AM-0001-W912HV21R0006 - APSI SPECS.pdf

APSI Fuel Distribution & Upgrade 20AF0002

SECTION 09 97 13.15

LOW VOC POLYSULFIDE INTERIOR COATING OF WELDED STEEL PETROLEUM FUEL TANKS

02/15

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 in the text by the basic designation only.

AMERICAN PETROLEUM INSTITUTE (API)

API Std 653 (2014; Addendum 1 2018) Tank Inspection, Repair, Alteration, and Reconstruction

ASTM INTERNATIONAL (ASTM)

ASTM D56 (2016a) Standard Test Method for Flash Point by Tag Closed Cup Tester

ASTM D93 (2016) Standard Test Methods for Flash-Point by Pensky-Martens Closed Cup Tester

ASTM D185 (2007; R 2012) Standard Test for Coarse Particles in Pigments

ASTM D476 (2015) Dry Pigmentary Titanium Dioxide Pigments

ASTM D523 (2014; R 2018) Standard Test Method for Specular Gloss

ASTM D714 (2002; R 2017) Standard Test Method for Evaluating Degree of Blistering of Paints

ASTM D1141 (1998; R 2013) Standard Practice for the Preparation of Substitute Ocean Water

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

ASTM D1475 (2013) Standard Test Method for Density of Liquid Coatings, Inks, and Related Products

ASTM D1640 (2003; R 2009) Drying, Curing, or Film Formation of Organic Coatings at Room Temperature

ASTM D2196 (2010) Standard Test Methods for Rheological Properties of Non-Newtonian Materials by Rotational (Brookfield type) Viscometer

ASTM D2240 (2015; E 2017) Standard Test Method for

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W912HV-21-R-0006 (AM-0001)

Rubber Property - Durometer Hardness

ASTM D2369 (2010; R 2015; E 2015) Volatile Content of Coatings

ASTM D2370 (1998; R 2010) Tensile Properties of Organic Coatings

ASTM D2698 (2005) Standard Test Method for Determination of the Pigment Content of Solvent-Reducible Paints by High-Speed Centrifuging

ASTM D2794 (1993; R 2019) Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact)

ASTM D2805 (2011) Standard Test Method for Hiding Power of Paints by Reflectometry

ASTM D3276 (2015; E 2016) Standard Guide for Painting Inspectors (Metal Substrates)

ASTM D3278 (1996; R 2011) Flash Point of Liquids by Small Scale Closed-Cup Apparatus

ASTM D3335 (1985a; R 2014) Low Concentrations of Lead, Cadmium, and Cobalt in Paint by Atomic Absorption Spectroscopy

ASTM D3718 (1985a; R 2015) Low Concentrations of Chromium in Paint by Atomic Absorption Spectroscopy

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

ASTM D3960 (2005; R 2013) Determining Volatile Organic Compound (VOC) Content of Paints and Related Coatings

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

ASTM D4400 (1999; E 2012; R 2012) Sag Resistance of Paints Using a Multinotch Applicator

ASTM D4541 (2017) Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers

ASTM D7334 (2008; R 2013) Standard Practice for Surface Wettability of Coatings, Substrates and Pigments by Advancing Contact Angle Measurement

ASTM D7588 (2011) Standard Guide for FT-IR Fingerprinting of a Non-Aqueous Liquid Paint as Supplied in the Manufacturer’s

SECTION 09 97 13.15 Page 2

Container

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 9001 (2008; Corr 1 2009) Quality Management Systems- Requirements

NACE INTERNATIONAL (NACE)

NACE CIP Level 3 NACE International Institute Certified Coating Inspector Program

NACE SP0169 (2015) Control of External Corrosion on Underground or Submerged Metallic Piping Systems

NACE SP0178 (2007) Design, Fabrication, and Surface Finish Practices for Tanks and Vessels to be Lined for Immersion Service

NACE SP0188 (1999; R 2006) Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

NACE TM0174 (2002) Laboratory Methods for the Evaluation of Protective Coatings and Lining Materials on Metallic Substrates in Immersion Service - Item No:21206

NACE SP0188 (1999; R 2006) Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

NIICAP AS-1 (2016) NACE Internationsal Institute Contractor Accreditation Program Audit Standard AS-1 Programs for Accreditation of Field and Shop Coatings Contractors

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC 7/NACE No.4 (2007; E 2004) Brush-Off Blast Cleaning

SSPC AB 1 (2015; E 2017) Mineral and Slag Abrasives

SSPC AB 2 (2015; E 2016) Cleanliness of Recycled Ferrous Metallic Abrasive

SSPC AB 3 (2003; E 2004) Ferrous Metallic Abrasive

SSPC Guide 12 (1998; E 2004) Guide for Illumination of Industrial Painting Projects

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

SSPC PA 17 (2012; E 2012) Procedure for Determining Conformance to Steel Profile/Surface Roughness/Peak Count Requirements

