W912P509B0019TSpecsAmendPgs.pdf

Fabrication of Miter Gates, Culvert Valves Chickamauga Lock Replacement and Culvert Bulkheads - Amendment Hamilton County, Tennessee

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 00 00

GENERAL REQUIREMENTS

PART 1 GENERAL

1.1 SCOPE

1.2 REFERENCES

1.3 SUBMITTALS

1.4 INSPECTIONS AND ACCEPTANCE OF WORK

1.4.1 General

1.4.2 Access to Work

1.5 FABRICATION SHOP STORAGE

1.6 STORAGE YARD

1.6.1 Site Access to Storage Yard

1.6.1.1 Marine Access

1.6.1.2 Land Access

1.6.2 Site Preparation

1.6.3 Storage Requirements

1.6.4 Maintenance of Storage Yard

1.7 DELIVERY OF FABRICATIONS

1.8 ACCIDENT PREVENTION

PART 2 PRODUCTS

2.1 FENCE AND GATE MATERIALS

2.1.1 Fence Fabric

2.1.2 Gates

2.1.3 Posts

2.1.4 Braces and Rails

2.1.5 Tension Wire

2.1.6 Concrete

2.1.7 Padlocks

2.2 STONE BASE

PART 3 EXECUTION (Not Used)

-- End of Section Table of Contents --

SECTION 01 00 00 Page 1

SECTION 01 00 00

GENERAL REQUIREMENTS

PART 1 GENERAL

1.1 SCOPE

This section of the Specifications provides general information and requirements. The work covered by these Specifications consists of furnishing all equipment, labor, and materials required for the fabrication and delivery of miter gates, culvert valves, and culvert bulkheads as shown on the drawings and as described herein within 21 months of the Notice to Proceed. The embedded metals are to be provided within 18 months of Notice to Proceed.

1.2 REFERENCES

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

ALABAMA DEPARTMENT OF TRANSPORTATION (ALDOT)

ALDOT Std Specs (2008) Standard Specifications For Highway Construction, including subsequent Supplementals to date

ASTM INTERNATIONAL (ASTM)

ASTM A 392 (2007) Standard Specification for Zinc-Coated Steel Chain-Link Fence Fabric

ASTM A 824 (2001; R 2007) Standard Specification for Metallic-Coated Steel Marcelled Tension Wire for Use With Chain Link Fence

ASTM C 94/C 94M (2009) Standard Specification for Ready-Mixed Concrete

ASTM F 1083 (2008) Standard Specification for Pipe, Steel, Hot-Dipped Zinc Coated (Galvanized) Welded, for Fence Structures

ASTM F 1184 (2005) Industrial and Commercial Horizontal Slide Gates

ASTM F 883 (2004) Padlocks

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office

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

SD-01 Preconstruction Submittals

Fabrication Shop Storage Plan; G RE

A plan describing in detail the proposed layout of mill steel and fabricated items at the Contractor's plant, for which partial payments are requested, shall be submitted for approval. The plan shall be submitted within 15 calendar days after Notice to Proceed.

Site Preparation Work Plan; G RE

A plan describing in detail the proposed work during site preparation activities at the storage yard shall be submitted for approval. The plan shall be submitted at least 60 calendar days prior to the proposed start of site preparation work. No site preparation work shall be started prior to approval of the work plan.

Storage Yard Plan; G RE

A plan describing in detail the proposed layout of delivered fabricated items at the storage yard shall be submitted for approval. The plan shall be submitted at least 60 calendar days prior to the proposed delivery of any item.

Delivery Work Plan; G RE

A plan describing in detail the proposed delivery methods of the fabrications shall be submitted for approval. The plan shall be submitted at least 60 calendar days prior to the proposed delivery of any item.

1.4 INSPECTIONS AND ACCEPTANCE OF WORK

1.4.1 General

Not withstanding other provisions of this contract, all materials and work to be performed under this contract shall be inspected and accepted by the Contracting Officer or his authorized representative(s). The Contracting Officer or his authorized representative shall be the individual(s) solely authorized to reject materials, disapprove or approve any work in progress, or order or direct any revision or change to the plans and specifications as presently shown and stated.

1.4.2 Access to Work

The Contractor shall provide safe access to the fabrication facility and any other areas where work on this contract is performed to permit inspection by the Government.

1.5 FABRICATION SHOP STORAGE

Mill steel, fabricated items, and appurtenances shall be stored in a manner to prevent permanent deflection, distortion, or other damage. Rubber seals shall be stored in as cool a place as practicable, preferably at 70 degrees F or less; and in no case shall the rubber be stored in the open or exposed

SECTION 01 00 00 Page 3 to the direct rays of the sun. Other storage requirements are stated in Sections 35 20 15 CULVERT BULKHEADS, 35 20 16.33 MITER GATES, 35 20 17 CULVERT VALVES, and 35 20 28 MITER GATE ANCHORAGE LOAD MEASUREMENT

INSTRUMENTATION.

