09 97 02 spec.pdf

SECTION 09 97 02

PAINTING: HYDRAULIC STRUCTURES

02/20

PART 1 GENERAL

1.1 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

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

ASTM D4263 (1983; R 2018) Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method

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

ASTM D7091 (2013) Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nondestructive Coatings Applied to Non-Ferrous Metals

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

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

SSPC Paint 38 (2006) Single-Component Moisture-Cure Weatherable Aliphatic Polyurethane Topcoat, Performance-Based

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

SSPC Paint 41 (2008) Moisture-Cured Polyurethane Primer or Intermediate Coat, Micaceous Iron Oxide Reinforced, Performance-Based

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

SSPC SP 1 (2015) Solvent Cleaning

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

1.2 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

Manufacturer's MSDS Product Data Sheet; G

SD-07 Certificates

SSPC QP-3 or AISC Complex Coatings Endorsement Certificate; G

Coating Thickness Gage Qualification

Qualified Coating Applicator; G

1.3 QUALIFICATIONS

Qualifications and experience must comply with the following.

1.3.1 Qualified Shop Painting Contractor

The Painting Contractor must be a certified SSPC QP 3 or AISC Complex Coatings Endorsement (CCE) Painting Contractor for all off-site surface preparation or coating application. Submit a copy of the applicable SSPC or AISC CCE Certificates. The contractor must have been certified prior to award of this contract and must remain certified for the duration of this contract. Submit all renewals if they occur during the contract performance period. Renewals must be achieved prior expirations occurring.

1.3.2 Qualified Coating Applicator

Submit records of qualification tests for each Qualified Coating Applicator.

Prior to the initiation of any work all coating applicators must be tested and certified as meeting the requirements of ASTM D4228. Certification must be administered by an authorized government representative.

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

1.3.2.1 Certification Test Procedure

Conduct certification testing of coating applicators at the job site in coordination with the Contracting Officer. Supply the fabricated test plates to be used for the tests and provide crane service, rigging, and any other work necessary to provide accessibility for the certification testing and inspection. The test plate must be painted in a near vertical position. In preparation, clean and prepare the test plate in accordance with the requirements of the contracted work. Perform abrasive blasting with the blast media to be used in the contract. The paints to be applied are Contractor supplied materials and are those previously tested and approved for use on the contract. Paints must be applied as specified in this contract. The painter being tested must mix and thin the paints to be used in the test and set up and adjust the application equipment for use.

Each painter must apply each of the types of paint comprising the specified system. The contractor's QC inspector must be present during the procedure to monitor the actions of the painter being tested.

1.3.2.2 Certification Criteria

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

1.3.3 Coating Thickness Gage Qualification

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

1.3.4 Certified Coating Inspector

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

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

Renewals must be achieved prior expirations occurring.

1.4 DELIVERY, STORAGE, AND HANDLING

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

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

1.5 AMBIENT CONDITIONS

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

PART 2 PRODUCTS

Submit Manufacturer's MSDS Product Data Sheet for each type of paint used;

for products that are specified to be applied in accordance with the manufacturer's recommendations, submit the paint manufacturer's product data sheet or other written instructions for those products. Costs for retesting rejected material will be deducted from payments to the Contractor .

PART 3 EXECUTION

3.1 CLEANING AND PREPARATION OF SURFACES TO BE PAINTED

3.1.1 General Requirements

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

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

Restore any paint damaged by welding operations to original condition.

Surfaces to be painted that will be inaccessible after construction, erection, or installation operations are completed must be painted before they become inaccessible.

3.1.2 Ferrous Surfaces Subject to Severe Exposure

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

The blast profile must be angular with a minimum profile height of 1.5 mils.

Select appropriate abrasive size and equipment operating parameters to limit maximum surface profile on new steel to 2.5 mils and to prevent increasing existing profile height on previously blasted steel. Where an existing profile is encountered, remove representative spots of existing coating with a chemical stripper and measure and document the existing profile prior to initiating blasting operations. Measure all surface profiles in accordance with ASTM D4417, Method C. Steel shot or other abrasives that do not produce an angular profile shall not be used. If recycled blast media is used, maintain an appropriate particle size distribution so that the specified profile is consistently obtained. Round all sharp edges including those caused by corrosion, to a nominal 1/16 inch radius and reblast the areas prior to painting. Remove weld spatter not dislodged by blasting with impact or grinding tools and reblast the areas prior to painting. Surfaces must be dry at the time of blasting. Conduct blast cleaning to SSPC SP 5/NACE No. 1 in the field and, unless otherwise specifically authorized, after final erection. Within 8 hours after blast cleaning, and in any case prior to the deposition of any detectable moisture, contaminants, or corrosion, clean all ferrous surfaces of dust and abrasive particles by brush, vacuum cleaner, and/or blown down with clean, dry, compressed air, and apply the first coat of paint.