SECTION 09 97 13.15 Page 3

SSPC SP 1 (2015) Solvent Cleaning

SSPC SP 10/NACE No. 2 (2007) Near-White Blast Cleaning

SSPC SP COM (2016; E 2017) Surface Preparation Commentary for Steel and Concrete Substrates

SSPC VIS 1 (2002; E 2004) Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

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

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

29 CFR 1910.134 Respiratory Protection

29 CFR 1910.1000 Air Contaminants

29 CFR 1926.59 Hazard Communication

1.2 DEFINITIONS

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

a. CEILING - interior tank surfaces that extend from the horizontal plane at the designated maximum fuel line upward, including the upper portion of the tank shell (walls), columns, structural steel, the underside of the roof plates and other steel components in this area.

b. SHELL - interior tank surfaces that extend along the vertical tank walls between the horizontal planes approximately 1 meter above the shell to bottom joint upward to the horizontal plane at the designated fuel line, including columns, wall plates, and other steel components in this area.

c. FLOOR - interior tank surfaces below the horizontal plane approximately 1 meter above the shell to bottom joint, including columns, wall plates, piping, pipe supports, bottom plates, and other steel components in this area.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for Contractor QC approval.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-05, Design Data

Environmental Control System

SECTION 09 97 13.15 Page 4

SD-06 Test Reports

Coatings Qualification Inspection Reports

Non-metallic Abrasive Qualification Test Reports; G

Metallic Abrasive Qualification Test Reports

Coating Sample Test Reports

Abrasive Sample Test Reports

Inspection Report Forms

Daily Inspection Reports

Recycled Metallic Abrasive Field Test Reports (Daily and Weekly)

SD-07 Certificates

Contract Errors, Omissions, and Other Discrepancies

Corrective Action Procedures

Implement Corrective Action

Coating Work Plan

Coating Materials

Non-metallic Abrasive

Metallic Abrasive

Qualifications of Certified Industrial Hygienist (CIH)

Qualifications of Individuals Performing Abrasive Blasting

Qualifications of Individuals Applying Coatings

Qualifications of Individuals Operating Plural Component Equipment

Qualifications of Certified Protective Coatings Specialist (PCS)

Qualifications of Coating Inspection Company

Qualifications of QC Specialist Coating Inspector

Qualifications of Testing Laboratory for Coatings

Qualifications of Testing Laboratory for Abrasive

Qualifications of Coating Contractors

Protective Coating Specialist (PCS)

Pre-Application Meeting

SD-08 Manufacturer's Instructions

SECTION 09 97 13.15 Page 5

Coating System Instructions

SD-11 Closeout Submittals

Disposal of Used Abrasive; G

Inspection Logbook; G

1.4 QUALITY ASSURANCE

1.4.1 Contract Errors, Omissions, and Other Discrepancies

Submit all errors, omissions, and other discrepancies in contract documents to the Contracting Officer within 30 days of contract award for all work covered in this Section, other than the work that will not be uncovered until a later date. All such discrepancies must be addressed and resolved, and the Coating Work Plan modified, prior to beginning the Initial and Follow-Up phases of work. Discrepancies that become apparent only after work is uncovered must be identified at the earliest discoverable time and submitted for resolution. Schedule time (Float) should be built into the project schedule at those points where old work is to be uncovered or where access is not available during the first 30 days after award, to allow for resolution of contract discrepancies.

1.4.2 Corrective Action (CA)

CA must be included in the Quality Control Plan.

1.4.2.1 Corrective Action Procedures

Develop procedures for determining the root cause of each non-compliance, developing a plan to eliminate the root cause so that the non-compliance does not recur, and following up to ensure that the root cause was eliminated. Develop Corrective Action Request (CAR) forms for initiating CA, and for tracking and documenting each step.

1.4.2.2 Implement Corrective Action

The Contractor must take action to identify and eliminate the root cause of each non-compliance so as to prevent recurrence. These procedures must apply to non-compliance in the work, and to non-compliance in the QC System. Corrective actions must be appropriate to the effects of the non-compliance encountered. Each CAR must be serialized, tracked in a Log to completion and acceptance by the Contracting Officer, and retained in project records. The Corrective Action Log, showing status of each CAR, must be submitted to the Contracting Officer monthly. A CAR may be initiated by either the Contractor or the Contracting Officer. The Contracting Officer must approve each CAR at the root cause identification stage, the plan for elimination stage, and the close out stage after verification that the root cause has been eliminated.

1.4.3 Coating Work Plan

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

b. Provide procedures for reviewing contract documents immediately after award to identify errors, omissions, and discrepancies so

SECTION 09 97 13.15 Page 6 that any such issues can be resolved prior to project planning and development of detailed procedures.

c. Provide procedures for verification of key processes during Initial Phase to ensure that contract requirements can be met.

Key processes must include surface preparation, coating application and curing, inspection, and documentation, and any other process that might adversely impact orderly progression of work.

d. Provide procedures for all phases of coating operations, including planned work, rework, repair, inspection, and documentation.

