manufactured by Wacker Chemie AG.

2.4.2.4 Ortho-phosphoric Acid

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

2.4.3 Solvent and Thinners

2.4.3.1 Methanol

Methanol (methyl alcohol) must conform to ASTM D1152.

2.4.3.2 Methyl Ethyl Ketone

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

2.4.3.3 Methyl Isobutyl Ketone

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

2.4.3.4 Methyl Isoamyl Ketone

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

2.4.3.5 Toluene

Toluene must conform to ASTM D841.

2.4.4 Silane B

Silane B for Formula VZ-108D must be N-beta-(aminoethyl)-gamma-aminopropyltrimethoxy silane. Silquest A-1120, produced by Momentive Performance Materials Inc., and Silane Z-6020, produced by Dow Corning Corporation, are products of this type.

2.5 TESTING

2.5.1 Chromatographic Analysis

Solvents in vinyl paints and thinners are 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 must take cognizance of the degree of purity of the individual solvents as commercially produced for the paint industry.

2.5.2 Vinyl Paints

Vinyl paints are subject to the following adhesion test. When V-766 or V-106 formulations are tested, spray apply 5 to 7 mils (dry) to mild steel panels. The steel panels must be essentially free of oil or other contaminants that may interfere with coating adhesion and be dry blast cleaned to a White Metal grade in compliance with SSPC SP 5/NACE No. 1 .

The surface must have an angular profile of 2.0 to 2.5 mils as measured by ASTM D4417, Method C. When V-102 or V-103 formulations are tested, spray apply the product over 1.5 to 2.5 mils (dry) of V-766 or V-106 known to pass this test. When VZ-108 is tested, the coating must 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 must be top coated with a V-766 known to pass this test. In all cases, the complete system must 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, dry the panel in a vertical position for 16 hours at 120 degrees F . After cooling for 1 hour, immerse the panel in tap water at 85 to 90 degrees F for 48 to 72 hours. Immediately upon removal, dry the panel with soft cloth and examine for adhesion as follows: With a pocket knife or other suitable instrument, make two parallel cuts at least 1 inch long, 1/4 to 3/8 inch apart through the paint film to the steel surface. Make a third cut perpendicular to and passing through the end of the first two. With the tip of the knife blade, loosen the film 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, grasp the free end of the paint film between the thumb and forefinger and pulled vertically in an attempt to remove the film as a strip from between the first two cuts. Remove the strip of paint film at a rate of approximately 1/10 inch per second and maintaining it 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 must not exhibit any delamination from the primer.

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

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

Remove deposits of grease or oil in accordance with SSPC SP 1 , prior to mechanical cleaning. Perform solvent cleaning with mineral spirits or other low toxicity solvents having a flash point above 100 degrees F . Use clean cloths and clean fluids to avoid leaving a thin film of greasy residue on the surfaces being cleaned. Protect items not to be prepared or coated from damage by the surface preparation methods. Protect machinery and electrical components against entry of blast abrasive and dust into working parts. Program cleaning and painting such that dust or other contaminants from the cleaning process do not fall on wet, newly painted surfaces. Protect surfaces not intended to be painted from the effects of cleaning and painting operations. Conduct welding of, or in the vicinity of, previously painted surfaces in a manner to prevent weld spatter from striking the paint and to otherwise reduce coating damage to a minimum. Restore any paint damaged by welding operations to original condition. Surfaces to be painted that will be inaccessible after fabrication, erection, or installation operations are completed must be painted before they become inaccessible.

3.1.2 Ferrous Surfaces Subject to Severe Exposure

Dry blast-clean ferrous surfaces subject to extended periods of immersion or as otherwise required to white metal according to SSPC SP 5/NACE No. 1 .

