Lydia Frenzel Conference Series - Advisory...

Thank you for downloading this file. If you would like further information on water jetting visit the Lydia Frenzel Conference Series. The Advisory Council is a nonprofit, privately funded membership organization that provides a forum for dialogue and the dissemination of information pertaining to the economic and social effects of technological development throughout the world.

The Council solicits and makes available pertinent information from both private and public sources, seeks expression of points of view from all who may wish to contribute, advances consensus opinions and selected issues of standards and standards organizations, develops networking to match speaking and information resources with the needs and demands of the community, and promotes specific seminars and symposia.

A Primary Mission of the Council is to promote effective means of surface preparation in the maintenance industry using water and water/abrasive blasting techniques.

This mission is viewed as important because the conservation of resources, particularly the public infrastructure, has a significant and long lasting economic impact on the well-being of every citizen.

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T & E RECYCLABLE FERROUS METALLIC ABRASIVE PPI 1 September 23, 2002, REV 00

PPI NBR: 63101- Test & Evaluate Recyclable Ferrous Metallic Abrasives DATE: 23 September 2002

PRESERVATION PROCESS INSTRUCTION (PPI) BALLAST TANK

(Test & Evaluate Recyclable Ferrous Metallic Abrasives) Surface Preparation Method of Abrasive Blasting


1. SCOPE: 1.1 Title: Cleaning, Surface Preparation and Painting Requirements for (area to be prepared). 1.2 If the PPI checkpoint criteria are met, the following table provides service life expectancy for the listed

system.

Coating System Life Expectancy: Area System Life Expectancy

Sigmaguard BT 20 years Sherwin Williams Dura-Plate UHS 20 years

Ameron 133/333 20 years EuroNavy ES 301 K, L and S 20 years

International Intergard 143 20 years

Ballast Tank

F150/F152 Type IV 5 years 2. REFERENCES: 2.a. Systems and Specifications, Steel Structures Painting Council, Volume 2 2.b. SSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages 2.c. MSDS and manufacturer’s ASTM F 718 sheets, Shipbuilders and Marine Paints and Coating Product /

Procedure Data Sheet for (Applicable QPL) Coating System Being Applied. 2.d. ASTM D 4417, Method C, Standard Test Methods for Field Measurement of Surface Profile of Blast

Cleaned Steel 2.e. OSHA 29 CFR 1915 Subparts C and Z 2.f. SSPC-VIS-1-89 Visual Standard For Abrasive Blast Cleaned Steel 2.g. SSPC-AB-2, Cleanliness of Recycled Ferrous Metallic Abrasives 2.h. SSPC-VIS-3 Visual Standard For Power and Hand Tool Cleaned Steel 3. APPENDICES: APPENDICES

APPENDIX TITLE APPLICABLE TO THIS PPI

1 QA INSPECTION FORM - ENVIRONMENTAL READINGS Y 2 QA INSPECTION FORM - SURFACE SOLUBLE SALT CONDUCTIVITY LOG Y 3 QA INSPECTION FORM – SURFACE PROFILE LOG Y 4 QA INSPECTION FORM – DRY FILM THICKNESS MEASUREMENTS Y 5 CHECKPOINTS & MILESTONES COMPLETION LOG Y 6 CERTIFIED COATING INSPECTOR’S CHECKPOINT SIGN OFF LOG Y 7 PAINT APPLICATION EQUIPMENT & PAINT CONSUMPTION LOG Y 8 SURFACE CONDUCTIVITY TESTING PROCEDURE Y

9 QA INSPECTION FORM – WET FILM THICKNESS MEASUREMENTS (For use with solvent coating systems) N

10 COATING SYSTEMS Y 11 QA INSPECTION FORM – CATHODIC PROTECTION EQUIPMENT N 12 REPAIR PROCEDURE FOR GOUGED TILE N

13 QA INSPECTION FORM – CLEANLINESS OF RECYCLED FERROUS METALLIC ABRASIVE Y


4. REQUIREMENTS: 4.1 SAFETY: Accomplish the safety precautions as specified in NSTM 631, Section 2, Ref. 2.e, and the Job