Address mobilization and setup, surface preparation, coating application, coating initial cure, tracking and correction of non-compliant work, and demobilization. Coordinate work processes with health and safety plans and confined space entry plans. For each process, provide procedures that include appropriate work instructions, material and equipment requirements, personnel qualifications, controls, and process verification procedures.

Provide procedures for inspecting work to verify and document compliance with contract requirements, including inspection forms and checklists, and acceptance and rejection criteria.

e. Provide procedures for correcting non-compliant work. Detailed procedures are required in advance to avoid delays in meeting overcoat windows as well as to avoid delays in production.

Provide procedures for repairing defects in the coating film, such as runs, drips, sags, holidays, overspray, as well as how to correct coating thickness non-compliance, any other areas of repair or rework that might be adversely affected by delays in preparing and approving new procedures.

f. If a procedure is based on a proposed or approved request for deviation, the deviation must be referenced. Changes to procedures must be noted by submittal number and date approved, clearly delineating old requirements and new requirements, so that the records provide a continuous log of requirements and procedures.

1.4.4 Design Data

1.4.4.1 Environmental Control System

Submit design details of the proposed environmental control system to include ventilation, humidity control, and temperature regulation.

Provide calculations for humidity control during separate surface preparation and coating application procedures, ventilation requirements during coating application, and maximum allowable coating application rates to coincide with ventilation. Include basis of design data on local conditions. Provide equipment layout sketches and procedures showing function of each piece of equipment and fail-safe measures. A Certified Industrial Hygienist must approve calculations, work procedures and personal protective equipment.

1.4.5 Test Reports

1.4.5.1 Coatings Qualification Inspection Reports

Submit test results from independent laboratory for material required in

SECTION 09 97 13.15 Page 7 paragraph COATING MATERIALS. Samples must have been tested within the last two years. Note that this testing is for the purpose of prequalifying the coating material.

1.4.5.2 Metallic Abrasive Qualification Test Reports

Submit results for abrasive as required in paragraph 4 REQUIREMENTS of SSPC AB 3 . Submit test results from independent laboratory of representative samples of each abrasive to be used on the jobsite.

Samples must have been tested within the last three years. Note that this testing is for the purpose of prequalifying the abrasive.

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

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

ABRASIVE.

1.4.5.4 Non-metallic Abrasive Qualification Test Reports

Submit results for abrasive as required in paragraph 4 REQUIREMENTS of SSPC AB 1 . Submit test results from independent laboratory of representative samples of each abrasive to be used on the jobsite.

Samples must have been tested within the last three years. Note that this testing is for the purpose of prequalifying the abrasive.

1.4.6 Qualifications

1.4.6.1 Qualifications of Certified Industrial Hygienist (CIH)

Submit name, address, telephone number, FAX number, and e-mail address of the independent third party CIH. Provide evidence of experience with hazards involved in industrial coating application work.

1.4.6.2 Qualifications of Certified Protective Coatings Specialist (PCS)

Submit name, address, telephone number, FAX number, and e-mail address of the independent third party PCS. Submit documentation that the specialist is certified through SSPC or NACEincluding certification number and date of certification/recertification. If the PCS is employed by the same coating inspection company to which the coating inspector is employed, this does not violate the independent third-party requirements. The PCS must remain certified during the entire project, and the Contracting Officer must be notified of any change in certification status within 10 days of the change. The PCS must not be the designated coating inspector.

1.4.6.3 Qualifications of Coating Inspection Company

Submit documentation that the coating inspection company performing all coating inspection functions is certified by NACE or ISO 9001 . The coating inspection company submitted and approved must remain and not changed through completion of the contract. The coating inspection company must remain so certified for the duration of the coating work. If a coating inspection company's certification expires, the firm will not be allowed to perform any inspection functions, and all surface preparation and coating application work must stop, until the certification is reissued. Requests for extension of time for any delay to the completion of the project due to an inactive certification will not be considered and liquidated damages will apply. Notify the Contracting Officer of any

SECTION 09 97 13.15 Page 8 change in coating inspection company certification status. Notify the Contracting Officer of all scheduled and unannounced on site inspections and furnish a copy of all inspection reports.

1.4.6.4 Qualifications of QC Specialist Coating Inspector

Submit documentation that each coating inspector is employed, and qualified to NACE CIP Level 3 , by the selected coating inspection company. Each inspector must remain employed by the coating inspection company while performing any coating inspection functions. In addition to the handwritten records, the inspector must employ the electronic reporting program TruQC or equivalent as outlined in Table III. The Administrator must be the designated Government Representative for the project.

1.4.6.5 Qualifications of Individuals Performing Abrasive Blasting

Submit name, address, and telephone number of each person that will be performing abrasive blasting. Each blaster must remain certified by SSPC to the SSPC C-7 Dry Abrasive Blaster Program or by NACE through NIICAP AS-3 accreditation during the entire period of abrasive blasting, and the Contracting Officer must be notified of any change in qualification status.