The Contractor is required to submit a fabrication shop storage plan for approval by the Contracting Officer. The plan shall include a layout of the proposed locations of all items stored at the fabrication shop, for which partial payments are requested.

1.6 STORAGE YARD

The storage site is located at the TVA Muscle Shoals Reservation in Alabama. Site operations at this storage yard will impact or be impacted by other organizations. The Contractor is responsible for coordinating with others in scheduling activities in order to minimize or eliminate conflicts. The point of contact for TVA is Wesley Jaynes Phone:

256-386-3752. Photographs of the storage yard are provided at the back of Section 01 00 50 FORMS AND ATTACHMENTS.

1.6.1 Site Access to Storage Yard

The Contractor is advised that access restrictions will apply to both land and water based activities in the storage yard area. These restrictions are defined in the following paragraphs.

1.6.1.1 Marine Access

This site is accessible by water upstream of Wilson Dam, as shown in the contract drawings. The use or construction of other marine access locations near the storage yard area require the necessary environmental clearances and must be approved by TVA and the Contracting Officer. It is likely that permission to use an alternate marine access location will depend, at least partially, on an environmental assessment as described in Section 01 57 20 ENVIRONMENTAL PROTECTION of these Specifications.

1.6.1.2 Land Access

Land access to the TVA storage yard is accessible off Highway 133 as shown on the contract drawings. Use of any TVA lands outside the designated area requires approval from the Contracting Officer and TVA. In addition, the Contractor shall adhere to all load restrictions and speed limits on public roads when hauling material to the storage yard.

1.6.2 Site Preparation

The Contractor is required to complete preparation of the storage yard, as specified herein and as shown in the Contract Drawings, within 6 months after Notice to Proceed.

The site is generally flat and has crushed stone over much of the 1.6 acres area. There are approximately 800 linear feet of fence to be removed and approximately 1,100 linear feet of fence to be constructed. The new fence will be a 7-ft height chain-linked fence and will follow the general alignment of the existing fence, however some sections are not currently fenced. Two 30 ft roller gates (each with two 15 ft sections) shall be constructed at the locations recommended by the Contractor. A padlock shall be provided for each gate. The site shall be graded for uniformity and a stone base (6 inch thick minimum) shall be spread and compacted over

SECTION 01 00 00 Page 4 the entire area. An existing drainage ditch shall be graded as necessary to maintain adequate drainage and keep water from standing. The compacted stone base shall be adequate to transport and store steel components weighing as much as 75 tons.

Demolish and dispose of existing concrete/stone ramps (approximately 40 ft.

x 50 ft.) in approved landfill. Demolish and dispose of approximately 7 concrete foundation pads (1 @ 12 ft. x 12 ft. and 6 @ 4 ft. x 18 ft.).

Dispose of 6 steel stop logs, steel rack and any other miscellaneous material to clear the site.

The Contractor is required to submit a site preparation work plan for approval by the Contracting Officer.

1.6.3 Storage Requirements

Miter gates, culvert valves, culvert valve bulkheads and bridges will be stored outdoors at the site. Fabricated components will be constructed, painted and stored on lagging which will support them in a safe and transportable manner for up to 5 years. A corridor from gate to gate shall be left open such that components and appurtenances may be stored for easy removal. It is likely that steel embedments and gate sections will be removed first, but all components should be accessible without the need to rearrange them. Adequate turning radius and distance should be preserved to access the components fabricated under this contract in addition to two fixed span bridges constructed under a separate contract. The bridges will be approximately 15 ft. x 113 ft. and 16 ft. x 30 ft and will likely be delivered before the miter gates, culvert valves and culvert bulkheads.

The rubber seals shall be stored indoors at the nearby Corps of Engineers' Tennessee River Operations Center. It shall be stored on lagging to support the seals and avoid deformation for up to 5 years. The Point of Contact for access and storage of the seals is Gerald Choat Phone: 615-847-5535.

The Contractor is required to submit a storage yard plan for approval by the Contracting Officer. The plan shall include a layout that shows the proposed locations of all items to be delivered to the storage yard, including the two steel bridges that are being fabricated under a separate contract.

1.6.4 Maintenance of Storage Yard

The Contractor is responsible for maintaining the storage yard.

Maintenance of the storage yard includes:

a. Control of vegetation.

b. Restoring low areas of stone base to original grade.

c. Rearranging stored fabrications, as necesary, to maintain proper storage.

The Contractor shall maintain the storage yard throughout the contract period until deilivery and acceptance of all components.

