http://corpinfo.panynj.gov/documents/20049-O/http://corpinfo.panynj.gov/documents/20049-O/

316250 - 1

N 07/07/17

DIVISION 31

SECTION 316250

PROTECTIVE COATING FOR STEEL PILING

PART 1. GENERAL

1.01 SUMMARY

This Section specifies requirements for shop application of protective coating on steel piling.

1.02 REFERENCES

The following is a listing of the publications referenced in this Section:

American Society for Testing and Materials (ASTM) ASTM D 3359 Test Methods for Rating Adhesion by Tape Test. ASTM D 4414 Standard Practice for Measurement of Wet Film Thickness by Notch

Gages. ASTM D 4417 Test Methods for Field Measurement of Surface Profile of Blast

Cleaned Steel. ASTM D 4541 Test Method for Pull-Off Strength of Coatings Using Portable

Adhesion Testers. ASTM D 4285 Test Method for Indicating Oil or Water in Compressed Air.

American Welding Society (AWS) AWS D1.1 Structural Welding Code – Steel. AWS D1.5 Bridge Welding Code.

The Society for Protective Coatings (SSPC) SSPC-Paint 16 Coat Tar Epoxy-Polyamide Black (or Dark Red) Coating. SSPC-SP 1 Solvent Cleaning. SSPC-SP 2 Hand Tool Cleaning. SSPC-SP 3 Power Tool Cleaning. SSPC-SP 10 Near-White Blast Cleaning. SSPC-SP 11 Power Tool Cleaning to Bare Metal. SSPC-PA 1 Shop, Field, and Maintenance Painting of Steel. SSPC-PA 2 Procedure for Determining Conformance to Dry Coatings Thickness

Requirements. SSPC-VIS 1 Guide and Reference Photographs for Steel Surfaces Prepared by Dry

Abrasive Blast Cleaning. U.S. Army Corps of Engineers (USACE)

Paint Specification C-200A.

316250 - 2

1.03 QUALITY ASSURANCE

A. Coating System Compatibility The coating system, including all primers and undercoats, shall be produced by the manufacturer of the topcoat.

B. Coating of Steel Piling - Shop Requirements Arrange for shop coating of steel piling to be done by firms that are approved by the Engineer.

C. Quality Control (QC)

1. Verify that the entity performing coating of steel piling has a written Quality Control Program. The QC Program shall contain, but not be limited to, the following:

a. The qualifications of QC staff, including training records and experience.

b. The authority of QC staff and reporting lines in the firm's organization chart.

c. Standards and specifications used by QC staff for inspection purposes.

d. Inspection reports and other records documenting compliance with this Section and with the Engineer's requirements.

e. List of inspection equipment and calibration procedures used by QC staff.

f. Procedure for QC staff to advise the shop foreman, in writing, of non-conforming Work.

2. Contractor's Responsibility

a. The Contractor is responsible for Quality Control, which entails the daily inspection of all coating. All inspections shall be performed by the Contractor's QC staff. The Quality Control Program shall ensure that coating systems are applied according to the coating manufacturer's technical data sheets subject to approval by the Engineer for surface preparation, ambient conditions, application parameters, curing and film thickness.

b. The Engineer will perform Quality Assurance inspections to verify that the Contractor's Quality Control Program is being followed.

3. Schedule and Engineer Approval

a. Submit a schedule for surface preparation and painting at least 30 days prior to beginning coating Work.

b. At least 10 days prior to coating, notify the Engineer.

1.04 DELIVERY, STORAGE, AND HANDLING

Store materials not in actual use in tightly covered containers at a minimum ambient temperature of 45 deg F and a maximum ambient temperature of 90 deg F in a well-ventilated area. Maintain containers used in storage of coatings in a clean condition, free of foreign materials and residue.

316250 - 3

1.05 SUBMITTALS

See Appendix "A" for submittal requirements.

PART 2. PRODUCTS

2.01 ABRASIVES

A. Abrasives shall be dry and free of oil, grease, corrosion producing chemicals and other deleterious contaminants.

B. Abrasives shall be shaped and sized to produce a sharp, angular profile height of 2-3 mils, unless the requirements of the coating manufacturer are more restrictive. In this case comply with profile requirements specified by the coating manufacturer.