1.4.6.6 Qualifications of Individuals Applying Coatings

Submit name, address, and telephone number of each person that will be applying coatings. Each applicator must remain certified by SSPC to the SSPC C-12 Marine/Industrial Airless Spray Program or SSPC C-15 Plural Component Spray Program, Spray Painter Category, or by NACE through NIICAP AS-3 accreditation during the entire period of coating application, and the Contracting Officer must be notified of any change in qualification status.

1.4.6.7 Qualifications of Individuals Operating Plural Component Equipment

Submit name, address, and telephone number of each person that will be operating plural component equipment. Each operator must remain certified by SSPC to the SSPC C-15 Plural Component Spray Program, Spray Painter Category, or by NACE through NIICAP AS-3 accreditation during the entire period of coating application, and the Contracting Officer must be notified of any change in qualification status.

1.4.6.8 Qualifications of Testing Laboratory for Coatings

Submit name, address, telephone number, FAX number, and e-mail address of the independent third party laboratory selected to perform testing of coating samples for compliance with specification requirements. Submit documentation that laboratory is regularly engaged in testing of paint samples for conformance with specifications, and that employees performing testing are qualified.

1.4.6.9 Qualifications of Testing Laboratory for Abrasive

Submit name, address, telephone number, FAX number, and e-mail address of the independent third party laboratory selected to perform testing of abrasive for compliance with specification requirements. Submit documentation that laboratory has experience in testing samples of abrasive for conformance with specifications, and that employees performing testing are qualified.

SECTION 09 97 13.15 Page 9

1.4.6.10 Qualifications of Coating Contractors

All Contractors and Subcontractors that perform surface preparation or coating application must be certified to NIICAP AS-1 and ISO 9001 prior to contract award, and must remain certified while accomplishing any surface preparation or coating application. The painting Contractors and painting Subcontractors must remain so certified for the duration of the project.

If a Contractor's or Subcontractor's certification expires, the firm will not be allowed to perform any work until the certification is reissued.

Requests for extension of time for any delay to the completion of the project due to an inactive certification will not be considered and liquidated damages will apply. Notify the Contracting Officer of any change in Contractor certification status. Notify the Contracting Officer of all scheduled and unannounced on site audits and furnish a copy of all audit reports.

All Contractors and Subcontractors that perform surface preparation or coating application must be certified to ISO 9001 prior to contract award, and must remain certified while accomplishing any surface preparation or coating application. The painting Contractors and painting Subcontractors must remain so certified for the duration of the project. If a Contractor's or Subcontractor's certification expires, the firm will not be allowed to perform any work until the certification is reissued.

Requests for extension of time for any delay to the completion of the project due to an inactive certification will not be considered and liquidated damages will apply. Notify the Contracting Officer of any change in Contractor certification status. Notify the Contracting Officer of all scheduled and unannounced on site inspections from the ISO certifying organization and furnish a copy of all inspection reports.

1.4.6.11 Coating Materials

Provide manufacturer's certification of conformance to contract requirements.

1.4.6.12 Non-metallic Abrasive

Provide manufacturer's certification that the materials are currently approved by the Naval Sea Systems Command and listed on the Qualified Products List (QPL) for the specified materials Provide manufacturer's certification of conformance to contract requirements and provide copies of test results. .

1.4.6.13 Metallic Abrasive

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

1.4.7 Protective Coating Specialist (PCS)

The PCS must be considered a QC Specialist and must report to the QC Manager, as specified in Section 01 45 00.00 10 QUALITY CONTROL. The PCS must approve all submittals prior to submission to the QC Manager for approval or submission to the government for approval.

1.4.8 Pre-Application Meeting

After approval of submittals but prior to the initiation of coating work, SECTION 09 97 13.15 Page 10

W912HV-21-R-0006 (AM-0001)

j2ee9gsg Line

Contractor representatives, including at a minimum, project superintendent and QC manager, paint foreman, coating inspector, and PCS must have a pre-application coating preparatory meeting. This meeting must be in addition to the pre-construction conference. Specific items addressed must include: corrective action requirements and procedures, coating work plan, safety plan, coordination with other Sections, inspection standards, inspection requirements and tools, test procedures, environmental control system, safety plan, and test logs. Notify Contracting Officer at least ten days prior to meeting.

1.5 PRODUCT DATA

1.5.1 Coating System Instructions

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

1.6 DELIVERY AND STORAGE

Ship, store, and handle materials in accordance with NACE SP0169.

Maintain temperature in storage spaces between 5 and 29 degrees C, and air temperature more than 3 degrees C above the dew-point at all times.

Inspect materials for damage prior to use and return non-compliant materials to manufacturer. Remove materials with expired shelf life from government property immediately and notify the Contracting Officer.

If materials are approaching shelf life expiration and an extension is desired, samples may be sent to the manufacturer, along with complete records of storage conditions, with a request for shelf life extension.

If the manufacturer finds the samples and storage data suitable for shelf life extension, the manufacturer may issue an extension, referencing the product evaluation and the review of storage records.

