09 97 02 Amendment 0002.pdf

LD5A, LD8 and LD10 Anchorage Replacement W912ES21B0010

SECTION TABLE OF CONTENTS

DIVISION 09 - FINISHES

SECTION 09 97 02

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

1.2 SAFETY, HEALTH, AND ENVIRONMENTAL REQUIREMENTS

1.2.1 Safety

1.2.1.1 Abrasive Blasting

1.2.1.2 Workers Other Than Blasters

1.2.1.3 Cleaning Before and After Abrasive Blasting

1.2.1.4 Pretreatment of Metals and Concrete with Acids

1.2.1.5 Paint Mixing

1.2.1.6 Confined Spaces

1.2.1.7 Paint Spraying

1.2.1.8 Explosion Proof Equipment

1.2.1.9 Further Precautions

1.2.1.10 Ignition Sources

1.2.2 Health

1.2.2.1 Air Monitoring

1.2.2.2 Medical Status

1.2.2.3 Change in Medical Status

1.2.3 Environmental Protection

1.2.3.1 Waste Classification, Handling, and Disposal

1.2.3.2 Containment

1.2.3.3 Visible Emissions Monitoring

1.2.3.4 PM-10 Monitoring

1.3 SUBMITTALS

1.4 QUALIFICATIONS

1.4.1 Certified Environmental, Health, and Safety (EHS) Professionals

1.4.2 Qualified Shop Painting Contractor

1.4.3 Qualified Coating Applicator

1.4.3.1 Certification Test Procedure

1.4.3.2 Certification Criteria

1.4.4 Coating Thickness Gage Qualification

1.4.5 Certified Coating Inspector

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 AMBIENT CONDITIONS

PART 2 PRODUCTS

2.1 SPECIAL PAINT FORMULAS

2.2 PAINT FORMULATIONS

2.2.1 Formula VZ-108D

2.2.2 Formula V-766E

2.3 INGREDIENTS FOR SPECIAL PAINT FORMULAS

2.3.1 Pigments and Suspending Agents

2.3.1.1 Aluminum Powder

2.3.1.2 Carbon Black

SECTION 09 97 02 Page 1

2.3.1.3 Zinc Dust

2.3.1.4 Iron Oxide

2.3.1.5 Titanium Dioxide

2.3.1.6 Suspending Agent E

2.3.1.7 Suspending Agent F

2.3.2 Resins, Plasticizer, and Catalyst

2.3.2.1 Plasticizer

2.3.2.2 Vinyl Resin, Type 3

2.3.2.3 Vinyl Resin, Type 4

2.3.2.4 Ortho-phosphoric Acid

2.3.3 Solvent and Thinners

2.3.3.1 Methanol

2.3.3.2 Methyl Ethyl Ketone

2.3.3.3 Methyl Isobutyl Ketone

2.3.3.4 Methyl Isoamyl Ketone

2.3.3.5 Toluene

2.3.4 Silane B

2.3.5 Propylene Oxide

2.3.6 PRIMER FOR SLIP CRITICAL JOINTS

2.4 TESTING

2.4.1 Chromatographic Analysis

2.4.2 Vinyl Paints

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

3.1.2 Ferrous Surfaces

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

3.3 PAINT SYSTEMS APPLICATION

3.3.1 Fabricated and Assembled Items

3.3.2 Surface Preparation

3.3.3 System No. 5-E-Z

3.3.4 System No. 21-A-Z

3.3.5 Protection of Nonpainted Items and Cleanup

3.4 INSPECTION

3.5 PAINTING SCHEDULES

3.6 CONTRACTOR QUALITY CONTROL

3.6.1 Contractor Quality Control Personnel

3.6.2 Inspection Hold Points

3.6.3 Quality Control Program

-- End of Section Table of Contents --

SECTION 09 97 02 Page 2

SECTION 09 97 02

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

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

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

SECTION 09 97 02 Page 3

Qualification of Coating Applicators for Application of Coatings to Steel Surfaces