1.7 DELIVERY OF FABRICATIONS

The contractor is required to submit a delivery work plan for approval by

SECTION 01 00 00 Page 5 the Contracting Officer. The plan shall describe in detail the proposed methods of delivery of the fabricated items. The plan shall address equipment, machinery and site limitations identified in the specifications and discussed at a pre-delivery meeting between the Contractor and the Contracting Officer. The plan shall be submitted at least 60 calendar days prior to proposed delivery of any item. The plan shall include, but not be limited to the following:

a. Type and size of barge(s) to be used for delivery.

b. Propelling unit to be used for delivery.

c. Location and description of intermediate assembly or handling areas (if any) between the fabrication location and the delivery location.

d. Cranes and other lifting and positioning equipment to be used.

e. Packaging of components.

f. Blocking.

g. Pre-assembly after delivery.

1.8 ACCIDENT PREVENTION

Accident prevention requirements that are applicable to this project during site operations are stated in Section 01 35 26 GOVERNMENTAL SAFETY REQUIREMENTS. Site operations include TVA storage yard preparation, delivery and unloading to the TVA storage yard and any required pre-assembly at the delivery location.

PART 2 PRODUCTS

2.1 FENCE AND GATE MATERIALS

2.1.1 Fence Fabric

Fence fabric for the 7-foot-high fence shall conform to ASTM A 392, Class 1, zinc-coated steel wire with minimum coating weight of 1.2 ounces of zinc per square foot of coated surface. Fabric shall be fabricated of 9 gauge wire woven in 2 inch mesh. Fabric shall be twisted and barbed on the top selvage and knuckled on the bottom selvage.

2.1.2 Gates

ASTM F 1184. Gate shall be the Type II, Class 1. Gate frames shall conform to strength and coating requirements of ASTM F 1083 for Group IA, steel pipe, with external coating Type A, nominal pipe size (NPS) 1-1/2.

Gate fabric shall be as specified for chain link fabric. Gate leaves shall have either intermediate members and diagonal truss rods or shall have tubular members as necessary to provide rigid construction, free from sag or twist. Gate fabric shall be attached to the gate frame by method standard with the manufacturer except that welding will not be permitted.

Latches, hinges, stops, keepers, rollers, and other hardware items shall be furnished as required for the operation of the gate. Latches shall be arranged for padlocking so that the padlock will be accessible from both sides of the gate. Stops shall be provided for holding the gates in the open position.

SECTION 01 00 00 Page 6

2.1.3 Posts

ASTM F 1083, zinc-coated. Group IA, with external coating Type A steel pipe. Line posts and terminal (corner, gate, and pull) posts selected shall be of the same designation throughout the fence. Gate post shall be for the gate type specified subject to the limitation specified in

ASTM F 1184.

2.1.4 Braces and Rails

ASTM F 1083, zinc-coated, Group IA, steel pipe, size NPS 1-1/4.

2.1.5 Tension Wire

Tension wire shall be Type I or Type II, Class 2 coating, in accordance with ASTM A 824.

2.1.6 Concrete

ASTM C 94/C 94M, using 3/4 inch maximum size aggregate, and having minimum compressive strength of 3000 psi at 28 days. Grout shall consist of one part portland cement to three parts clean, well-graded sand and the minimum amount of water to produce a workable mix.

2.1.7 Padlocks

Padlocks shall conform to ASTM F 883, Type, Size 1-3/4 inch.

2.2 STONE BASE

Stone base shall be Dense Graded Aggregate (DGA) conforming to the general requirements of ALDOT Std Specs Section 801 COARSE AGGREGATE.

PART 3 EXECUTION (Not Used)

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SECTION 01 00 00 Page 7

SECTION TABLE OF CONTENTS

DIVISION 09 - FINISHES

SECTION 09 97 02

PAINTING: HYDRAULIC STRUCTURES

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Surface Preparation Procedures