1.7 COATING HAZARDS

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

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

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

1.8 WORK SEQUENCE

Coat tank interior following tank tightness testing..

1.9 JOB SITE REFERENCES

Make available to the Contracting Officer at least one copy each of API Std 653 , ASTM D3276, ASTM D3925, ASTM D4285, NACE SP0178 and companion visual comparator, NACE SP0188, SSPC SP COM, SSPC SP 1 , SSPC 7/NACE No.4 , SSPC SP 10/NACE No. 2 , SSPC PA 2 , SSPC PA 17 , SSPC Guide 12 , SSPC VIS 1 , SSPC CAS, and SSPC C 14.

SECTION 09 97 13.15 Page 11

PART 2 PRODUCTS

2.1 COATING SYSTEM

Alternate systems or products will not be considered. All coating materials must be supplied by one supplier. The entire coating system is intended to be applied in the field. Alternatively, surface preparation may be accomplished in the shop, following all temperature, humidity, and testing requirements listed herein, followed by an application of a hold-primer. Upon completion of field fabrication, all shop-applied coatings must be removed, surfaces prepared to SSPC SP 10/NACE No. 2 , and the specified coating system applied. Adjust all shop preparation to avoid conflicts with final surface preparation requirements.

2.1.1 Coating Materials

Modified epoxy novolac polysulfide coating materials complying with Table I and Table II. The first and finish coat materials are identical except that the coats must be in contrasting colors to allow identification.

Note that the qualification testing requires immersion testing for six months.

2.2 COATING SAMPLE COLLECTION AND SHIPPING KIT

Provide 2 kits that contains one liter can for the base and activator of each SZC material, an appropriately sized can for each activator, dipping cups for each component to be sampled, a shipping box sized for the samples to be shipped, and packing material. Extract 2 samples of each component, mark cans for the appropriate components including manufacturers name, address, batch numbers, batch size shipped to the project site and date of manufacture. Store in QC Manager's office until completion of project. If unforeseen coating issues arise ship 1 complete sample (including base and activator) with all batch information to the pre-chosen approved Independent laboratory for evaluation. Include all pertinent information from the project. The QC Manager is to arrange pick-up and shipping to the approved coating testing laboratory.

2.3 ABRASIVE SAMPLE COLLECTION AND SHIPPING KIT

Provide a kit that contains one suitable plastic bag or container for each sample to be collected. Mark containers for the appropriate component.

Provide shipping documents, including either pre-paid shipping or a shipper number that can be used by the QC Manager to arrange pickup, addressed to the approved coating testing laboratory.

2.4 TEST KITS

2.4.1 Test Kit for Measuring Chloride, Sulfate and Nitrate Ions on Steel and Coated Surfaces

To be considered for approval, each proposed test kit must meet the following requirements:

a. Kit contains all materials, supplies, tools and instructions for field testing and on-site quantitative evaluation of chloride, sulfate and nitrate ions;

b. Kit extract solution is acidic, factory pre-measured, pre-packaged, SECTION 09 97 13.15 Page 12 and of uniform concentration;

c. Kit components and solutions are mercury free and environmentally friendly;

d. Kit contains new materials and solutions for each test extraction;

e. Extraction test container (vessel, sleeve, cell) creates a sealed, encapsulated environment during salt ion extraction;

f. Test extract container is suitable for testing the following steel surfaces: horizontal (up/down configuration), vertical, flat, curved, smooth, pitted, and rough;

g. All salt ion concentrations are directly measured in micrograms per square centimeter.

2.4.2 Test Kit for Measuring Chlorides in Abrasives

To be considered for approval, each proposed test kit must:

a. Be a completely self-contained test kit with all materials, supplies, tools and instructions to take tests and identify results;

b. Use identifiable, consistent, factory pre-measured test extract solution;

c. Provide for testing equal volumes of abrasive and test solution;

d. Provide for taking direct measurements of the chloride ion in parts per million (PPM), without using conversion charts or tables;

e. Provide all new components for extraction and titration for each test;

f. Provide a factory sealed titration device for each test;

g. Use the extract sampling container as the titration container.

2.4.3 Test Kit for Identifying Amine Blush on Epoxy Surfaces

Test kit must meet the following requirements:

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

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

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

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

2.5 ABRASIVE

The referenced abrasive specifications have maximum limits for soluble salts contamination, however, this maximum level of contamination does not guarantee that contamination will not be transferred to the steel surface

SECTION 09 97 13.15 Page 13 during abrasive blasting. Other factors such as on-site handling and recycling can allow contamination of abrasive. Contractors are cautioned to verify that the chosen abrasive, along with work and storage processes, allow the final surface cleanliness requirements to be achieved.

Successful testing of chlorides in abrasive does not negate the final acceptance testing of steel surfaces.