The blast profile must be angular with a minimum profile height of 1.5 mils . Select appropriate abrasive size and equipment operating parameters to limit maximum surface profile on new steel to 2.5 mils and to prevent increasing existing profile height on previously blasted steel. Where an existing profile is encountered, remove representative spots of existing coating with a chemical stripper and measure and document the existing profile prior to initiating blasting operations. Measure all surface profiles in accordance with ASTM D4417, Method C. Steel shot or other abrasives that do not produce an angular profile must not be used. If recycled blast media is used, maintain an appropriate particle size distribution so that the specified profile is consistently obtained. Round all sharp edges including those caused by corrosion, to a nominal 1/16 inch radius and reblast the areas prior to painting. Remove weld spatter not dislodged by blasting with impact or grinding tools and reblast the areas prior to painting. Surfaces must be dry at the time of blasting.

Conduct blast cleaning to SSPC SP 5/NACE No. 1 in the field and, unless otherwise specifically authorized, after final erection. Within 8 hours after blast cleaning, and in any case prior to the deposition of any detectable moisture, contaminants, or corrosion, clean all ferrous surfaces of dust and abrasive particles by brush, vacuum cleaner, and/or blown down with clean, dry, compressed air, and apply the first coat of paint. Authorization to extend this 8 hour coating requirement for shop application, application within dehumidified containment, or other conditions will not be granted. Upon written request by the Contractor, the KO may authorize mill or shop cleaning of assembled or partially assembled components specified to receive one of the vinyl-type paint systems or Systems 6-A-Z and 21-A-Z employing the epoxy zinc-rich primer or Systems 23-A-Z and 23-B-Z employing SSPC Paint 40 moisture cure urethane zinc-rich primer. Shop coat all shop blasted surfaces with the first and second coats of the specified paint system. At the time field painting is initiated, apply an additional single spray coat of the zinc rich primer to the epoxy zinc-rich and moisture cure urethane primed surfaces as specified in the paint system instructions. Maintain the shop coating in good condition by cleaning and touching up of areas damaged during the fabrication and transportation periods. If pinpoint or general rusting appears, the defective areas must be reblasted and repainted at no added cost to the Government. Prior to the field application of subsequent coats, thoroughly clean soiled areas of the shop coating and all welds or other unpainted or damaged areas must be cleaned and coated in a manner to make them equivalent to adjacent, undamaged paint surfaces.

3.2 PAINT APPLICATION

3.2.1 General

Unless otherwise specified, the finished coating must be free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, and variations in color, texture, and gloss. Do not initiate the application of initial or subsequent coatings until the KO has verified that atmospheric conditions and the surfaces to be coated are satisfactory. Each paint coat must be applied in a manner that will produce an even, continuous film of uniform thickness. Provide special attention to edges, corners, crevices, seams, joints, welds, rivets, corrosion pits, and other surface irregularities to ensure that they receive an adequate thickness of paint. Spray equipment must be equipped with traps and separators and where appropriate, mechanical agitators, pressure gauges, pressure regulators, and screens or filters. Air caps, nozzles, and needles must be as recommended by the spray equipment manufacturer for the material being applied. Airless-type spray equipment may be used only on broad, flat, or otherwise simply configured surfaces, except that it may be employed for general painting if the spray gun is equipped with dual or adjustable tips of proper types and orifice sizes.

The use of airless-type equipment is not allowed for the application of vinyl paints.

3.2.2 Mixing and Thinning of Coatings other than the Vinyl Formulations

Paints must be thoroughly mixed, strained where necessary, and kept at a uniform composition and consistency during application. Incorporate dry-powder pigments specified to be added at the time of use, into the vehicle or base paint with the aid of powered stirrers, in a manner that will produce a smooth, homogeneous mixture free of lumps and dry particles. Where necessary to suit conditions of the surface temperature, weather, and method of application, the paint may be thinned immediately prior to use. Thinning, induction time and pot life must comply with the manufacturers written instructions (PDS). Bring any paint that has been stored at a temperature below the manufacturer's application temperature range up to at least 70 degrees F before being mixed and thinned. Its temperature in the spray tank or other working container must not fall below the manufacturer's specified application temperature range during the application. Any paint that has deteriorated in any manner to a degree that it cannot be restored to essentially its original condition by customary field-mixing methods must not be used and must be removed from the project site. In order to determine its suitability for application, resample and submit for testing any paint and thinner that is more than 1 year from the date of manufacture or last documented testing. Moisture cure urethane paint must be resampled and resubmitted for testing to determine its suitability for application whenever the paint is more than six months beyond the date of manufacture on the container or more than 6 months beyond the last documented laboratory testing.

