Amendment_1_Specifications.pdf

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.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO HB-17 (2002; Errata 2003; Errata 2005, 17th Edition) Standard Specifications for Highway Bridges

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 2014) Fineness of Dispersion of Pigment-Vehicle Systems by Hegman-Type Gage

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 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 2014) 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 (2017) Standard Specification for Nitration Grade Toluene

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

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

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

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

SSPC SP 1 (2015) Solvent 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

1.2 WORK PERFORMANCE

Perform work 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.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. 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

Submit samples of all special paint formulas 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.

Solvent and Thinners

Submit samples of the thinners which are those solvents used to reduce the viscosity of the paint.

SD-07 Certificates

Qualified Paint Applicator

Documentation of certification shall be submitted for all paint applicators.

Coating Thickness Gage Qualification

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

1.4 QUALIFICATIONS

Qualifications and experience shall comply with the following.

1.4.1 Qualified Paint Applicator

Submit documentation of certification 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

Conduct Certification testing of paint applicators at the job site in coordination with the Contracting Officer. Supply the fabricated test plates to be used for the tests and 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 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

Submit documentation of certification 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

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 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

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 0.2 100.0

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

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

100.0 656.6 90.11

COMPONENT B

Silane B 100.0 4.1 0.47

COMPONENT C

Zinc Dust 100.0 550.0 9.42 100.00 (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-gallonplastic 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 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 Coasting

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 100.00

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 Carbon Black

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

2.3.1.2 Zinc Dust

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

2.3.1.3 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 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.

2.3.1.4 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.

2.3.1.5 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.

2.3.1.6 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.

2.3.1.7 Aluminum Powder

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

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.

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 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 thereof shall be cleaned of weld flux, spatter, and other harmful deposits by blasting, power 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 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 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.

3.1.2 Ferrous Surfaces Subject to Severe Exposure

Ferrous surfaces subject to extended periods of immersion or as otherwise required shall be dry blast-cleaned to SSPC SP 5/NACE No. 1. The blast profile, unless otherwise specified, shall be 1.5 to 2.5 mils as measured by ASTM D4417, Method C. 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. Within 6 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. Coatings shall be maintained in good condition by cleaning and touching up of areas damaged during the fabrication and delivery period. If pinpoint or general rusting appears, surfaces shall be reblasted and repainted at no additional cost to the Government.

3.1.3 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.

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. 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. Airless-type equipment shall not be used for the application of vinyl paints.

3.2.2 Mixing and Thinning

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

3.2.3 Atmospheric and Surface Conditions

Paint shall be applied only to surfaces that are above the dew point temperature and that are completely free of moisture as determined by sight and touch. Paint shall not be applied to surfaces upon which there is detectable frost or ice. Except as otherwise specified, the temperature of the surfaces to be painted and of air in contact therewith shall be not less than 45 degrees F during paint application nor shall paint be applied if the 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 applying artificial heat, provided the minimum temperatures and surface dryness requirements prescribed previously are maintained. Paint shall not be applied to surfaces heated by direct sunlight or other sources to temperatures that will cause detrimental blistering, pinholing, or porosity of the film. The Contractor shall take daily sling-psychrometer readings before painting operations are commenced. A daily log of the dew point determination and the time of the determination shall be maintained and submitted to the Contracting Officer.

3.2.4 Time Between Surface Preparation and Painting

Surfaces that have been cleaned and/or otherwise prepared for painting shall be primed as soon as practicable after such preparation has been completed but in no case longer than 6 hours, and in any event, prior to any deterioration of the prepared surface.

3.2.5 Method of Paint Application

Unless otherwise specified, paint shall be applied by brush or spray to ferrous and nonferrous metal surfaces. Special attention shall be directed toward ensuring adequate coverage of edges, corners, crevices, pits, rivets, bolts, welds, and similar surface irregularities. Other methods of application to metal surfaces shall be subject to the specific approval of the Contracting Officer. Whenever application of paint by a specific method to a surface is permitted or directed, it is to be understood that all areas inaccessible to that method shall be coated by alternate means.