ASTM D4417 (2019) Field Measurement of Surface Profile of Blast Cleaned Steel

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

INTERNATIONAL SAFETY EQUIPMENT ASSOCIATION (ISEA)

ANSI/ISEA Z87.1 (2020) Occupational and Educational Personal Eye and Face Protection Devices

ANSI/ISEA Z358.1 (2014) American National Standard for Emergency Eyewash and Shower Equipment

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH (NIOSH)

NIOSH 2003-154 (2003; 4th Ed; Supple 3) NIOSH Manual of Analytical Methods

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

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

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

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

SECTION 09 97 02 Page 4

Procurement

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

U.S. DEPARTMENT OF DEFENSE (DOD)

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

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

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1910.20 Access to Employee Exposure and Medical Records

29 CFR 1910.94 Ventilation

29 CFR 1910.134 Respiratory Protection

29 CFR 1910.146 Permit-required Confined Spaces

29 CFR 1926.62 Lead

40 CFR 50.6 National Primary and Secondary Ambient Air Quality Standards for PM10

40 CFR 58 Ambient Air Quality Surveillance

40 CFR 60 Standards of Performance for New Stationary Sources

40 CFR 261 Identification and Listing of Hazardous Waste

40 CFR 262 Standards Applicable to Generators of Hazardous Waste

40 CFR 262.22 Number of Copies

40 CFR 263 Standards Applicable to Transporters of Hazardous Waste

49 CFR 171 General Information, Regulations, and Definitions

1.2 SAFETY, HEALTH, AND ENVIRONMENTAL REQUIREMENTS

Perform work in accordance with all applicable health, safety, and environmental requirements as well as EM 385-1-1 . Submit matters of interpretation of these requirements to the Contracting Officer for resolution before starting work. If no clarifications are sought, then the submittal is not necessary. Where the regulations conflict, the most stringent requirements apply. This paragraph supplements the health, safety, and environmental requirements of EM 385-1-1 .

SECTION 09 97 02 Page 5

1.2.1 Safety

Submit an Accident Prevention Plan in accordance with the requirements of Section 01 of EM 385-1-1 , including, but not limited to, each of the topic areas listed in Appendix A therein and the specified requirements.

Develop each topic in a concise manner to include management and operational aspects. Submit a Ventilation Assessment Plan complying with all applicable safety standards.

1.2.1.1 Abrasive Blasting

For abrasive blasting comply with the requirements in Section 06.I of EM 385-1-1 . In addition to the requirements in Section 20 of EM 385-1-1 , use hoses and hose connections of a type to prevent shock from static electricity. Join hose lengths together by approved couplings of a material and type designed to prevent erosion and weakening of the couplings. The couplings and nozzle attachments must fit on the outside of the hose and be designed to prevent accidental disengagement.

1.2.1.2 Workers Other Than Blasters

Protect workers, other than blasting operators working in close proximity to abrasive blasting operations. Use MSHA/NIOSH-approved half-face or full-face air purifying respirators equipped with high-efficiency particulate air (HEPA) filters and eye protection meeting ANSI/ISEA Z87.1 .

Use hearing protectors (ear plugs and/or ear muffs) providing a noise reduction rating of at least 20 dBA or as needed to provide adequate protection. Provide personal protective equipment where required by 29 CFR 1910.146 and in accordance with 29 CFR 1910 , Subpart I.

1.2.1.3 Cleaning Before and After Abrasive Blasting

Cleaning with compressed air must be in accordance with Section 20.B.5 of EM 385-1-1 and personnel protected as specified in 29 CFR 1910.134 . When cleaning with solvents, provide ventilation where required by 29 CFR 1910.146 or where the concentration of solvent vapors exceeds 10 percent of the Lower Explosive Limit (LEL). Ventilation must be in accordance with 29 CFR 1910.94 , paragraph (c)(5).