1.2.1.1 Hoses And Nozzles

1.2.1.2 Workers Other Than Blasters

1.2.2 Paint Application

1.2.2.1 Explosion Proof Equipment

1.2.2.2 Further Precautions

1.2.2.3 Ignition Sources

1.2.3 Cleaning

1.2.4 Environmental Protection

1.2.5 Waste Classification, Handling, and Disposal

1.2.6 Visible Emissions Monitoring

1.2.7 Air Quality Monitoring

1.2.7.1 PM-10 Monitoring

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Certified Professional

1.4.2 Qualified Painting Contractor

1.4.3 Coating Thickness Gage Qualification

1.4.4 Safety and Health Provisions

1.4.5 Medical Status

1.4.6 Change in Medical Status

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 ENVIRONMENTAL REQUIREMENTS

PART 2 PRODUCTS

2.1 SPECIAL PAINT FORMULAS

2.2 PAINT FORMULATIONS

2.2.1 Formula V-766e

2.2.2 Formula VZ-108d

2.2.3 Formula P-38, Aluminum Phenolic Finish Coat

2.2.3.1 Quantitative Requirements

2.2.3.2 Water Resistance

2.3 INGREDIENTS FOR SPECIAL PAINT FORMULAS

2.3.1 Pigments and Suspending Agents

2.3.1.1 Carbon Black

2.3.1.2 Zinc Dust

2.3.1.3 Iron Oxide

2.3.1.4 Titanium Dioxide

2.3.1.5 Suspending Agent E

2.3.1.6 Suspending Agent F

2.3.2 Resins, Plasticizer, and Catalyst

SECTION 09 97 02 Page 1

2.3.2.1 Diisodecyl Phthalate

2.3.2.2 Vinyl Resin, Type 3

2.3.2.3 Vinyl Resin, Type 4

2.3.2.4 Ortho-phosphoric Acid

2.3.3 Solvent and Thinners

2.3.3.1 Methanol

2.3.3.1 Methyl Ethyl Ketone

2.3.3.2 Methyl Isobutyl Ketone

2.3.3.3 Methyl Isoamyl Ketone

2.3.3.4 Toluene

2.3.4 Silane B

2.4 TESTING

2.4.1 Chromatographic Analysis

2.4.2 Vinyl Paints

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

3.1.2 Ferrous Surfaces Subject to Atmospheric Exposures

3.1.3 Ferrous Surfaces Subject to Severe Exposure

3.1.4 Damp and Wet Ferrous Metal Surfaces

3.2 PAINT APPLICATION

3.2.1 General

3.2.2 Mixing and Thinning

3.2.3 Time Between Surface Preparation and Painting

3.2.4 Method of Paint Application

3.2.5 Coverage and Film Thickness

3.2.5.1 Measurement on Ferrous Metal

3.2.6 Progress of Painting Work

3.2.7 Contacting Surfaces

3.2.8 Drying Time Prior to Immersion

3.2.9 Protection of Painted Surfaces

3.2.10 Vinyl Paints

3.2.10.1 General

3.2.10.2 Vinyl Zinc-Rich Primer

3.2.10.3 Vinyl Paints

3.3 PAINT SYSTEMS APPLICATION

3.3.1 Fabricated and Assembled Items

3.3.2 Surface Preparation

3.3.3 System No. 2

3.3.4 System No. 5-E-Z

3.3.5 Protection of Nonpainted Items and Cleanup

3.4 INSPECTION

3.5 PAINTING SCHEDULES

-- 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.

AMERICAN SOCIETY OF SAFETY ENGINEERS (ASSE/SAFE)

ASSE/SAFE Z87.1 (2003) Standard for Occupational and Educational Eye and Face Protection

ASTM INTERNATIONAL (ASTM)

ASTM D 1045 (2008) Sampling and Testing Plasticizers Used in Plastics

ASTM D 1152 (2006) Methanol (Methyl Alcohol)

ASTM D 1153 (2006) Methyl Isobutyl Ketone

ASTM D 1200 (1994; R 2005) Viscosity by Ford Viscosity Cup

ASTM D 1210 (2005) Fineness of Dispersion of Pigment-Vehicle Systems by Hegman-Type Gage

ASTM D 1308 (2002; R 2007) Effect of Household Chemicals on Clear and Pigmented Organic Finishes

ASTM D 1475 (1998; R 2008) Standard Test Method for Density of Liquid Coatings, Inks, and Related Products

ASTM D 153 (1984; R 2008) Specific Gravity of Pigments

ASTM D 1640 (2003) Drying, Curing, or Film Formation of Organic Coatings at Room Temperature

ASTM D 2369 (2007) Volatile Content of Coatings

ASTM D 281 (1995; R 2007) Oil Absorption of Pigments by Spatula Rub-Out

ASTM D 2917 (2007) Methyl Isoamyl Ketone

ASTM D 3721 (2005) Synthetic Red Iron Oxide Pigment

ASTM D 4206 (1996; R 2007) Sustained Burning of Liquid

SECTION 09 97 02 Page 3

Mixtures Using the Small Scale Open-Cup Apparatus

ASTM D 4417 (2003) Field Measurement of Surface Profile of Blast Cleaned Steel

ASTM D 520 (2000; R 2005) Zinc Dust Pigment

ASTM D 561 (1982; R 2008) Carbon Black Pigment for Paint

ASTM D 7091 (2005) 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 D 740 (2005) Methyl Ethyl Ketone

ASTM D 841 (2002e1; R 2008) Nitration Grade Toluene

ASTM D 962 (1981; R 2008e1) Aluminum Powder and Paste Pigments for Paints

ASTM E 1347 (2006) Color and Color Difference Measurement by Tristimulus (Filter) Colorimetry

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2007; AMD 1 2008) National Electrical Code - 2008 Edition

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH (NIOSH)

NIOSH 98-119 (1998; 4th Ed) Supplement 2 to NIOSH Manual of Analytical Methods

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC Paint 25 (1997; E 2004) Paint Specification No.