3.2.6 Coverage and Film Thickness

Film thickness or spreading rates shall be as specified hereinafter. Where no spreading rate is specified, the paint shall be applied at a rate normal for the type of material being used. In any event, the combined coats of a specified paint system shall completely hide base surface and the finish coats shall completely hide undercoats of dissimilar color.

3.2.6.1 Measurement on Ferrous Metal

Where dry film thickness requirements are specified for coatings on ferrous surfaces, measurements shall be made with a gage qualified in accordance with paragraph Coating Thickness Gage Qualification. They shall be calibrated and used in accordance with ASTM D7091. They shall be calibrated using plastic shims with metal practically identical in composition and surface preparation to that being coated, and of substantially the same thickness (except that for measurements on metal thicker than 1/4 inch, the instrument may be calibrated on metal with a minimum thickness of 1/4 inch). Frequency of measurements shall be as recommended for field measurements by ASTM D7091 and reported as the mean for each spot determination. The instruments shall be calibrated or calibration verified prior to, during, and after each use.

3.2.7 Progress of Painting Work

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

Sufficient time shall elapse between successive coats to permit them to dry properly for recoating, and this period shall be modified as necessary to suit adverse weather conditions. Paint shall be considered dry for recoating when it feels firm, does not deform or feel sticky under moderate pressure of the finger, and the application of another coat of paint does not cause film irregularities such as lifting or loss of adhesion of the undercoat. All coats of all painted surfaces shall be unscarred and completely integral at the time of application of succeeding coats. At the time of application of each successive coat, undercoats shall be cleaned of dust, grease, overspray, or foreign matter by means of airblast, solvent cleaning, or other suitable means. Undercoats of high gloss shall, if necessary for establishment of good adhesion, be scuff sanded, solvent wiped, or otherwise treated prior to application of a succeeding coat.

3.2.8 Contacting Surfaces

Bolted connection faying surfaces surfaces shall be painted with primer only before connecter installation. Unless otherwise specified, corrosion-resisting metal surfaces (i.e., stainless steel, aluminum bronze, and galvanized surfaces) shall not be painted.

3.2.9 Protection of Painted Surfaces

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

Items that have been painted shall not be handled, worked on, or otherwise disturbed until the paint coat is fully dry and hard. All coated metalwork shall be stored out of contact with the ground in a manner and location that will minimize the formation of water-holding pockets; soiling, contamination, and deterioration of the paint film, and damaged areas of paint on such metalwork shall be cleaned and touched up without delay.

3.2.10 Contacting Surfaces

Bolted connection faying surfaces shall be painted with primer only before connecter installation. Unless otherwise specified, corrosion-resisting metal surfaces (i.e. stainless steel, aluminum bronze, and galvanized surfaces) shall not be painted.

3.2.11 Drying Time Prior to Immersion

Minimum drying periods after final coat prior to immersion shall be:

vinyl-type paint systems at least 3 days. Minimum drying periods shall be increased twofold if the drying temperature is below 65 degrees Fahrenheit and/or if the immersion exposure involves considerable abrasion.

3.2.10 Vinyl Paints

3.2.10.1 General

Vinyl paints shall be spray applied, except that areas inaccessible to spraying shall be brushed. All of the vinyl paints require thinning for spray application except the zinc-rich vinyl paint (Formula VZ 108d) which will normally require thinning only under certain weather conditions.

Thinners for vinyl paints shall be as follows:

APPROXIMATE AMBIENT AIR TEMPERATURE

(Degrees F.)

Below 50 MEK

50 - 70 MIBK

Above 70 MIAK

The amount of thinner shall be varied to provide a wet spray and avoid deposition of particles that are semidry when they strike the surface.