2.5.1 Non-metallic Abrasive

Conform to SSPC AB 1 , Class A except that:

a. The maximum allowable chloride content is 7 parts per million (ppm) as measured with the test kit described in the paragraph TEST KIT FOR MEASURING CHLORIDES IN ABRASIVES. Modify the requirements of SSPC AB 2 to substitute requirement for one chloride test for each "WATER SOLUBLE CONTAMINANTS" test required.

b. The maximum allowable Chromium and Cadmium content of the work mix must be less than 0.1 percent by wt. when tested in accordance with ASTM D3718 for Chromium and ASTM D3335 for Cadmium. Modify the requirements of SSPC AB 2 to add requirement for one Chromate test and one Cadmium test for each "LEAD" test required.

Use abrasive that is specifically selected and graded to provide a sharp, angular profile to the specified depth. Do not use ungraded abrasive.

Make adjustments to processes or abrasive gradation to achieve specified surface profile. Recycled non-metallic abrasive must meet all requirements of the specification each time that it is placed in the blast pot.

2.5.2 Metallic Abrasive

2.5.2.1 New and Remanufactured Steel Grit

Conform to the chemical and physical properties of SSPC AB 3 Class 1 (Steel) only. Class 2 (Iron) abrasive must not be used.

To develop a suitable work mix from new steel abrasive, a minimum of 200 to 400 recycles is required, therefore, it is advantageous for a Contractor to use remanufactured steel grit or grit reclaimed from a previous project. Such grit must be considered to conform if it can be traced to new grit conforming to SSPC AB 3 Class 1 and it meets all cleanliness requirements of SSPC AB 3 Class 1 when brought to the current jobsite. Submit one representative sample of this work mix to the laboratory for testing, along with samples of new material. Acceptance and use of this work mix must not be used to justify any deviation from surface preparation requirements.

2.5.2.2 Recycled Steel Grit

Abrasive media must conform to the chemical and physical properties of SSPC AB 2 except that:

a. The maximum allowable chloride content is 7 parts per million (ppm) as measured with the test kit described in article entitled "Test Kit for Measuring Chlorides in Abrasives." Modify the requirements of SSPC AB 2 to substitute requirement for one chloride test for each "WATER SOLUBLE CONTAMINANTS" test required.

SECTION 09 97 13.15 Page 14

b. The maximum allowable Chromium and Cadmium content of the work mix must be 0.1 percent by wt. when tested in accordance with ASTM D3718 for Chromium and ASTM D3335 for Cadmium. Modify the requirements of SSPC AB 2 to add requirement for one Chromate test and one Cadmium test for each "LEAD" test required.

PART 3 EXECUTION

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

3.1 COATING AND ABRASIVE SAMPLE COLLECTION AND TESTING

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

3.1.1 Coating Sample Collection

Provide 2 sample collection kits as required in paragraph COATING SAMPLE COLLECTION AND SHIPPING KIT. From each lot, obtain a one liter sample of each base material, and proportional samples of each activator based on mix ratio, by random selection from sealed containers in accordance with ASTM D3925. Prior to sampling, mix contents of each sealed container to ensure uniformity. As an alternative to collecting small samples from kits, entire kits may be randomly selected and shipped to laboratory, observing all requirements for witnessing and traceability. For purposes of quality conformance inspection, a lot is defined as that quantity of materials from a single, uniform batch produced and offered for delivery at one time. A batch is defined as that quantity of material processed by the manufacturer at one time and identified by number on the label.

Identify samples by designated name, specification number, batch number, project contract number, sample date, intended use, and quantity involved. The QC Manager will take possession of the packaged samples and hold until instructed to contact a shipping company to arrange for pickup, and relinquish the samples only to the shipping representative for shipment to the approved laboratory for testing as required by paragraph

COATING SAMPLE TEST REPORTS.

3.1.2 Abrasive Sample Collection

Provide a sample collection kit as required in paragraph ABRASIVE SAMPLE COLLECTION AND SHIPPING KIT. For purposes of quality conformance inspection, a lot must consist of all abrasive materials of the same type from a single, uniform batch produced and offered for delivery at one time. Obtain samples of each abrasive lot using the sampling techniques and schedule of the relevant SSPC AB standard reference. The addition of any substance to a batch must constitute a new lot. Identify samples by designated name, specification number, lot number, project contract number, sample date, intended use, and quantity involved. The QC Manager will take possession of the packaged samples, contact the shipping company to arrange for pickup, and relinquish the samples only to the shipping representative for shipment to the approved laboratory for testing as required by paragraph ABRASIVE SAMPLE TEST REPORTS.

3.1.3 Coating Sample Test Reports

Submit test results for each lot of coating material delivered to the

SECTION 09 97 13.15 Page 15 jobsite. Test samples of coating material for compliance with requirements of Table I. Reject entire batch represented by samples that fail one or more tests, select new lots, and test samples.

3.1.4 Abrasive Sample Test Reports

Submit test results for each lot of abrasive delivered to the jobsite.