25Zinc Oxide, Alkyd, Linseed Oil Primer for Use Over Hand Cleaned Steel Type I and Type II

SSPC QP 1 (1998; E 2004) Standard Procedure for Evaluating Painting Contractors (Field Application to Complex Industrial Structures)

SSPC SP 1 (1982; E 2004) Solvent Cleaning

SSPC SP 5 (2007) White Metal Blast Cleaning

SSPC SP 6 (2007) Commercial Blast Cleaning

SECTION 09 97 02 Page 4

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2008) Safety and Health Requirements Manual

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FED-STD-595 (Rev B; Am 1) Colors Used in Government Procurement

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

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1910.134 Respiratory Protection

29 CFR 1910.146 Permit-required Confined Spaces

29 CFR 1910.20 Access to Employee Exposure and Medical Records

29 CFR 1910.94 Ventilation

29 CFR 1926 Safety and Health Regulations for Construction

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

1.2 SYSTEM DESCRIPTION

Allow at least 30 days for sampling and testing. Sampling may be at the jobsite or source of supply. Notify the Contracting Officer when the paint and thinner are available for sampling. Sampling of each batch will be witnessed by the Contracting Officer unless otherwise specified or directed. Submit a 1-quart sample of paint and thinner for each batch proposed for use. The sample shall be labeled to indicate formula or specification number and nomenclature, batch number, batch quantity, color, date made, and applicable project contract number. Testing will be performed by the Government. Costs for retesting rejected material will be deducted from payments to the Contractor at the rate of 300 dollars for each paint sample retested and 200 dollars for each thinner retested.

1.2.1 Surface Preparation Procedures

For abrasive blasting comply with the requirements in Section 06.H of

EM 385-1-1.

1.2.1.1 Hoses And Nozzles

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. Hose

SECTION 09 97 02 Page 5 lengths shall be joined together by approved couplings of a material and type designed to prevent erosion and weakening of the couplings. The couplings and nozzle attachments shall fit on the outside of the hose and 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, by utilizing MSHA/NIOSH-approved half-face or full-face air purifying respirators equipped with high-efficiency particulate air (HEPA) filters, eye protection meeting or exceeding ASSE/SAFE Z87.1 and 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. Personal protective equipment shall be provided where required by 29 CFR 1910.146 and in accordance with 29 CFR 1910, Subpart I.

1.2.2 Paint Application

1.2.2.1 Explosion Proof Equipment

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

Electric motors used to drive exhaust fans shall not be placed inside spraying areas or ducts. Fan blades and portable air ducts shall be constructed of nonferrous materials. Motors and associated control equipment shall be properly maintained and grounded. The metallic parts of air-moving devices, spray guns, connecting tubing, and duct work shall be electrically bonded and the bonded assembly shall be grounded.

1.2.2.2 Further Precautions

a. Workers shall wear nonsparking safety shoes.

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

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

1.2.2.3 Ignition Sources

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

1.2.3 Cleaning

Cleaning with compressed air shall be in accordance with Section 20.B.5 of EM 385-1-1 and personnel shall be protected as specified in 29 CFR 1910.134.

SECTION 09 97 02 Page 6

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 shall be in accordance with 29 CFR 1910.94, paragraph (c)(5).

1.2.4 Environmental Protection

In addition to the requirements of Section 01 57 20 ENVIRONMENTAL PROTECTION comply with the following environmental protection criteria.

1.2.5 Waste Classification, Handling, and Disposal

The Contractor is responsible for assuring the proper disposal of all hazardous and nonhazardous waste generated during the project. Store nonhazardous waste in closed containers separate from hazardous waste storage areas. All nonhazardous waste shall be transported in accordance with local regulations regarding waste transportation.

1.2.6 Visible Emissions Monitoring

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. In no case shall visible emissions extend greater than 150 feet in any direction horizontal from the containment. In no case shall visible emissions be observed in the area of any sensitive receptor. If such emissions occur the job shall be shut down immediately and corrective action taken. Notify the foreman whenever visible emissions exceed 40 seconds in a 1 hour period. The foreman shall be notified and the job shall be shut down and corrective action taken whenever visible emissions exceed 75 seconds in a 2 hour period. Total observed visible emissions from the containment shall not exceed 5 percent of the work day. Shutdown and corrective action shall be taken to prevent such an occurrence. Document each time that the work is halted due to a violation of the visible emissions criteria.