Order during surface preparation and the application of marine coatings. 4.2 WORK NOTICE: The contractor shall post the notice at the ship’s quarterdeck or other designated location

for each job or separate area at least four hours, but not more than 24 hours, prior to the start of work. The notice shall contain the following information: ship’s name and hull number, work item number, compartment or frame number, identification of hazard, date and time of work process and identification of engineering and work practice controls. Deliver notification of work planned for a weekend or Monday following that weekend to the Commanding Officer’s representative not later than 0900 on the Friday immediately preceding that weekend. Deliver notification of work planned on a federal holiday and on the day following the federal holiday to the Commanding Officer’s representative not later than 0900 on the last working day preceding the federal holiday.

4.3 QUALITY ASSURANCE REQUIREMENTS: 4.3.1 REQUIREMENTS FOR COATED AREAS. Surface preparation shall be accomplished by certified

blasters. Coating systems shall be applied by certified painters and test / inspection records maintained IAW the requirements of NSTM 631, Section 11. Checkpoints and final inspections shall be signed off by certified coating inspectors.

4.3.2 BLASTERS AND PAINTER CERTIFICATION. The implementing contractor shall maintain a certification

program for blasters and painters working on the project IAW NSTM 631, Section 11.5. 4.3.3 COATING INSPECTOR CERTIFICATION: The implementing contractor shall maintain a certification

program for coating inspectors working on the project IAW the requirements of NSTM 631, Section 11.6. At a minimum, coating inspectors shall be certified and maintain certification to the National Association of Corrosion Engineers (NACE) Session I, or the NAVSEA Basic Paint Inspector Course (NBPI).

4.3.4 COATING INSPECTOR RESPONSIBILITIES: Coating inspectors are responsible for requirements listed

in NSTM 631, Section 11.7. 4.3.4.1 Responsible Government Representative certified coating inspector shall verify checkpoints and sign all

applicable Appendices. 4.3.4.2 Implementing Contractor shall perform all in-process inspections and checkpoints. 4.3.4.3 The Responsible Government Representative shall be present for and verify all in-process inspections /

checkpoints. 4.3.4.4 Implementing Contractor shall participate in a joint Ship’s Force and SUPSHIP personnel safety brief,

when directed by the SUPERVISOR, prior to the start of recommended PCP. 4.3.5 IN-PROCESS INSPECTIONS: Inspections are to be completed as listed in NSTM 631, Section 11.

Responsible Government Representative certified coating inspector shall be given prior notice and shall perform an inspection of each coated area when the following checkpoints are reached: process control procedure, pre-surface preparation & cleaning, contamination containment and masking, surface preparation, paint storage area, prime coat, between each successive coat of paint, topcoat of paint applied and area ready for final inspection. The inspector is required to examine all data maintained by the paint foremen concerning environmental conditions, surface cleanliness, surface profile, and paint thickness. Data shall be verified, depending on the checkpoint in question, including surface cleanliness, surface profile, dry film thickness and workmanship. Environmental data, such as temperatures, relative humidity and dew point need only be verified if the inspector is doubtful of the recorded values. Deficiencies in personnel training, certification, record maintenance, equipment maintenance or any matter that is not IAW good painting practice shall be recorded. The coating inspector shall verify the successful completion of each checkpoint and sign and date the applicable spaces on Appendix 6.


4.3.6 DEVIATIONS: All surface preparation and coating applications shall be IAW delineated guidance herein. Any deviation will require NAVSEA approval and Contracting Officer (or representative) sign-off.

4.3.7 A TYCOM / NAVSEA authorized representative will provide QA oversight of this process. Implementing

Contractor shall provide the Government QA inspector a minimum of four (4) hour notification of all checkpoints prior to accomplishing the checkpoint.