1.2.1.4 Pretreatment of Metals and Concrete with Acids

Personnel must be protected in accordance with 29 CFR 1910 , Subpart I. In addition to the requirements of Section 05 of EM 385-1-1 , provide an eyewash in accordance with ANSI/ISEA Z358.1 , paragraph (6).

1.2.1.5 Paint Mixing

Provide local exhaust ventilation in the area where coatings are mixed.

This ventilation system must be capable of providing at least 100 linear fpm of capture velocity in the mixing zone. Avoid exposure of skin and eyes by wearing appropriate chemically resistant gloves, safety goggles, and face shields meeting the requirements of ANSI/ISEA Z87.1 . Provide a personal eyewash unit within close proximity to the mixing operation in accordance with ANSI/ISEA Z358.1 , paragraph (9). All powered mixing equipment must be either pneumatic or double insulated (intrinsically safe), in order to guard against fire or explosion. Individuals who have a history of, or develop a sensitivity to epoxy or polyurethane resin systems, must not conduct work tasks or otherwise be exposed to such chemicals.

SECTION 09 97 02 Page 6

1.2.1.6 Confined Spaces

When using solvent-based paint in confined spaces, prepare a Confined Spaces Plan. Provide ventilation to exchange air in the space at a minimum rate of 5,000 cubic feet per minute per spray gun in operation.

It may be necessary to install both a mechanical supply and exhaust ventilation system to effect adequate air changes within the confined space. Locate and affix all air-moving devices to an opening of the confined space in a manner assuring that the airflow is not restricted or short circuited and is supplied in the proper direction. A suitable means of egress must be maintained at all times. Continue ventilation after completion of painting and through the drying phase of the operation. If the ventilation system fails or the concentration of volatiles exceeds 10 percent of the LEL (except in the zone immediately adjacent to the spray nozzle), stop painting and evacuate spaces until adequate ventilation is provided. Provide an audible alarm that signals system failure as an integral part of the ventilation system. Check the effectiveness of the ventilation by using ventilation smoke tubes and making frequent oxygen and combustible gas readings during painting operations. Exhaust ducts must discharge clear of the working areas and away from possible sources of ignition. Submit detailed written standard operating procedures for confined spaces in accordance with 29 CFR 1910.146 and EM 385-1-1 , Section 6H, Section 34. The procedures must include:

a. Certificates of calibration for all testing and monitoring equipment.

The certificates of calibration must include: type of equipment, model number, date of calibration, firm conducting calibration, and signature of individual certifying calibration.

b. Methods of inspection of personal protective equipment prior to use.

c. Engineering controls and other work practices designed to reduce airborne hazardous chemical exposures to a minimum.

d. Specification of the design and installation of ventilation systems which provide adequate oxygen content and provide for the dilution of paint solvent vapor, lead, and other toxic particulates within the confined space. Procedures must also include plans to evaluate the adequacy of air flow patterns.

1.2.1.7 Paint Spraying

Submit a comprehensive written Respiratory Protection Plan in accordance with 29 CFR 1910.134 , 29 CFR 1926.62 , and EM 385-1-1 , Section 05.G.

During all spray painting operations, spray painters must use approved SCBA or SAR (air line) respirators, unless valid air sampling has demonstrated contaminant levels to be consistently within concentrations compatible with the Assigned Protection Factor (APF) of an air-purifying respirator. Persons with facial hair that may interfere with the seal or valve function of a half or full facepiece style respirator may wear a hood or helmet respirator provided the APF is sufficient for the exposure. Air-purifying chemical cartridge/canister respirators that have a particulate prefilter and are suitable for the specific type(s) of gas/vapor and particulate contaminant(s) may be used for nonconfined space painting, mixing, and solvent cleaning. These respirators may be used provided the measured or anticipated concentration of the contaminant(s) in the breathing zone of the exposed worker does not exceed the APF for the respirator and the gas/vapor has good warning properties or the

SECTION 09 97 02 Page 7 respirator assembly is equipped with a NIOSH-approved end of service life indicator for the gas(es)/vapor anticipated or encountered. Where paint contains toxic elements that may become airborne during painting in nonconfined spaces, air-purifying half- and full-facepiece respirators or powered air-purifying respirators equipped with appropriate gas vapor cartridges, in combination with a high-efficiency filter, or an appropriate canister incorporating a high-efficiency filter, must be used.