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

1.2.7 Air Quality Monitoring

1.2.7.1 PM-10 Monitoring

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

Failure to meet air quality regulatory limits shall require air monitoring to be repeated immediately after corrective actions have been taken. Also conduct preproject PM-10 monitoring. The preproject PM-10 monitoring shall be conducted a minimum of 2 weeks prior to the beginning of the project.

The monitoring shall continue for a minimum of 3 days to establish background levels. A report of the results shall be submitted to the Contracting Officer within 48 hours and shall include:

SECTION 09 97 02 Page 7

a. Name and location of jobsite.

b. Date of monitoring.

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

d. Identification and serial number of monitoring units.

e. Drawing showing specific location of monitoring units.

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

g. Wind direction and velocity.

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

i. Name and address of laboratory.

j. Laboratory test procedure.

k. Laboratory test results.

l. Signatures of 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 information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Safety and Health Provisions; G

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; each topic shall be developed in a concise manner to include management and operational aspects.

Respirators; G

A comprehensive written respiratory protection program in accordance with 29 CFR 1910.134, 29 CFR 1926.62, and Section 05.E of EM 385-1-1.

Certified Laboratory; G

An Airborne Sampling Plan detailing the NIOSH 98-119, 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), to be used

SECTION 09 97 02 Page 8 to conduct the analysis of any collected air samples.

Medical Status; G

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 shall include the date of the medical evaluation, the physician's name, signature, and telephone number.

Visible Emissions Monitoring; G

A Visible Emissions Monitoring Plan. The plan shall include the provisions for halting work and correcting the containment in the event unacceptable emissions are observed. General statements shall not be used; specific methods, procedures, and details are required.

PM-10 Monitoring; G

A plan for monitoring emissions of particulate matter 10 microns or less in size (PM-10). The plan shall comply with the requirements of EPA regulation 40 CFR 50.6 and paragraph PM-10 Monitoring. The plan shall also include provisions for halting work and correcting the containment in the event unacceptable emissions occur.

SD-04 Samples

Special Paint Formulas; G Paint Formulations; G

Samples of all special paint formula, Military, Master Painter Institute, Commercial Item Description, and SSPC paints. For products that are specified to be applied in accordance with the manufacturer's recommendations also submit the paint producers product data sheet or other written instructions for those products.

Solvent and Thinners; G

Samples of the thinners or solvents used to reduce the viscosity of the paint.

SD-06 Test Reports

PM-10 Monitoring; G

Reports of the PM-10 monitoring tests.

Certified Laboratory; G

Reports of airborne sampling tests.

Inspection; G

Records of inspections and operations performed. Submittals shall be made on a daily basis.

SECTION 09 97 02 Page 9

SD-07 Certificates

Qualifications; G

Certification for all job sites. Submittal of the qualifications and experience of any additional qualified and competent persons employed to provide onsite environmental, safety, and health shall also be provided. Obtain acceptance of this submission prior to the submission of other required environmental, safety, and health submittal items.

Qualified Painting Contractor; G

A copy of their current SSPC QP 1 certification.

Coating Thickness Gage Qualification; G

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

1.4 QUALITY ASSURANCE

Qualifications and experience shall comply with the following.

1.4.1 Certified Professional

Utilize a qualified and competent person as defined in Section 01 of EM 385-1-1 to develop the required safety and health submittal and to provide onsite safety and health services during the contract period. The person shall 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. Certify that the Certified Industrial Hygienist (CIH) holds current and valid certification from the American Board of Industrial Hygiene (ABIH), that the IH is considered board eligible by written confirmation from the ABIH, or that the CSP holds current and valid certification from the American Board of Certified Safety Professionals. 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 shall have successfully completed an EPA or state accredited lead-based paint abatement Supervisor course specific to the work to be performed and shall possess current and valid state and/or local government certification, as required.

1.4.2 Qualified Painting Contractor

Provide a Contractor certified SSPC-QP 1 Painting Contractor.

1.4.3 Coating Thickness Gage Qualification

Submit documentation of certification for all coating thickness gages.

Magnetic flux thickness gages as described in ASTM D 7091 shall be used to make all coating thickness measurements on ferrous metal substrates. .

Gages shall have an accuracy of +/- 3 percent or better. Gages to be used on the job shall be certified by the manufacturer as meeting these

SECTION 09 97 02 Page 10 requirements.

1.4.4 Safety and Health Provisions

Perform work in accordance with the requirements of 29 CFR 1910, 29 CFR 1926, EM 385-1-1, and other references as listed herein. Submit matters of interpretation of the standards to the Contracting Officer for resolution before starting work. Where the regulations conflict, the most stringent requirements shall apply. This paragraph supplements the requirements of EM 385-1-1, paragraph (1). In any conflict between Section 01 of EM 385-1-1 and this paragraph, the provisions herein shall govern.