3.2.3 Time between Surface Preparation and Painting

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

3.2.4 Method of Paint Application

Unless otherwise specified, paint must be applied by brush, roller, or spray to ferrous and nonferrous metal surfaces. Special attention must be directed toward ensuring adequate coverage of edges, corners, crevices, pits, rivets, bolts, welds, and similar surface irregularities. Other methods of application to metal surfaces are subject to the specific approval of the KO. Paint on plaster, concrete, or other nonmetallic surfaces must be applied by brush, roller, and/or spray.

3.2.5 Coverage and Film Thickness

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

3.2.6 Coating Thickness Measurement on Metal

Where dry film thickness requirements are specified for coatings on metal surfaces, make measurements with a gage qualified in accordance with paragraph Coating Thickness Gage Qualification and calibrated and used in accordance with ASTM D7091. Prior to each use, establish the Base Metal Reading (BMR) for the gage as specified in the test method. Verify the accuracy of the gage using plastic shims as specified by the test method both prior to and following each set of measurements. Perform dry film measurements on all areas of the structure being coated in accordance with SSPC PA 2 with Level 1 thickness restrictions. Perform a sufficient number of thickness measurements to ensure that every area on every member is in compliance with the requirements of this contract. Report all thickness measurements as the mean for each spot determination.

3.2.7 Progress of Painting Work

Where field painting on any type of surface has commenced, complete the entire painting operation on that portion of the work, including priming and finishing coats, as soon as practicable and without prolonged delays.

Allow sufficient time between successive coats to permit them to dry properly for recoating, modifying this period as necessary to suit adverse weather conditions. Paint is considered dry for recoating when it feels firm, does not deform or feel sticky under moderate pressure of the finger, and the application of another coat of paint does not cause film irregularities such as lifting or loss of adhesion of the undercoat. All coats of all painted surfaces must be unscarred and completely integral at the time of application of succeeding coats. At the time of application of each successive coat, clean undercoats of dust, grease, overspray, or foreign matter by means of air blast, solvent cleaning, or other suitable means. Cement and mortar deposits on painted steel surfaces, not satisfactorily removed by ordinary cleaning methods, must be brush-off blast cleaned and completely repainted as required. If necessary for establishment of good adhesion, scuff sand high gloss undercoats, and, solvent wipe, or otherwise treat prior to application of a succeeding coat. Apply field coats on metal after erection except as otherwise specified and except for surfaces to be painted that will become inaccessible after erection.

3.2.8 Contacting Surfaces

When riveted or ordinary bolted contact is to exist between surfaces of ferrous or other metal parts of substantially similar chemical composition, such surfaces will not be required to be painted, but any resulting crevices must subsequently be filled or sealed with paint.

Contacting metal surfaces formed by high-strength bolts in friction-type connections must not be painted. Where a nonmetal surface is to be in riveted or bolted contact with a metal surface, the contacting surfaces of the metal must be cleaned and given three coats of the specified primer.

Unless otherwise specified, corrosion-resisting metal surfaces, including cladding therewith, must not be painted.

3.2.9 Drying Time Prior to Immersion

Minimum drying periods after final coat prior to immersion are: epoxy and moisture cure urethane systems at least 5 days, vinyl-type paint systems at least 3 days, and cold-applied coal tar systems at least 7 days.

Increase minimum drying periods twofold if the drying temperature is below 65 degrees F and/or if the immersion exposure involves considerable abrasion.

3.2.10 Protection of Painted Surfaces

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

Items that have been painted must not be handled, worked on, or otherwise disturbed until the paint coat is fully dry and hard. Store all metalwork coated in the shop or field prior to final erection out of contact with the ground in a manner and location that will minimize the formation of water-holding pockets; soiling, contamination, and deterioration of the paint film. Damaged areas of paint on such metalwork must be cleaned and touched up without delay. Apply the first field coat of paint within a reasonable period of time after the shop coat and in any event before weathering of the shop coat becomes extensive.