2.02 COATINGS

The coating system shall consist of two coats of coal tar epoxy meeting the requirements of SSPC-Paint 16 with Type 1 pitch (USACE Specification C-200A).

A. Coal Tar Epoxies

Subject to compliance with the requirements of this Section, furnish and install products of one of the following, or approved equal:

1. Bitumastic 300 M, manufactured by Carboline Co., St. Louis, MO.

2. TarGuard Coal Tar Epoxy, manufactured by Sherwin-Williams Co., Cleveland, OH.

3. Sigma C200a Coal Tar Epoxy, manufactured by Sigma Coatings, Harvey, LA.

B. Touch-up coatings for repair of coating defects and damage shall be as recommended by the coating manufacturer and approved by the Engineer.

PART 3. EXECUTION

3.01 SURFACE PREPARATION

A. Weld Spatter, Sharp Edges and Holes

1. Remove slag, flux deposits, weld spatter and surface irregularities such as slivers, tears, fins and hackles; follow AWS D1.1 or D1.5 as applicable. Grind any resulting burrs smooth, including burrs around holes. Do not remove any weld material that will weaken weld strength.

2. Prior to preparation, break sharp edges such as those created by flame cutting and shearing. Do not break rolled edges of angles, channels and wide flange beams without the Engineer's approval.

B. Compressed Air Cleanliness

1. Compressed air shall be free from moisture and oil contamination.

316250 - 4

2. Use the white blotter test in accordance with ASTM D 4285 to verify the cleanliness of the compressed air. Conduct the test at the start of each shift for each compressor system.

3. If testing indicates contamination, soiling or discoloration visible on the paper, change filters, clean traps, add moisture separators or filters, or make adjustments as necessary to achieve clean, dry air. Reinspect surfaces prepared or coated since the last satisfactory test and reblast such surfaces at no additional cost to the Authority.

C. Prior to dry abrasive blast cleaning, remove all visible oil, grease, soil, drawing and cutting compounds and other soluble contaminants from bare steel in accordance with SSPC-SP 1.

D. Abrasive Blasting

1. Perform abrasive blasting in accordance with SSPC-SP 10 using a production line shot and grit blast machine or by air blast. Maintain the abrasive work mix such that the final surface profile is within the required range. Use SSPC-VIS 1 to evaluate the degree of cleaning.

2. Provide expendable or recyclable abrasives that are dry and free of oil, grease and corrosion producing or other deleterious contaminants. Check the abrasive daily (or more frequently if required) for oil, grease or dirt contamination with the vial test. The test consists of adding a sample of abrasive from the inside of the blast machine to a sealable vial filled with deionized water. The vial is shaken for one minute and allowed to settle for five minutes. If any oil or grease is floating on top of the water, then the abrasive is contaminated. If the water becomes cloudy, then it contains dirt. Do not use contaminated or dirty abrasives to blast steel surfaces.

3. Do not conduct surface preparation when the surface temperature is less than 5 deg F above the dew point.

4. The steel surface profile shall be 2.0-3.5 mils. Measure the surface profile of each pile, paying special attention to areas that may have been shielded during blasting. Measure the surface profile using Testex replica tape in accordance with ASTM D 4417. Retain the impressed tapes and file with the Quality Control inspection records.

3.02 MIXING AND HANDLING

A. Do not use coating materials that have exceeded their shelf life.

B. When required by the coating manufacturer, warm paints stored at less than 50 deg F to above 50 deg F prior to mixing.

C. Mix coatings in accordance with the requirements of the coating manufacturer using mechanical equipment such as a jiffy mixer.

D. Mix only complete kits of multi-component materials. Mixing of partial kits is not allowed.

E. Do not use two-component materials beyond the pot life established by the coating manufacturer's technical data sheets.

316250 - 5

3.03 COATING APPLICATION

A. General

1. Apply the coatings in accordance with the requirements of this Section, the coating manufacturer and SSPC-PA 1.

2. In the event of a conflict between the manufacturer's technical data and the requirements of this Section, comply with this Section unless the requirements of the manufacturer are more restrictive. In these cases, advise the Engineer in writing of the conflict and comply with the Engineer's written instructions.