4.3.8 DEVELOP AND ACCOMPLISH PROCESS CONTROL PROCEDURE (PCP): Submit two legible copies of

each PCP not later than seven working days prior to start of the process required by the procedure to the Responsible Implementing Authority. The procedure shall contain the following minimum information:

-Contractor’s name and address, -Process title, number, and date developed, -Description of process, including critical factors which have direct bearing on the process quality

and safety, -Qualification requirements for the personnel performing the work, -Inspection and documentation forms, -Acceptance and rejection criteria for checkpoints, -The method utilized to ensure personnel accomplishing the procedure have direct knowledge of the requirements prior to beginning work. A copy of the procedure shall be at the work site during the performance of work, -Develop PCP matrix to include the entire job process with start dates, surface preparation dates, coating application dates, etc., -Weekly, update matrix as needed based on schedule changes, until completion / closure of each space or job item, -The method utilized to control the procedure, -Identification of hazardous materials which will be used in the process or hazardous waste that will be generated by the accomplishment of the process and the methodology, which will be utilized to minimize the quantity of these materials, which will require control and disposal, -Approval signature and title of the contractor’s representative and the date of submission. 4.3.9 CHECKPOINT (PCP): Provide to responsible QA representative for review and comment on the PCP five

(5) days prior to commencement of this process. 4.4 RECORD KEEPING: 4.4.1 RECORD KEEPING DURING SURFACE PREPARATION / PAINT APPLICATION: A permanent record of

environmental conditions, surface preparation and paint application operations shall be maintained. Data shall be entered on Appendices 1 - 5. Environmental information on Appendix 1 shall be updated every 4 hours, posted at the job site and an updated copy provided to the coating inspector at each checkpoint for review. The record shall include dates and times of surface preparations and painting operations, air temperatures, surface temperature, relative humidity and dew point. Enter on Appendix 3 the abrasive blast media QPL, manufacturer, type and size of abrasive used (when used), along with the TESTEX PRESS-O-FILM tapes used to measure surface profile.

4.4.2 REVIEW OF RECORDS FOR FINAL COATING EVALUATION: A certified paint inspector authorized to

represent NAVSEA shall review the Appendices of each critical area to ensure adequate quality control of the painting process. Records shall include all the test and inspection data required by NSTM 631 Table 631-11.1. Failure to produce such records, or records which indicate that surface preparation and painting was not done IAW governing specifications/instructions, will be grounds for rejection.

4.4.3 Ensure process control documentation provides a record of the data required to control and determine satisfactory completion of the process. 4.4.4 Submit updated or changed PCP procedures to the SUPERVISOR at least three working days prior to implementation. 4.5 TEMPORARY SERVICES: The project will require temporary services such as, but not limited to, lighting,

compressed air, ventilation, fresh water, electrical services, and crane service. Ensure all equipment is IAW safety requirements delineated in NSTM 631, Section 2.


4.6 FORWARDING APPENDICES AND RETENTION OF RECORDS: After the project is completed, forward two copies of the completed Appendix forms to the TYCOM, Supervisor of Shipbuilding and Responsible Implementing Authority. Records shall be maintained by the Supervisor for a period of 3 years.

4.7 LOG OF EQUIPMENT & MATERIAL USED: Record equipment information and material used in Appendix

7. Compare materials used, to paint materials and abrasive blast media (when used), specified in work order or contract.

4.8 ENVIRONMENTAL CONDITIONS: Maintain environmental conditions IAW Ref. 2.c and NSTM 631,

Sections 6, 7, and 8. Record measurements in Appendix 1. 4.8.1 Do not exceed the Maximum Relative Humidity levels of 50% after satisfactory soluble salt conductivity

level has been attained and satisfactory visual substrate surface condition has been achieved. 4.8.2 The application of Euronavy ES 301 is exempt from relative humidity and dew point requirements since it

may be applied on damp surfaces. 4.8.3 If environmental conditions are not provided or are unclear, contact Responsible Implementing Authority

for resolution. 4.9 TEMPERATURES TO BE MAINTAINED FOR PAINT COATING SYSTEMS: Ensure temperatures are

within acceptable limits as specified IAW Ref. 2.c and NSTM 631, Section 6.3. If inconsistencies in temperatures exist, NSTM 631 will supersede Ref. 2.c. If temperatures are not provided or are unclear, contact Responsible Implementing Authority for resolution.