1.2.1.8 Explosion Proof Equipment

Electrical wiring, lights, and other equipment located in the paint spraying areas must be of the explosion proof type designed for operation in Class I, Division 1, Group D, hazardous locations as required by the NFPA 70 . Electrical wiring, motors, and other equipment, outside of but within 20 feet of any spraying area, must not spark and must conform to the provisions for Class I, Division 2, Group D, hazardous locations.

Electric motors used to drive exhaust fans must not be placed inside spraying areas or ducts. Fan blades and portable air ducts must be constructed of nonferrous materials. Properly maintain and ground motors and associated control equipment. Electrically bond and ground the metallic parts of all air-moving devices, spray guns, connecting tubing, and duct work.

1.2.1.9 Further Precautions

a. Workers must wear nonsparking safety shoes.

b. Solvent drums taken into the spraying area must be grounded. Maintain metallic bonding between containers and drums when materials are being transferred.

c. Inspect insulation on all power and lighting cables to ensure that the insulation is in excellent working condition and is free of all cracks and worn spots. Ensure that no connections are within 50 feet of the operation, that lines are not overloaded, and that they are suspended with sufficient slack to prevent undue stress or chafing.

1.2.1.10 Ignition Sources

Ignition sources, including lighted cigarettes, cigars, pipes, matches, or cigarette lighters, and electronic smoking devices are prohibited in areas of solvent cleaning, paint storage, paint mixing, or paint application.

1.2.2 Health

Prepare and submit a Medical Surveillance Plan and a statement from the examining physician indicating the name of each employee evaluated and any limitations which will preclude the employee from performing the work required. The statement must include the date of the medical evaluation, the physician's name, signature, and telephone number.

1.2.2.1 Air Monitoring

Prepare and submit an Air Monitoring Test Plan. Perform air sampling and testing as needed to assure that workers are not exposed to contaminants above the permissible exposure limit. In addition, provide the Contracting Officer with a copy of the Air Monitoring Test Report from the laboratory within five working days of the sampling date, including records of air monitoring plans and tests performed. Submit reports as

SECTION 09 97 02 Page 8 soon as information is available. Also provide results from direct-reading instrumentation on the same day the samples are collected.

Prepare and submit an Airborne Sampling Plan detailing the NIOSH 2003-154 , Factory Mutual, or Underwriters Laboratories approved equipment, equipment calibration procedures, sampling methods, sampling to be performed, and analytical procedures to be used based on the type of work to be performed and anticipated toxic contaminants to be generated. Include the name of the accredited laboratory, listed by the American Industrial Hygiene Association (AIHA), that will be used to conduct the analysis of any collected air samples.

1.2.2.2 Medical Status

Prior to the start of work, and annually thereafter, submit a Medical Status Report. Medically evaluate all Contractor employees working with or around paint systems, thinners, blast media, those required to wear respiratory protective equipment, and those who will be exposed to high noise levels for the particular type of exposure they may encounter. The Report must include the employee's name, the tests performed and the name of the physician responsible for performing the tests, and a physician's statement that medical status would permit specific task performance.

Maintain medical records as required by 29 CFR 1910.20 . The evaluation must include:

a. Audiometric testing and evaluation of employees who will work in a noise environment with a time weighted average greater than or equal to 85 dBA.

b. Vision screening of employees who will require eye protection (employees who use full-facepiece respirators cannot wear contact lenses).

c. Medical evaluation of employees who will be required to wear respiratory protection must include, but is not limited to, the following:

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

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

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

(4) Determination of baseline values of biological indices for later comparison to changes associated with exposure to paint systems and thinners or blast media, which include: liver function tests to include SGOT, SGPT, GGPT, alkaline phosphates, bilirubin, complete urinalysis, EKG (employees over age 40), blood urea nitrogen (bun), serum creatinine, pulmonary function test, FVC, and FEV, chest x-ray (if medically indicated), blood lead and ZPP (for individuals where it is known there will be an exposure to materials containing lead), other criteria that may be deemed necessary by the Contractor's physician.