3. Apply the coating system to all surfaces, including accessible areas of both parts of channel locks.

B. Quality of Surface Preparation and Time Restrictions Prior to Coating

1. Verify that the surface exhibits the specified degree of cleaning immediately prior to coating. Reclean deficient areas. Do not apply coating unless the prepared surface is inspected and approved by the Engineer.

2. Apply the first coat within 12 hours of cleaning to bare metal. If the bare substrate is allowed to remain uncoated for more than 12 hours or if rerusting is evident, reclean the surface prior to coating.

C. Surface Cleanliness Prior to Coating and Between Coats

1. Do not perform coating application in areas where dust is being generated.

2. Thoroughly clean the surface of each coat prior to the application of the next coat to remove spent abrasive, dirt, dust, cement spatter and other deleterious materials. Pay particular attention to the removal of detrimental residue from surfaces such as corners and pockets. Clean the surfaces by vacuuming or blowing with compressed air.

3. If grease or oil has become deposited on the bare steel or on the surface of any of the applied coats, remove by solvent cleaning in accordance with SSPC-SP 1 prior to the application of the next coat. Use a solvent that is acceptable to the coating manufacturer.

D. Ambient Conditions During Coating Application

1. Apply coatings under the following conditions unless the requirements of the coating manufacturer are more restrictive:

a. Surface and Air Temperatures: Between 50 deg F and 100 deg F.

b. Relative Humidity: Less than 90 percent.

c. Dew Point: Surface temperature at least 5 deg F above the dew point temperature of the surrounding air.

d. Frost/Rain: Do not apply coatings to surfaces containing frost or free standing water, or during rain, fog or similar detrimental weather conditions.

2. Remove and replace any coating that is exposed to unacceptable conditions (e.g,. rain or dew) prior to adequate curing.

316250 - 6

E. Coating Thickness Apply materials to establish dry film thickness values in accordance with the requirements of this Section. Monitor coating application rate by use of wet film thickness gage in accordance with ASTM D 4414. Measure dry film thickness in accordance with SSPC-PA 2.

1. Give special attention to ensure that surfaces such as edges, corners, crevices, welds and exposed fasteners receive a dry film thickness equivalent to that of flat surfaces.

2. Apply additional coating to areas of insufficient thickness. Use care during application to assure that repairs blend in with the surrounding surfaces.

3. Remove excessive coating thickness and reapply the affected coats(s), unless directed otherwise by the Engineer.

F. Performance Requirements

1. The cured coating shall be of uniform gloss and thickness and shall be free of blisters, pinholes, fisheyes, sags, runs and any other irregularities.

2. The dry film thickness of the coating system shall be measured in accordance with SSPC-PA 2 and shall be a minimum of 18 mils at any point.

3. Test for continuity of coating with a holiday tester of 100 volts or less. Repair all holidays detected and retest to confirm repair. Use a high voltage holiday detector if coating system thickness exceeds 20 mils.

4. All coats of the system shall be well adhered to each other and to the substrate. At the Engineer's request conduct adhesion tests in accordance with ASTM D 3359 or ASTM D 4541 and repair all test areas. The acceptance criteria for the testing will be established by the Engineer. Remove all defective coating and reblast and recoat such areas in accordance with the requirements of this Section.

5. Maintain Quality Control records of the results of inspections and submit results to the Engineer as stipulated in Appendix "A".

G. Repair of Damaged and Unacceptable Coatings Before and After Pile Driving

1. Surface Preparation of Localized Areas

a. Repair localized damage, corrosion and unacceptable coatings.

b. Prepare the surface by cleaning in accordance with SSPC-SP 1 followed by SSPC-SP 2 or SSPC-SP 3. Uniformly roughen all surfaces.

c. For previously blast-cleaned steel: If the damage exposes the substrate, remove all loose material and prepare the steel in accordance with SSPC-SP 11 with a 2-mil profile.