4.10 CONTAMINATION CONTAINMENT AND MASKING FOR SURFACE PREPARATION AND PAINTING

OPERATIONS: The following requirements shall be observed, in addition to the specific requirements of the Job Order, for maintaining cleanliness of the ship, ship’s equipment, components, and spaces for the duration of the availability.

4.10.1 Prevent contamination and surface damage of the ship’s equipment, components, and spaces during

contamination-producing operations. 4.10.1.1 Plug, blank, wrap, cover, seal, and mask equipment, components, cables, wire ways, boats, and openings

using fire retardant/ water repellent materials, and prevent entry of contaminants to machinery, winches, rigging, machinery surfaces, weapons systems, electrical equipment, electronic equipment, valves, vents not in use, and other openings.

4.10.1.2 Install covering conforming to A-A-55308 and/or fire retardant plywood. 4.10.1.3 Install fire retardant industrial filter material on the intake of supply and exhaust end of ventilation systems

which will be in use. 4.10.1.4 Remove existing and install new filter or clean the filter material when airflow is restricted. 4.10.1.5 All protective measures are to be in place prior to start of any contamination-producing operations and

shall remain in place until the contamination-producing operations are complete. 4.10.1.6 Install double curtain baffles at the entrances of each access where airborne contamination could occur

during contamination-producing operations. Install a dirt-collecting mat on the deck directly inside each access. The SUPERVISOR will select a maximum of four doors. Tag out doors not designated for access.

4.10.1.7 Temporary coverings shall not be removed during contamination-producing operations without permission

of the SUPERVISOR. 4.10.2 PROTECTIVE COVERING: Inspect the integrity of the protective covering at the beginning of each shift in

which contamination-producing operations will be accomplished. Ensure that equipment and machinery have not been infiltrated by contaminants. Notify the SUPERVISOR immediately by verbal means, followed on the next workday in writing, if contamination or surface damage has occurred. Reseal to prevent further entry of contaminants or surface damage.


4.10.3 Maintain cleanliness of the work site free from accumulation of industrial debris caused by contractor and /or subcontractor employees on a continuous basis throughout the availability. Workspaces include those areas immediately under and adjacent, and those areas where service lines are run.

4.10.3.1 Area cleaning shall be accomplished no later than at the end of each shift, on a daily basis and prior to any

checkpoints. 4.10.3.2 Remove and dispose of industrial debris from the ship on a daily basis. 4.10.4 Accomplish an initial walk-through of all locations aboard ship where contractor responsible work will take

place, to observe cleanliness conditions. The inspection shall be made jointly with the SUPERVISOR and the ship’s Commanding Officer’s representative, and shall take place prior to the commencement of any work by the contractor.

4.10.4.1 Submit four legible copies of a written report of any unclean sites/spaces to the SUPERVISOR and

Commanding Officer of the ship within 72 hours after completion of the inspection. 4.10.5 Accomplish a cleanliness inspection on a daily basis whenever work is in progress. The inspection shall be

made jointly with the SUPERVISOR and the designated representative of the ship’s Commanding Officer. During inspection the responsible party shall be assigned. A written report of any unclean work sites/spaces shall be prepared by the contractor and copies distributed to the SUPERVISOR and Commanding Officer of the ship within four hours after completion of the inspection. The inspection report shall list the responsible activity (contractor, ship, etc.) for each unclean site/area. Unclean sites/areas determined as contractor responsible shall be immediately cleaned.