1.4.5 Medical Status

Prior to the start of work and annually thereafter, 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. Maintain medical records as required by 29 CFR 1910.20. The evaluation shall include:

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

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

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

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

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

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

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

1.4.6 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

SECTION 09 97 02 Page 11 around paint systems and thinners, blast media, or other chemicals shall 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. Notify the Contracting Officer in writing of any negative changes in employee medical status and the results of the physicians reevaluation statement.

1.5 DELIVERY, STORAGE, AND HANDLING

Process and package paints to ensure that within a period of one year from date of manufacture, they will not gel, liver, or thicken deleteriously, or form gas in the closed container. Paints, unless otherwise specified or permitted, shall be packaged in standard containers not larger than 5 gallons, with removable friction or lug-type covers. Containers for vinyl-type paints shall be lined with a coating resistant to solvents in the formulations and capable of effectively isolating the paint from contact with the metal container. Each container of paint or separately packaged component thereof shall be labeled to indicate the purchaser's order number, date of manufacture, manufacturer's batch number, quantity, color, component identification and designated name, and formula or specification number of the paint together with special labeling instructions, when specified. Paint shall be delivered to the job in unbroken containers. Paints that can be harmed by exposure to cold weather shall be stored in ventilated, heated shelters. All paints shall be stored under cover from the elements and in locations free from sparks and flames.

1.6 ENVIRONMENTAL REQUIREMENTS

Paint shall be applied only to surfaces that are above the dew point temperature and that are completely free of moisture as determined by sight and touch. Paint shall not be applied to surfaces upon which there is detectable frost or ice. Except as otherwise specified, the temperature of the surfaces to be painted and of air in contact therewith shall be not less than 45 degrees F during paint application nor shall paint be applied if the surfaces can be expected to drop to 32 degrees F or lower before the film has dried to a reasonably firm condition. During periods of inclement weather, painting may be continued by enclosing the surfaces and applying artificial heat, provided the minimum temperatures and surface dryness requirements prescribed previously are maintained. Paint shall not be applied to surfaces heated by direct sunlight or other sources to temperatures that will cause detrimental blistering, pinholing, or porosity of the film.

PART 2 PRODUCTS

2.1 SPECIAL PAINT FORMULAS

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

2.2 PAINT FORMULATIONS

Special paint formulas shall comply with the following:

SECTION 09 97 02 Page 12

2.2.1 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 Diisodecyl Phthalate 2.9 Methyl Isobutyl Ketone 32.0 Toluene 34.7 Ortho-Phosphoric Acid 0.2 100.0

a. The dispersion of pigment shall be accomplished by means of pebble mills or other approved methods to produce a fineness of grind ( ASTM D 1210) of not less than 7 on the Hegman scale. Grinding in steel-lined or steel-ball mills will not be permitted. No grinding aids, antisettling agents, or any other materials except those shown in the formula will be permitted. The paint shall show the proper proportions of specified materials when analyzed by chromatographic and/or spectrophotometric methods. The ortho-phosphoric acid shall be measured accurately and diluted with at least four parts of ketone to one part of acid and it shall be slowly incorporated into the finished paint with constant and thorough agitation.

b. The viscosity of the paint shall be between 60 and 90 seconds using ASTM D 1200 and a No. 4 Ford cup.

c. The white and gray paints shall be furnished in the volume ratio designated by the purchaser. The gray paint shall contain no pigments other than those specified. Enough carbon black shall be included to produce a dry paint film having a reflectance of 20-24 (ASTM E 1347).

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

2.2.2 Formula VZ-108d

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

INGREDIENTS PERCENT BY WEIGHT POUNDS GALLONS

COMPONENT A

Vinyl Resin, Type 3 16.6 109.2 9.65 Methyl Isobutyl Ketone 80.6 528.9 79.30 Suspending Agent E 0.7 4.6 0.28 Suspending Agent F 0.4 2.7 0.19 Methanol 0.5 3.3 0.50 Synthetic Iron Oxide (Red) 1.2 7.9 0.19

100.0 656.6 90.11

COMPONENT B

SECTION 09 97 02 Page 13

INGREDIENTS PERCENT BY WEIGHT POUNDS GALLONS

Silane B 100.0 4.1 0.47

COMPONENT C

Zinc Dust 100.0 550.0 9.42 100.00 (mixed paint)

a. The iron oxide and suspending agents shall be dispersed into the vehicle (Component A) to a fineness of grind of not less than 4 on the Hegman scale (ASTM D 1210). Grinding in steel-lined containers or using steel-grinding media shall not be permitted. The sole purpose of the iron oxide pigment is to produce a contrasting color. A red iron oxide-type 3 vinyl resin vehicle paste may be used in place of dry iron oxide provided compensating adjustment are made in the additions of Type 3 resin and methyl isobutyl ketone. The finished product with zinc dust added shall produce a paint which has a red tone upon drying and a reflectance of not more than 16 (ASTM E 1347).