2. Surface Preparation of Extensive Areas

a. Repair extensive areas of damage or unacceptable coating by methods acceptable to the Engineer, based on the nature of the defect.

b. For previously blast-cleaned steel, blast surface back to original requirements. Use extreme care to avoid overblast damage to the surrounding coating.

316250 - 7

3. Feathering of Repair Areas

a. Feather the existing coatings surrounding each repair location. Feather for a distance of 1 to 2 inches to provide a smooth, tapered transition into the coating.

b. Verify that the edges of coating around the periphery of the repair areas are tight and intact by probing with a putty knife in accordance with the requirements of SSPC-SP 3. Roughen the existing coating in the feathered area to assure proper adhesion of the repair coats.

H. Coating Application in Repair Areas

1. When the bare substrate is exposed in the repair area, reapply all coats of the system to the specified thickness.

2. When the damage does not extend to the bare substrate, reapply only the affected coats.

3. Maintain the thickness of the system in overlap areas within the specified total thickness tolerances.

4. For field touch-up after pile driving, use touch-up coatings as recommended by the coating manufacturer and approved by the Engineer.

3.04 PROTECTION

Ensure that coated items are not shipped until cured. Protect all fully coated and cured items from handling and shipping damages using padded slings, dunnage, separators and tie-downs.

END OF SECTION

316250 - 8

SECTION 316250

PROTECTIVE COATING FOR STEEL PILING

APPENDIX "A"

SUBMITTALS Submit the following in accordance with the requirements of "Shop Drawings, Catalog Cuts and Samples" of Division 1 - GENERAL PROVISIONS:

A. Product Data

1. For specific products listed in 2.02 A and B, submit the following for each product:

a. Manufacturer's printed Technical Data Sheets.

b. Material Safety Data Sheets (MSDS).

c. Manufacturer's printed product label and application instructions.

2. For products other than those expressly listed in 2.02 A and B submit the following for each product:

a. Information adequate for the Engineer to compare the specified product and the proposed substitution; including, but not limited to, technical specifications, test data, references to product use in existing installations, or any other data required by the Engineer.

B. Surface Preparation/Coating Plan

1. Written procedures for conducting the Work of this Section including but not limited to the preparation of surfaces, abrasive "work mix" analysis; coating mixing, application and repair; recoat times and cleaning between coats; and specific details for the preparation and coating of welds.

2. A comprehensive listing of the equipment that will be used for surface preparation and coating. A description of equipment repair and replacement capability, including the procedures that will be followed in the event of equipment failure so that lost production time is kept to a minimum.

C. Quality Control Inspection Plan Submit the Quality Control inspection plan that will be followed to confirm that all coating Work complies with the requirements of this Section. The plan shall include the following at a minimum:

1. Inspection organization chart including lines of authority and the experience, training and qualifications of Quality Control personnel.

2. Written inspection procedures for all phases of the Work, including the frequency of inspections that will be performed and the handling of non-conforming Work.

3. Documentation procedures including samples of the actual inspection forms that will be used for Work of this Section.

316250 - 9

4. Written description of equipment to be used for surface preparation and coating application inspection, calibration procedures, frequency of calibration and the methods for handling equipment that is found to be out of calibration.

D. Inspection Reports

1. Submit a copy of the inspection report template that will be used for the Work.

2. Submit one copy of the actual daily inspection reports to the Engineer each seven calendar days.

END OF APPENDIX "A"

INSTRUCTIONS TO ENGINEER/ARCHITECT 316250 - 1

SECTION 316250

PROTECTIVE COATING FOR STEEL PILING

INSTRUCTIONS TO ENGINEER/ARCHITECT

A. General

1. This coating system is used for land side applications. For salt water tidal and immersion service applications, use Section 316265.

2. Do not alter or revise the text of this Section.

3. Do not add manufacturers or coating materials unless such additions have been reviewed and approved by Materials Engineering prior to issuance of the Contract.

B. Contract Drawings Ensure that the Contract Drawings show the following items specified in the text:

(2.02 A) Finish schedule. (3.01 D) Required steel surface preparation.

C. Other Items

1. In Appendix "A", insert specific items for which submittals are required or "NONE" as applicable.

END OF INSTRUCTIONS