4.10.5.1 Inspections and reporting shall be accomplished during the daily fire prevention and housekeeping

inspections. 4.10.6 COVERING REMOVAL: Remove protective covering upon completion of contamination-producing

operations and inspect for presence of contamination or surface damage. Notify the SUPERVISOR immediately by verbal means, followed on the next workday in writing, if contamination or surface damage has occurred, prior to removal of the contamination and repair of damage.

4.10.7 Remove from the ship and dispose of debris and foreign matter generated as a result of work being

accomplished on this ship and from work being accomplished on other naval and private ships. Comply with the requirements of federal, state, and local laws, codes, regulations, and ordinances or as specified elsewhere in the Job Order.

4.11 ISOLATION, BLANKING AND TAGGING REQUIREMENTS: Notify the Commanding Officer’s

representative in writing of equipment, systems, circuits, components, piping, and valves that require isolation to accomplish work in the Work Item before any work is started on each individual Work Item so that tag-outs can be accomplished as required by ship’s instructions.

4.11.1 After ship’s force install tags; verify use of sufficient tags to prevent operation of equipment, systems,

circuits, components, piping, or valves from all stations that could exercise control. 4.11.2 A contractor’s representative shall print name, badge number, identify company, and sign on a ship’s tag-out

record sheet and tags after installation, indicating repair activity satisfaction with the completeness of the tag-out and alerting personnel removing tags that contractor concurrence is required.

4.12 Post warning signs and barriers and install temporary positive means to prevent closure or movement of

component that create a safety hazard. 4.13 Do not disturb, modify, remove, energize, or operate any switch, fitting, valve, or other equipment affixed

with a ship’s isolation or DANGER tag. 4.13.1 Do not remove or relocate ship’s isolation or DANGER tags.


4.13.2 Notify the Commanding Officer’s representative immediately when the contractor’s work is complete and the system, piping, or circuit is ready for activation to accomplish removal of tags.

4.13.3 The contractor’s representative shall sign the ship’s tag-out log sheet to show concurrence in tag removal

and clearance before removal. 4.13.4 Verify removal and clearance of all isolation or DANGER tags in accordance with ship’s instruction before

the equipment is operationally tested or operated. 5. PRE-SURFACE PREPARATION: 5.1 STRUCTURAL INSPECTION: Prior to commencement of work, the government will provide an authorized

representative to conduct a structural inspection for the entire area to be prepared. Heavily rusted or corroded area, damaged metal and holes in the structure or piping shall be documented and provided to ship’s force and Responsible Contracting Authority to determine if further structural evaluation or NDT is warranted and for possible repair before surface preparation.

5.2 PRE-SURFACE CONDITIONING: Before surface preparation the Responsible Implementing Authority

shall have all welds, protrusions, projections and spikes ground smooth; pits in the welds shall be ground out; all weld splatter shall be removed. If using a non-edge retentive coating radius all edges, flanges, cutouts, angles, pipe hangers and foot/hand holds to a minimum radius of 3mm.

NOTE: RADIUSING OF EDGES, FLANGES, CUTOUTS, ANGLES, PIPE HANGERS, AND FOOT/HAND

HOLDS IS NOT REQUIRED WHEN USING APPROVED EDGE RETENTIVE COATINGS. 5.3 DEGREASE / FRESH WATER WASH DOWN: Prior to surface preparation, remove all surface

contaminants such as sea salts, grease and oil (hydrocarbons), loose rust; mud and marine growth with 3,000-psi minimum fresh water wash down. Use vacuum to remove standing water followed by an adequate period of time to allow the surface to dry prior to surface preparation. SSPC-SP-1 requirements shall be met.