3.2.11 Vinyl Paints

3.2.11.1 General

Vinyl paints must be thoroughly mixed and kept at a uniform composition and consistency during application. Any paint that has deteriorated in any manner to a degree that it cannot be restored to essentially its original condition by customary field-mixing methods must not be used and must be removed from the project site. In order to determine its suitability for application, resample and submit for testing any paint and thinner that is more than 1 year from the previous documented testing.

Each applied coat of vinyl paint must be free from any holidays, pinholes and bubbles. The finished coating must be free of excessive or unsightly brush marks, runs, drops, ridges, waves, laps and variations in color, and texture. Vinyl paints must be spray applied, except that areas inaccessible to spraying must be brushed. Vinyl Paints (Formulas V-102E, V-103C, V-106D, and V-766E) are ready-mixed paints designed to be spray applied over a wide range of ambient temperatures by field thinning with the proper type and amount of thinner. For spray application, they must be thinned as necessary up to approximately 25 percent ( 1 quart/gallon of base paint) with the appropriate thinner; when ambient and steel temperatures are above normal, up to 40-percent thinning may be necessary for satisfactory application. The zinc-rich vinyl paint (Formula VZ-108D) will normally require thinning only under certain weather conditions.

Thinners for vinyl paints must be as follows:

APPROXIMATE AMBIENT AIR TEMPERATURE (Degrees F)

Below 50 MEK

50 - 70 MIBK

Above 70 MIAK

Vary the amount of thinner to provide a wet spray and avoid deposition of particles that are semidry when they strike the surface. Do not apply vinyl paints when the temperature of the ambient air and receiving surfaces is less than 35 degrees F nor when the receiving surfaces are higher than 125 degrees F . Each double spray coat of vinyl paint must consist of a preliminary stripe coat applied by spray, brush, or combination thereof on edges, corners, interior angles, pits, seams, crevices, junctions of joining members, rivets, weld lines, and similar surface irregularities followed by an overall double spray coat. A double spray coat of vinyl-type paint consists of applying paint to a working area of not less than several hundred square feet (meters) in a single, half-lapped pass, followed after drying to at least a near tack-free condition by another spray pass applied at the same coverage rate and where practicable at right angles to the first. Rivets, bolts, and similar surface projections must receive sprayed paint from every direction to ensure complete coverage of all faces. Pits, cracks, and crevices must be filled with paint insofar as practicable, but in any event, all pit surfaces must be thoroughly covered and all cracks and crevices must be sealed off against the entrance of moisture. Keep fluid and atomization pressures as low as practicable consistent with good spraying results. Application of more than 2.0 mils , average dry film thickness, of vinyl paint per double spray coat typically indicates semidry application and must be avoided. Except where otherwise indicated, an undercoat of the vinyl-type paint may receive the next coat any time after the undercoat is tack-free and firm to the touch, provided that no speedup or delay in the recoating schedule results in film defects such as sags, runs, air bubbles, air craters, or poor intercoat adhesion.

Do not walk on, or otherwise abrade the prime coat or any other coat until it has hardened sufficiently to resist mechanical damage.

3.2.11.2 Vinyl Zinc-Rich Primer

Primer must be field mixed combining components A, B, and C in accordance with label instructions. After mixing, keep the paint covered at all times to avoid contamination and apply the mixed paint within 8 days after mixing. When the ambient and/or steel temperature is below about 80 degrees F , the paint will not normally require thinning; however, the paint must at all times contain sufficient volatiles (thinners) to permit it to be satisfactorily atomized and to provide a wet spray and to avoid deposition of particles that are semidry when they reach the surface. The paint must be stirred continuously during application at a rate that will prevent the zinc dust from settling. When spraying is resumed after any interruption of longer than 15 minutes, the entire length of the material hose must be whipped vigorously until any settled zinc is redispersed.