Authorization to extend this 8 hour coating requirement for shop application, application within dehumidified containment, or other conditions will not be granted. Upon written request by the Contractor, the Contracting Officer may authorize mill or shop cleaning of assembled or partially assembled components specified to receive one of the vinyl-type paint systems or Systems 6-A-Z and 21-A-Z employing the epoxy zinc-rich primer or Systems 23-A-Z and 23-B-Z employing SSPC Paint 40 moisture cure urethane zinc-rich primer. Shop coat all shop blasted surfaces with the first and second coats of the specified paint system. At the time field painting is initiated, apply an additional single spray coat of the zinc rich primer to the epoxy zinc-rich and moisture cure urethane primed surfaces as specified in the paint system instructions. Maintain the shop coating in good condition by cleaning and touching up of areas damaged during the construction period. If pinpoint or general rusting appears, the defective areas must be reblasted and repainted at no added cost to the Government. Prior to the field application of subsequent coats, thoroughly clean soiled areas of the shop coating and all welds or other unpainted or damaged areas must be cleaned and coat in a manner to make them equivalent to adjacent, undamaged paint surfaces.

3.2 PAINT APPLICATION

3.2.1 General

Unless otherwise specified, the finished coating shall be free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, and variations in color, texture, and gloss. Do not initiate the application of initial or subsequent coatings until the Contracting Officer has verified that atmospheric conditions and the surfaces to be coated are satisfactory. Each paint coat must be applied in a manner that will produce an even, continuous film of uniform thickness.

Provide special attention to edges, corners, crevices, seams, joints, welds, rivets, corrosion pits, and other surface irregularities to ensure that they receive an adequate thickness of paint. Spray equipment must be equipped with traps and separators and where appropriate, mechanical agitators, pressure gauges, pressure regulators, and screens or filters.

Air caps, nozzles, and needles must be as recommended by the spray equipment manufacturer for the material being applied. Airless-type spray equipment may be used only on broad, flat, or otherwise simply configured surfaces, except that it may be employed for general painting if the spray gun is equipped with dual or adjustable tips of proper types and orifice sizes. The use of airless-type equipment is not allowed for the application of vinyl paints.

3.2.2 Mixing and Thinning of Coatings other than the Vinyl Formulations

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

3.2.3 Time Between Surface Preparation and Painting

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

3.2.4 Method of Paint Application

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

3.2.5 Coverage and Film Thickness

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

3.2.6 Coating Thickness Measurement on Metal

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

3.2.7 Progress of Painting Work

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

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

3.2.8 Contacting Surfaces

When riveted or ordinary bolted contact is to exist between surfaces of ferrous or other metal parts of substantially similar chemical composition, such surfaces will not be required to be painted, but any resulting crevices must subsequently be filled or sealed with paint. Contacting metal surfaces formed by high-strength bolts in friction-type connections must not be painted. Where a nonmetal surface is to be in riveted or bolted contact with a metal surface, the contacting surfaces of the metal must be cleaned and given three coats of the specified primer. Unless otherwise specified, corrosion-resisting metal surfaces, including cladding therewith, must not be painted.

3.2.9 Protection of Painted Surfaces

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

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

3.3 PAINT SYSTEMS APPLICATION

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

3.3.1 Fabricated and Assembled Items

Items that have been fabricated and/or assembled into essentially their final form and that are customarily cleaned and painted in accordance with the manufacturer's standard practice will be exempted from equivalent surface preparation and painting requirements described herein, provided that:

a. Surfaces primed (only) in accordance with such standard practices are compatible with specified field-applied finish coats.

b. Surfaces that have been primed and finish painted in accordance with the manufacturer's standard practice are of acceptable color and are capable of being satisfactorily touched up in the field.

c. Items expressly designated herein to be cleaned and painted in a specified manner are not coated in accordance with the manufacturer's standard practice if different from that specified herein.

3.3.2 Surface Preparation

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

3.3.3 System No. 3-A-Z

Apply paint by spray to an average dry film thickness of a minimum of 6.5 mils for the completed system, and a thickness at any spot of not be less than 5.5 mils. The dry film thickness of the zinc-rich coat must be approximately 2.5 mils with no spot less than 2.0 mils. The thickness of the V-766E mid coat must be sufficient to completely hide the primer.

Specified film thickness, including the prescribed total, must be attained in any event, and any extra coats needed to attain specified thickness must be applied at no additional cost to the Government. Attaining of the specified film thickness in fewer than the prescribed number of coats or spray passes will be acceptable provided heavier applications do not cause pinholes, bubbles, blisters, or voids in the dried film. The application of more than 2.0 mils (dry film thickness) per double spray coat or more than 1.0 mil per single spray pass of nonzinc paint typically indicates the paint is not being applied wet enough to properly flow out and must be avoided.

3.4 INSPECTION

Surface preparation and painting inspections must be conducted by an inspector certified as meeting one of the following designations: SSPC-PCI Level 2, NACE-CIP Level 2. The inspector will inspect and document all work phases and operations on a daily basis and submit daily Inspection Reports. As a minimum the daily report must contain the following:

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

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

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

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

3.5 PAINTING SCHEDULES

SYSTEM NO. 3-A-Z

Items or surfaces to be coated:

All Steel, Excluding Fully Embedded Members

SURFACE

PREPARATION

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

White metal blast cleaning

Vinyl zinc-rich

VZ-108D

(double spray coat)

White Vinyl V-766E (double spray coat)

Aluminum Vinyl V-102E (double spray coat)

Aluminum Vinyl V-102E (double spray coat)

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