5.4 CHECKPOINT (Pre-Surface Preparation Inspection): NOTE: ULTRAVIOLET LIGHTS SHALL NOT BE USED IN MERCURY EXCLUSION AREAS. 5.4.1 (Visual and Ultraviolet (UV) Light): Conduct a visual inspection to verify all surfaces within the scope of the

project are free of hydrocarbons, and other contaminants such as sea salts, loose rust, mud, and marine growth, which could become imbedded in the surface to be prepared. Inspect surface using a UV light (approx. 60 Å) to detect hydrocarbons on the surface. The ultraviolet light will not allow the proper detection of hydrocarbons on the surface if the surface being inspected is exposed to day or artificial light. Therefore for proper UV light hydrocarbon detection, lights must be off for interior spaces, and the inspection must be conducted during darkness for surfaces exposed to sunlight. Take appropriate safety measures to prevent worker hazards in the darkened space.

5.4.1.1 When hydrocarbons are present, the hydrocarbons will fluoresce as bright green, lime green, or blue/violet

on the surface. 5.4.1.2 To remove detected contaminants or hydrocarbons, accomplish a solvent wipe on affected areas. Follow

SSPC-SP-1 to remove contaminants and hydrocarbons. 5.4.1.3 If contaminants or hydrocarbons are detected on the surface after attempting to solvent spot repair, the

Responsible Implementing Authority shall require the surface be de-greased again as directed in paragraph 5.3.

5.4.2 (Structural and Pre-Surface Conditioning): Verify all surfaces within the scope of the project are IAW

paragraphs 5.1 and 5.2. 5.4.3 (Contamination Containment and Masking): Verify all surfaces within the scope of the project are IAW

paragraphs 4.10 through 4.11.


6. SURFACE PREPARATION: 6.1 Monitor environmental conditions throughout surface preparation operations to ensure they meet

requirements as specified in paragraphs 4.8 and 4.9. Record measurements in Appendix 1. 6.2 ABRASIVE BLASTING: Accomplish the overhaul surface preparation requirements of Tables 631-1-3 and

631-11-1, ll (Surface Preparation), for the location/area being prepared. Minimum requirement is SSPC-SP-10. The blast media, must meet the requirements specified in NSTM 631, or have written authorization for use from NAVSEA 05M.

6.2.1 CHECKPOINT (Cleanliness of Recycled Ferrous Metallic Abrasive (RFMA): Accomplish testing procedure

of RFMA IAW Ref. 2.g. Record testing results in Appendix 13. 6.3 POWER TOOL CLEANING ON SURFACES INACCESSIBLE TO ABRASIVE BLASTING: 6.3.1 Accomplish the requirements of SSPC-SP-11 Power Tool Cleaning to Bare Metal to remove all the

existing coating and corrosion products. Surface preparation accomplished using a surface preparation device such as a disk sander or power wire wheel that burnishes, polishes or smoothes the surface is not authorized. A minimum surface profile of 1 mil is required.

6.3.2 Feather edges of adherent paint in adjacent areas remaining after cleaning. 6.3.3 The Responsible Implementing Authority shall have the authority to reject this method in any area if the

surface can be shown to have adequate accessibility for Abrasive Blasting. 6.4 SURFACE PROFILE: 6.4.1 For areas prepared to SSPC-SP-10 accomplish a surface profile of 2-4 mils (50-100µ). 6.5 CHECKPOINT (Surface Preparation): Accomplish IAW Table 631-11-1, II (Surface Preparation). The record shall show the extent of the inspection and detailed results. The degree of surface cleanliness

shall be IAW the NACE/SSPC surface preparation standard specified; surface profile, soluble salt measurements, and adequacy of cleanup operations shall be recorded. Inspect all surfaces to ensure 100% of all grit and dust have been removed. The inspections shall be conducted to standardized acceptance criteria. Visual aids, such as Ref. 2.f or Ref. 2.h may be used to ensure quality standards are met. Enter data on all applicable Appendices.