SECTION 09 97 02 Page 9

1.2.2.3 Change in Medical Status

Any employee whose medical status has changed negatively due to work related chemical and/or physical agent exposure while working with or around paint systems and thinners, blast media, or other chemicals must be evaluated by a physician, and obtain a physicians statement as described in paragraph MEDICAL STATUS prior to allowing the employee to return to those work tasks. Submit a Change in Medical Status Report detailing any negative changes in employee medical status and the results of the physicians reevaluation statement.

1.2.3 Environmental Protection

In addition to the requirements of Section 01 57 20.00 13 ENVIRONMENTAL PROTECTION, prepare an Environmental Protection Plan incorporating the submittals for Containment Plan, Waste Disposal Plan, and Emissions Monitoring Plan. The submitted plan must also address all aspects of establishing and demarcating regulated areas, ventilation/containment system performance verification, and reporting of accidental releases.

Comply with the following environmental protection criteria.

1.2.3.1 Waste Classification, Handling, and Disposal

Prepare and submit a Waste Disposal Plan in accordance with the requirements of 40 CFR 261 and 40 CFR 262 including classification and handling. The Contractor is responsible for assuring the proper disposal of all hazardous and nonhazardous waste generated during the project.

Regardless of the results of 40 CFR 261 App II, Mtd 1311, all waste generated from abrasive blasting, lead-containing paints with recyclable steel or iron abrasives must be either disposed of as a hazardous waste or be stabilized with proprietary pre-blast additives . Where stabilization is preferred, employ a proprietary blast additive, that has been blended with the blast media prior to use. Place hazardous waste in properly labeled, closed containers shielded adequately to prevent dispersion of the waste by wind or water. Any evidence of improper storage is cause for immediate shutdown of the project until corrective action is taken. Store nonhazardous waste in closed containers separate from hazardous waste storage areas. Transport all hazardous waste by a licensed transporter in accordance with 40 CFR 263 and 49 CFR 171 , Subchapter C. Transport all nonhazardous waste in accordance with local regulations regarding waste transportation. In addition to the number of copies required by 40 CFR 262.22 , supply one copy of each Waste Manifest to the Contracting Officer prior to transportation.

1.2.3.2 Containment

Prepare a Containment Plan for containing debris generated during paint removal operations. Include drawings, load-bearing capacity calculations, and wind load calculations. When the design is such that the spent abrasive is allowed to accumulate in quantities greater than 1,000 pounds, and/or impart a significant wind load on the structure, have the drawings approved by a registered structural engineer. The drawings and calculations must be stamped with the engineer's seal. Also identify the type and placement of water booms, methods for anchoring the booms, and the procedures for removing debris. Contain debris generated during paint removal operations in accordance with the requirements of SSPC Guide 6 , Class 2A. Where required, verify the containment air pressure visually.

SECTION 09 97 02 Page 10

1.2.3.3 Visible Emissions Monitoring

Prepare a Visible Emissions Monitoring Plan including the provisions for halting work and correcting the containment in the event unacceptable emissions are observed. General statements must not be used; specific methods, procedures, and details are required. Measure the time of emissions in accordance with 40 CFR 60 , App A, Mtd 22. Monitor visible emissions for not less than 15 minutes of every hour. Calculate visible emissions for each hour by extrapolation. Visible emissions must not extend greater than 150 feet in any direction horizontal from the containment. Visible emissions must not be observed in the area of any sensitive receptor. If such emissions occur shut down the job immediately and take corrective action. Notify the foreman whenever visible emissions exceed 200 seconds in a 1 hour period. Whenever visible emissions exceed 300 seconds in a 2 hour period notify the foreman, shut down the job, and take corrective action. If the total observed visible emissions from the containment exceeds 5 percent of the work day, shut down the job and take corrective action to prevent such an occurrence. Document each time that the work is halted due to a violation of the visible emissions criteria.