Test samples of metallic abrasive to the requirements of paragraph REQUIREMENTS of SSPC AB 3 , except paragraph 4.1.5 DURABILITY. Test samples of non-metallic abrasive to the requirements of paragraph REQUIREMENTS of SSPC AB 1 . Reject entire lot represented by samples that fail one or more tests, select new lots, and test samples.

3.2 LIGHTING

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

3.3 ENVIRONMENTAL CONDITIONS

3.3.1 Tank Containment

Maintain exterior tank containment in full working condition during interior surface preparation, coating application, and initial curing to aid in maintaining interior environmental conditions.

3.3.2 Control System Requirements

Provide and utilize dehumidification and ventilation equipment to control humidity, temperature, and vapor levels in tank from beginning of abrasive blasting through coating application and for 16 hours after the last coating is applied. System must maintain vapor concentrations at or below 10 percent of Lower Explosive Limit (LEL). System may incorporate any combination of solid desiccant and direct expansion refrigeration equipment. No liquid, granular, calcium chloride, or lithium chloride drying systems will be accepted. Use only electric, indirect fired combustion, indirect friction, or steam coil auxiliary heaters. System must be compatible with removal of dust and solvent vapors, and must have fail-safe measures to ensure reliability during operations.

3.3.3 Automated Monitoring Requirements

Provide continuous monitoring of DH equipment, and temperature, relative humidity, and dew point data at pertinent points on the structure, during surface preparation, coating application, and initial cure. This data does not suffice for documentation of conformity to surface conditions during application and cure of coating. Locate sensors to provide pertinent data for the surface preparation and coat application being performed, as well as the temperature extremes on the structure. Describe the location plan, including required moves, in the Work Plan. Make data available to the Contracting Officer through Internet access. Provide monitoring equipment to perform as follows:

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

b. Monitoring equipment must have backup power such that data collection and transmission to web server will be uninterrupted during the entire

SECTION 09 97 13.15 Page 16 period of the dehumidification requirement;

c. Monitoring equipment must have capability to measure surface temperatures at a minimum of four locations anywhere on a structure, regardless of size of structure;

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

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

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

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

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

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

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

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

There is no requirement for connectivity of the monitoring system to control the DH equipment, therefore, any combination of equipment having the required functionality will be accepted.

3.3.4 Humidity Control for Surface Preparation and First Coat Application

Provide and utilize dehumidification equipment to maintain relative humidity at appropriate level to prevent prepared steel surfaces from corroding at all times during abrasive blasting through coating application. Failure of humidity control system, or failure to maintain proper conditions, during surface preparation stage may allow surface rusting, which will be rejected and require rework. All surfaces to be coated must meet all requirements at time of coating application. Failure of humidity control system during coating application stage will be cause for removal and replacement of all materials applied and cured while conditions were not as prescribed above.

Note that reduction of relative humidity below approximately 25 percent may affect application and curing characteristics. Contact coating manufacturer for appropriate limitations on lower relative humidity levels.

3.3.5 Humidity Control for Application of Finish Coat and Initial Curing

Provide and utilize dehumidification equipment to maintain relative humidity at the coldest steel surface in tank below 55 percent at all

SECTION 09 97 13.15 Page 17 times during coating application, and initial curing. This measurement is not the same as measuring the relative humidity of ambient air in the tank, and will require either electronic equipment to monitor relative humidity at the steel surface, or complex calculations to convert relative humidity of air in tank to relative humidity at steel surface. An approved alternative method of monitoring dehumidification that requires less sophisticated equipment or calculations is to maintain a minimum dew point depression of 10 degrees C below coldest steel surface temperature.

This is in lieu of specific relative humidity and dew point requirements in this Section. Failure to maintain specified humidity control during application may cause formation of condensation during the coating application stages prior to the indicated dry-hard period and will be cause for removal and replacement of all materials contacted by condensation.

3.4 EQUIPMENT USED IN TANK

Equipment used in the tank after surface preparation begins must not leave any oily residue from exhaust or other sources. Internal combustion driven equipment, other than that powered by natural or bottled gas, must not be used.

3.5 SURFACES TO BE COATED

Prepare and coat interior tank surfaces of the horizontal aboveground storage tanks, including carbon steel piping within the tank. Do not coat aluminum or stainless steel components. Remove tank components, including ATG level transmitters, level indicators, and level switches during abrasive blasting and coating application.

3.6 SURFACE PREPARATION

3.6.1 Abrasive Blasting Equipment

Use abrasive blasting equipment of conventional air, force-feed, or pressure type. Maintain a minimum pressure of 650 kPa at nozzle. Confirm that air supply for abrasive blasting is free of oil and moisture when tested in accordance with ASTM D4285. Test air quality at each startup, but in no case less often than every five operating hours.