Vinyl paints shall not be applied 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 spray coat of vinyl paint shall consist of a preliminary extra spray pass 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 shall consist of applying paint to a working area of not less than several hundred square feet 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 shall receive sprayed paint from every direction to ensure complete coverage of all faces. Pits, cracks, and crevices shall be filled with paint insofar as practicable, but in any event, all pit surfaces shall be thoroughly covered and all cracks and crevices shall be sealed off against the entrance of moisture. Fluid and atomization pressures shall be kept as low as practicable consistent with good spraying results. Unless otherwise specified, not more than 2.0 mils, average dry film thickness, of vinyl paint shall be applied per double spray coat. 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 shall cause film defects such as sags, runs, air bubbles, air craters, or poor intercoat adhesion. Neither the prime coat nor any other coat shall be walked upon or be subjected to any other abrading action until it has hardened sufficiently to resist mechanical damage.

3.2.10.2 Vinyl Zinc-Rich Primer

Primer shall be mixed combining components A, B, and C. Mixing shall be in accordance with label instructions. After mixing, the paint shall be kept covered at all times to avoid contamination and shall be applied within eight days after it is mixed. When the ambient and/or steel temperature is below about 80 degrees F, the paint will not normally require thinning;

however, the paint shall 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 shall 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 shall be whipped vigorously until any settled zinc is redispersed. Long periods of permitting the paint to remain stagnant in the hose shall be avoided by emptying the hoses whenever the painting operation is to be suspended for more than 1 hour. The material (paint) hoses shall be kept as short as practicable, preferably not more than 50 feet in length. Equipment used for spraying this zinc primer shall 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; no type of hot spray shall be used. An average dry film thickness of up to 2.5 mils may be applied in one double-spray coat.

Unless specifically authorized, not more than 8 days shall elapse after application of a VZ-108d zinc-rich coat before it receives a succeeding coat. It is authorized to extend the recoat time where prime-painted pieces are assembled, bolted and retensioned three weeks after initial tensioning such that retensioning can be accomplished prior to subsequent coats of paint. Ensure that the primed surfaces to receive paint are clean and dry prior to application of successive coats. Water shall remove dust. Detergent shall remove grease and oil.

3.2.10.3 Vinyl Paints

Vinyl Paints (Formula V-766e) is a ready-mixed paint 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, it shall be thinned as necessary up to approximately 25 percent (1 quart per 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.

3.3 PAINT SYSTEMS APPLICATION

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

3.3.1 Surface Preparation

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

3.3.2 System No. 3-A-Z

Paint shall be spray applied to an average dry film thickness of a minimum of 6.5 mils for the completed system, and the thickness at any point shall not be less than 5.5 mils. The dry film thickness of the zinc-rich coat shall be approximately 2.5 mils. The specified film thickness shall be attained in any event, and any extra coats needed to attain the specified thickness shall be applied at no additional cost to the Government.

Attaining the specified film thickness by applying fewer than the prescribed number of coats or spray passes will be acceptable provided heavier applications do not cause an increase in pinholes, bubbles, blisters, or voids in the dried film and also provided that not more than

2.0 mils (dry film thickness) per double spray coat nor more than 1.0 mil per single spray pass of nonzinc paint shall be applied at one time.

3.4 INSPECTION

The Contractor shall inspect, document, and report all work phases and operations on a daily basis. As a minimum the daily report shall contain the following:

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

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

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

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

3.5 PAINTING SCHEDULES

SYSTEM NO. 3-A-Z

Items or surfaces to be coated: All ferrous surfaces (excluding stainless steel surfaces, and rubber seals). Miter gate faying surfaces shall be coated with primer.

SURFACE

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

White metal Vinyl zinc- White Vinyl Aluminum Vinyl Aluminum Vinyl blast rich VZ-108d V-766e V-102e V-102e cleaning (double (double (double (as needed to spray coat) spray coat) spray coat) obtain required thickness)

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