Documentation must include the cause for shutdown and the corrective action taken to resolve the problem.

1.2.3.4 PM-10 Monitoring

Prepare and submit a PM-10 Monitoring Plan for monitoring emissions of particulate matter 10 microns or less in size (PM-10) in compliance with the requirements of EPA regulation 40 CFR 50.6 and this paragraph. The plan must also include provisions for halting work and correcting the containment in the event unacceptable emissions occur. Position the air monitoring equipment in accordance with 40 CFR 58 , App E, Subpart (8). In addition, a minimum of two PM-10 monitors must be used at the project site, one downwind from the project and one in the area of greatest public access (e.g., playground, school yard, or homeowner's yard). When the project is in an area where there are critical receptors nearby, monitoring must be conducted throughout the entire period that abrasive blasting and cleanup operations are performed. Otherwise, perform monitoring 4 of the first 8 days and on a regular basis thereafter for a sum total of 25 percent of the time surface preparation and debris cleanup are performed. If air quality regulatory limits are not met, take corrective actions and immediately repeat air monitoring. Conduct the preproject PM-10 monitoring a minimum of 2 weeks prior to the beginning of the project and continue for a minimum of 3 days to establish background levels. Submit a PM-10 Test Report to the Contracting Officer within 48 hours, that includes:

a. Name and location of jobsite.

b. Date of monitoring.

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

d. Identification and serial number of monitoring units.

e. Drawing showing specific location of monitoring units.

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

g. Wind direction and velocity.

SECTION 09 97 02 Page 11

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

i. Name and address of laboratory.

j. Laboratory test procedure.

k. Laboratory test results.

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

1.3 SUBMITTALS

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

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

SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Safety, Health, and Environmental Requirements; G

Accident Prevention Plan; G

Confined Spaces Plan; G

Respiratory Protection Plan; G

Airborne Sampling Plan; G

Ventilation Assessment Plan; G

Medical Surveillance Plan; G

Environmental Protection Plan; G

Waste Manifest

Waste Disposal Plan; G

Containment Plan; G

Visible Emissions Monitoring Plan; G

PM-10 Monitoring Plan; G

SD-03 Product Data

Manufacturer's MSDS Product Data Sheet; G

SD-04 Samples

Product Samples; G

Special Paint Formulas; G

Solvent and Thinners; G

SECTION 09 97 02 Page 12

SD-06 Test Reports

PM-10 Test Report

Inspection Reports

Medical Status Report

Change in Medical Status Report

Air Monitoring Test Plan; G

Air Monitoring Test Report

SD-07 Certificates

Certified EHS Professional

Coating Thickness Gage Qualification

Qualified Coating Applicator; G

Contractors Qc Painting And Coating Inspector

1.4 QUALIFICATIONS

Qualifications and experience must comply with the following.

1.4.1 Certified Environmental, Health, and Safety (EHS) Professionals

Provide a certificate for each Certified EHS Professional; submit qualifications and experience of qualified and competent persons employed to provide preconstruction and onsite environmental, safety, and health services. Obtain acceptance of this submission prior to the submission of other required environmental, safety, and health submittal items. Utilize a qualified and competent person as defined in EM 385-1-1 , Section 01 to develop the required safety and health submittal and to provide onsite safety and health services during the contract period. The person must be a Certified Industrial Hygienist (CIH), an Industrial Hygienist (IH), or a Certified Safety Professional (CSP) with a minimum of 3 years of demonstrated experience in similar related work. The CIH, IH, or CSP may utilize other qualified and competent persons, as defined in EM 385-1-1 , to conduct on-site safety and health activities as long as these persons have a minimum of 2 years of demonstrated experience in similar related work and are under the direct supervision of the CIH, IH, or CSP. For lead containing jobsites, the competent and qualified person must have successfully completed an EPA or state accredited lead-based paint abatement Supervisor course specific to the work to be performed and possess current and valid state and/or local government certification, as required.