3.6.2 Operational Evaluation of Abrasive

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

3.6.3 Surface Standard

Inspect surfaces to be coated, and select plate with similar properties and surface characteristics for use as a surface standard. Blast clean one or more 300 mm square steel panels as specified in paragraph SURFACE PREPARATION. Record blast nozzle type and size, air pressure at nozzle and compressor, distance of nozzle from panel, and angle of blast to establish procedures for blast cleaning. Measure surface profile in accordance with SSPC PA 17 . When the surface standard complies with all specified requirements, seal with a clearcoat protectant. Use the surface standard for comparison to abrasive blasted surfaces throughout the course of work.

SECTION 09 97 13.15 Page 18

3.6.4 Pre-Preparation Testing for Surface Contamination

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

3.6.4.1 Pre-Preparation Testing for Oil and Grease Contamination

a. Inspect all surfaces for oil and grease contamination using two or more of the following inspection techniques: 1) Visual inspection,

2) WATER BREAK TEST, 3) BLACK LIGHT TEST, and 4) CLOTH RUB TEST.

Reject oil or grease contaminated surfaces, clean using a water based pH neutral degreaser in accordance with SSPC SP 1 , and recheck for contamination until surfaces are free of oil and grease.

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

c. BLACK LIGHT TEST - Inspect surfaces for oil and grease contamination using the light specified in paragraph BLACK LIGHT.

Use light no more than 381 mm from surface unless testing indicates that the specific oil or grease found in tank fluoresce at a greater distance. Use light in tank that is completely sealed from light infiltration, under a hood, or at night. Any fluorescing on steel surfaces is indication of petroleum oil/grease contamination. Use either WATER BREAK TEST or CLOTH RUB TEST to confirm both contaminated and non-contaminated areas detected by BLACK LIGHT TEST. The BLACK LIGHT TEST may not be used during inspection of prepared surfaces for oil and grease contamination unless proven to fluoresce the oil and grease found in the specific tank and documented during testing prior to abrasive blasting. Generally, only petroleum oil/grease will fluoresce, however, some may not fluoresce sufficiently to be recognized and other methods, such as the WATER BREAK TEST or CLOTH RUB TEST, must be used to confirm findings of the BLACK

LIGHT TEST.

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

3.6.4.2 Pre-Preparation Testing for Soluble Salts Contamination

Test surfaces for soluble salts, and wash as required, prior to abrasive blasting. Soluble salt testing is also required in paragraph PRE-APPLICATION TESTING FOR SOLUBLE SALTS CONTAMINATION as a final acceptance test of prepared surfaces after abrasive blasting, and successful completion of this phase does not negate that requirement.

This phase is recommended since pre-preparation testing and washing are generally more advantageous than attempting to remove soluble salt contamination after abrasive blasting. Effective removal of soluble salts will require removal of any barrier to the steel surface, including rust.

This procedure may necessitate combinations of wet abrasive blasting, high pressure water rinsing, and cleaning using a solution of water washing and soluble salts remover. The soluble salts remover must be acidic, SECTION 09 97 13.15 Page 19 biodegradable, nontoxic, noncorrosive, and after application, will not interfere with coating adhesion. Delays between testing and preparation, or testing and coating application, may allow for the formation of new contamination. Use potable water, or potable water modified with a soluble salt remover, for all washing or wet abrasive blasting. Test methods and equipment used in this phase are selected at the Contractor's discretion.

3.6.5 Abrasive Blasting

a. Prepare steel surfaces in accordance with NACE SP0169 and as specified herein.

b. On new surfaces abrasive blast steel surfaces to near-white metal in accordance with SSPC SP 10/NACE No. 2 . Prepared surfaces must conform to SSPC VIS 1 and must match the prepared test-panels.

Provide a 50 to 75 micron surface profile. Reject profile greater than 75 microns, discontinue abrasive blasting, and modify processes and materials to provide the specified profile. Measure surface profile in accordance with SSPC PA 17 , using Rmax as the measure of profile height. Record all measurements required in this standard. Measure profile at rate of three test areas for the first 100 square meters plus one test area for each additional 100 square meters or part thereof. When surfaces are reblasted for any reason, retest profile as specified. Following abrasive blasting, remove dust and debris by vacuum cleaning. Do not attempt to wipe surface clean.

c. On previously coated and prepared surfaces determine and establish the average blast profile existing. If existing blast profile is greater than the required 75 microns established for new surfaces this average profile must be reported and a mutual agreement by the government and contractor at the pre-application meeting must be determined to not increase the existing profile. Abrasive blast the steel surfaces to near-white metal in accordance with SSPC SP 10/NACE No. 2 using abrasive and technique which does not increase the existing profile. Provide a minimum 75 microns surface profile but no additional profile than that existing.

Reject profile greater than existing, discontinue abrasive blasting, and modify processes and materials to provide the specified agreed existing profile. Prepared surfaces must conform to SSPC VIS 1 and must match the prepared test-panels. Measure surface profile in accordance with SSPC PA 17 , using Rmax as the measure of profile height. Record all measurements required in this standard. Measure profile at rate of three test areas for the first 100 square meters plus one test area for each additional 100 square meters or part thereof. Provide two additional measurements for each non-compliant measurement.