Long periods of permitting the paint to remain stagnant in the hose must be avoided by emptying the hoses whenever the painting operation is to be suspended for more than 1 hour. Keep the material (paint) hoses as short as practicable, preferably not more than 50 feet in length. Equipment used for spraying this zinc primer must not be used for spraying other vinyl-type paints without first being thoroughly cleaned, since many of the other paints will not tolerate zinc contamination. Do not use any type of hot spray. An average dry film thickness of up to 2.5 mils may be applied in one double-spray coat. Unless specifically authorized, any coat of VZ-108 must receive a succeeding coat within 8 days.

3.2.11.3 Repair of Vinyl Coating Defects

Coating defects should be repaired when they are first observed but must be repaired prior to coating acceptance. Runs and sags may be brushed out before becoming dry. Pinholes must be physically closed by scrubbing with a brush wet with ketone solvent before the succeeding coat is applied.

Overspray that will not be melted smooth by the succeeding coat must be removed by scrubbing with a brush wet with ketone solvent. Minor overspray in the final coat that results only in a reduced gloss at the outer limits of the spray pattern is not considered a defect and requires no additional attention. Insufficient thickness or incomplete hiding must be corrected with additional paint before the succeeding coat is applied. If any defect extends to the substrate, it must be determined if the substrate is corroding. In the case of pinholes it may be necessary to use magnification to observe the substrate. If the substrate is showing any corrosion, the required surface preparation must be restored by spot blasting, and the entire coating system replaced at that location.

Following the spot blasting the edges of the remaining coating must be scrubbed with ketone solvent to assure all remaining coating is tightly adhering before the new coating is applied. If VZ-108 does not receive the required succeeding coat within the required 8 days, it must be removed by abrasive blasting and replaced.

3.2.12 Coal Tar-Epoxy (Black) Paint (Formula C-200A)

3.2.12.1 Mixing

Add Component B to previously stirred Component A and thoroughly mix together with a heavy-duty mechanical stirrer just prior to use. The use of not more than 1 pint of xylene thinner per 1 gal of paint is permitted to improve application properties and extend pot life. The pot life of the mixed paint, extended by permissible thinning, may vary from 2 hours in very warm weather to 5 or more hours in cool weather. Pot life in warm weather may be extended by precooling the components prior to mixing;

cooling the mixed material; and/or by slow, continuous stirring during the application period. Apply the mixed material before unreasonable increases in viscosity take place.

3.2.12.2 Application

High-pressure airless spray equipment must be equipped with spray tips of appropriate size for the structural members being coated. Brush application must be with a stiff-bristled brush heavily laden with material and wielded in a manner to spread the coating smoothly and quickly without excessive brushing. The coverage rate of the material is approximately 110 square feet/gal per coat to obtain 20 mils (dry thickness) in a two coats of the C-200a. The paint must flow together and provide a coherent, pinhole-free film. The direction of the spray passes (or finish strokes if brushed) of the second coat must be at right angles to those of the first where practicable.

3.2.12.3 Subsequent Coats

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

Where the curing time of a coal tar-epoxy undercoat exceeds 72 hours at normal temperatures, 10 hours at extreme conditions, or where the undercoat develops a heavy blush, or when spot repair of damage is required, it must be given one of the following treatments before the subsequent coat is applied:

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

b. Remove the blush and/or soften the surface of the coating by wiping it with cloths dampened with 1-methyl-2-pyrrolidone. The solvent may be applied to the surface by fog spraying followed by wiping, but any puddles of solvent must be mopped up immediately after they form.

Apply the subsequent coat in not less than 15 minutes or more than 3 hours after the solvent treatment.

3.2.12.4 Repair of Coal Tar-Epoxy (Black) Paint (Formula C-200A) Defects

Coating defects should be repaired when they are first observed but must be repaired prior to coating acceptance. Runs, sags, pinholes and other visible application defects in any coat may be brushed out before the material cures. Excessive thickness as a result of runs, sags or heavy application of any coat that has been allowed to cure must be reduced to the specified thickness limitation. Any actions that damage the required surface profile must be followed by spot blasting to restore the profile prior to reapplication of the coating system in that area.

3.2.12.5 Ambient Temperature

Coal tar-epoxy paint must not be applied when the receiving surface or the ambient air is below 50 degrees F nor if it can be reasonably anticipated that the…