1.4.2 Qualified Shop Painting Contractor

The Painting Contractor must be a certified SSPC QP 3 Painting Contractor for all off-site surface preparation or coating application. Submit a copy of the applicable SSPC Certificates. 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

SECTION 09 97 02 Page 13 expirations occurring.

1.4.3 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.

Applicators failing the certification procedure will not be permitted to apply any paint on the project.

1.4.3.1 Certification Test Procedure

Conduct certification testing of coating 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. 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.

1.4.3.2 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.

1.4.4 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. Use eddy current thickness gages as described in ASTM D7091 to measure coating thickness on all nonferrous 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.

1.4.5 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.

1.5 DELIVERY, STORAGE, AND HANDLING

Process and package paints to ensure that within a period of one year from

SECTION 09 97 02 Page 14 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.

1.6 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

Submit Product Samples of each batch of thinner, solvent, and paint to the Government for testing. Submit Manufacturer's MSDS Product Data Sheet 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 or other written instructions for those products. Allow at least 30 days from time of delivery to the contracting officer 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 Contracting Officer. 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 deducted from payments to the Contractor at the rate of 1700 dollars for each paint sample retested and 350 dollars for each thinner retested.

2.1 SPECIAL PAINT FORMULAS

Special paints must have the composition as indicated in the formulas

SECTION 09 97 02 Page 15 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.

2.2 PAINT FORMULATIONS

Special paint formulas must comply with the following:

2.2.1 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

SECTION 09 97 02 Page 16 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.

2.2.2 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

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

SECTION 09 97 02 Page 17 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 .

2.3 INGREDIENTS FOR SPECIAL PAINT FORMULAS

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

2.3.1 Pigments and Suspending Agents

2.3.1.1 Aluminum Powder

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

2.3.1.2 Carbon Black

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

2.3.1.3 Zinc Dust

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

2.3.1.4 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.

2.3.1.5 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.

2.3.1.6 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.

SECTION 09 97 02 Page 18

2.3.1.7 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.

2.3.2 Resins, Plasticizer, and Catalyst

2.3.2.1 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.

2.3.2.2 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 shall have film-forming properties. Vinnol H 15/50, as manufactured by Wacker Chemie AG, meets these requirements.

2.3.2.3 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 shall have film-forming properties. Vinnol H 15/50, as manufactured by Wacker Chemie AG, meets these requirements.

2.3.2.4 Ortho-phosphoric Acid

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

2.3.3 Solvent and Thinners

2.3.3.1 Methanol

Methanol (methyl alcohol) must conform to ASTM D1152.

2.3.3.2 Methyl Ethyl Ketone

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

2.3.3.3 Methyl Isobutyl Ketone

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

2.3.3.4 Methyl Isoamyl Ketone

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

SECTION 09 97 02 Page 19

2.3.3.5 Toluene

Toluene must conform to ASTM D841.

2.3.4 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.

2.3.5 Propylene Oxide

Propylene oxide must be a commercially pure product suitable for the intended use.

2.3.6 PRIMER FOR SLIP CRITICAL JOINTS

Provide a Class B coating in accordance with AASHTO HB-17 for slip critical joints. Apply primer on slip critical joints prior to any other painting of components. Primer in accordance with all federal, state, and local volatile organic compounds (VOC) rules and regulations. If flash rusting occurs, reclean the surface prior to application of primer.

2.4 TESTING

2.4.1 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.

2.4.2 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

SECTION 09 97 02 Page 20 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 construction, erection, or installation operations are completed must be painted before they become inaccessible.

3.1.2 Ferrous Surfaces

Dry blast-clean ferrous surfaces 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.