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

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

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

2.2.3 Formula P-38, Aluminum Phenolic Finish Coat

This material shall be a ready-mixed aluminum paint. The pigment shall be leafing aluminum powder or paste conforming to the requirements of ASTM D 962 Types I or II, Class B, Medium. The vehicle shall be a phenolic resin varnish of 33-gallon oil length. The resin portion of the vehicle shall be a dry granular phenol-formaldehyde resin made from aliphatic

SECTION 09 97 02 Page 14 para-substituted phenols with substituting groups containing four to eight carbon atoms. The oil portion of the vehicle shall consist of not less than 80% tung oil and the remainder shall be alkali refined linseed oil.

The vehicle shall not contain rosin derivatives. Paint solvents shall consist of aliphatic and aromatic hydrocarbons as necessary. The paint shall meet the requirements of paragraphs Quantitative Requirements and Water Resistance.

2.2.3.1 Quantitative Requirements

The paint shall have the following properties.

Characteristics Requirement (minimum/maximum)

Pigment, percent by weight of paint 13 / -- Volatile, percent by weight of paint, ASTM D 2369 -- / 45 Nonvolatile vehicle, percent by weight of paint 42 / -- Viscosity, seconds, ASTM D 1200 35 / 45 Flash point, Degrees F (C), ASTM D 4206 86 (30)/ -- Leafing, percent 50 / -- Density, pounds per gallon, ASTM D 1475 8 / -- Dry, set-to-touch, hours, ASTM D 1640 0.5 / 2 Dry, to recoat, hours, ASTM D 1640 -- / 16

2.2.3.2 Water Resistance

Prepare a test panel by spray applying two coats of paint to a 3 by 6 inch solvent cleaned matte-finish steel test plate. Each coat shall have a dry film thickness of approximately 2.0 mils. Allow 24 hours dry time between coats. Air dry the prepared panel 72 hours and immerse in distilled water at 73 +/- 2 degree F for 72 hours in accordance with ASTM D 1308. The test paint shall exhibit no wrinkling or blistering immediately upon removal of the panel from the water. The paint shall be no more than slightly affected when examined two hours after removal and after 24 hours shall show no more than a slight visible whitening or dulling in comparison to the unexposed film.

2.3 INGREDIENTS FOR SPECIAL PAINT FORMULAS

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

2.3.1 Pigments and Suspending Agents

2.3.1.1 Carbon Black

Carbon black shall conform to ASTM D 561, Type I or II.

2.3.1.2 Zinc Dust

Zinc dust pigment shall conform to ASTM D 520, Type II.

2.3.1.3 Iron Oxide

Iron oxide, (Dry) synthetic (red), shall conform to ASTM D 3721. In addition, the pigment shall have a maximum oil absorption of 24 and a specific gravity of 4.90 to 5.20 when tested in accordance with ASTM D 281 and ASTM D 153, Method A, respectively. When the pigment is dispersed into specified vinyl paint formulation, the paint shall have color approximating

SECTION 09 97 02 Page 15

FED-STD-595 color 10076 (dark red paint), and shall show no evidence of incompatibility or reaction between pigment and other components after 6 months storage.

2.3.1.4 Titanium Dioxide

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

2.3.1.5 Suspending Agent E

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

2.3.1.6 Suspending Agent F

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

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

2.3.2 Resins, Plasticizer, and Catalyst

2.3.2.1 Diisodecyl Phthalate

Diisodecyl Phthalate shall have a purity of not less than 99.0 percent, shall contain not more than 0.1 percent water, and shall have an acid number (ASTM D 1045) of not more than 0.10.

2.3.2.2 Vinyl Resin, Type 3

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

2.3.2.3 Vinyl Resin, Type 4

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

2.3.2.4 Ortho-phosphoric Acid

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

SECTION 09 97 02 Page 16

2.3.3 Solvent and Thinners

2.3.3.1 Methanol

Methanol (methyl alcohol) shall conform to ASTM D 1152.

2.3.3.1 Methyl Ethyl Ketone

Methyl ethyl ketone (MEK) shall conform to ASTM D 740.

2.3.3.2 Methyl Isobutyl Ketone

Methyl isobutyl ketone (MIBK) shall conform to ASTM D 1153.

2.3.3.3 Methyl Isoamyl Ketone

Methyl isoamyl ketone (MIAK) shall conform to ASTM D 2917.

2.3.3.4 Toluene

Toluene shall conform to ASTM D 841.

2.3.4 Silane B

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

2.4 TESTING

2.4.1 Chromatographic Analysis

Solvents in vinyl paints and thinners shall be subject to analysis by programmed temperature gas chromatographic methods and/or spectrophotometric methods, employing the same techniques that give reproducible results on prepared control…