6.5.1 (Surface Profile Measurements): Accomplish IAW Ref. 2.d. Record one measurement every 200 ft²

randomly dispersed over the entire prepared area. Abrasive manufacturer, type and mesh size used shall be entered on Appendix 3 along with the TESTEX PRESS-O-FILM tapes used to measure surface profile.

6.5.2 (Soluble Salt Measurements Conductivity Testing): Accomplish conductivity tests IAW the method described

in Appendix 8. Use HORIBA B-173 or equivalent NAVSEA approved test equipment. Measurements shall be made randomly over the prepared surface. Take five (5) measurements every 1,000 ft² (90m²). Areas less than 1,000 ft² (90m²) shall have (5) measurements made. For immersed applications, conductivity due to soluble salts (total ionic) shall not exceed 30µS/cm (microsiemens/cm).

6.5.2.1 If conductivity measurements for surfaces prepared to an SSPC-SP-10 exceed the respective values, water

wash using a minimum of 3,000 PSI fresh water. Soluble salt conductivity limit of the fresh water shall not exceed 200µS/cm (microsiemens/cm). To ensure effective low-pressure water washing, the operator shall maintain the wand within a maximum distance of 12 inches to the substrate. The angle of the wand relative to the substrate shall be maintained between 45º - 90º. Remove all standing water, dry the area, and retest. If flash rusting has occurred, or/and soluble salt conductivity still exceed limits rewash, dry the area and retest. If the soluble salt conductivity limit is not reached after 2 washes, then perform water wash to the affected areas using water that is below 30µS/cm (microsiemens/cm) for immersed applications. Repeat water wash and retest until satisfactory levels are obtained. If flash rusting has occurred, reblast the area and retest.


6.5.2.2 If conductivity measurements for surfaces prepared to an SSPC-SP-11 in an isolated area exceed the respective values, circle area and perform spot solvent cleaning (Super High Flash Naphtha) followed by retest.

6.5.2.3 For SSPC-SP-11 prepared surfaces not practical for the spot cleaning method, water wash with copious

amounts of fresh water using hand scrub brush. Soluble salt conductivity limit of the fresh water shall not exceed 200µS/cm (microsiemens/cm). Remove all standing water and dry the affected area. Disk sand using # 36 disk to remove all rust. Perform an SSPC-SP-1 solvent wipe on all sanded areas and retest. If the soluble salt conductivity limit is not reached after 2 washes, then perform water wash to the affected areas using water that is below 30µS/cm (microsiemens/cm) for immersed applications. Repeat necessary steps until satisfactory levels are obtained.

6.5.3 (Environmental): Verify environmental conditions were monitored and maintained IAW paragraphs 4.8

and 4.9. 6.5.4 (Contamination Containment and Masking): Verify all surfaces within the scope of the project are IAW

paragraph 4.10 prior to the application of paint. Surfaces must be clean and free of debris and dust. 6.5.5 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of

the checkpoint. At rescheduled checkpoint, QA will document satisfactory corrective actions taken to correct discrepancy.

6.5.6 In order to pass the checkpoint, Appendices 1-3 and 5 shall be up to date and submitted to QA. QA will

update Appendix 6. 7. PAINTING REQUIREMENTS: NOTE: IMPLEMENTING AUTHORITY WILL DESIGNATE COATING SYSTEM TO BE APPLIED. NOTE: IF A SILICON ALKYD IS TO BE APPLIED DIRECTLY ON TOP OF A SOLVENT FREE COATING, THE

SOLVENT FREE COAT SHALL BE ALLOWED TO CURE FOR MINIMUM OF 24 HOURS BEFORE APPLICATION OF SILICON ALKYD.

7.1 WET FILM MEASUREMENTS: During application, spray applicators shall monitor wet film thickness using

wet film gauges. Random wet film thickness (WFT) measurements shall be taken during the application process to ensure the specified dry film thickness (DFT) is achieved.

7.2 DRY FILM THICKNESS MEASUREMENTS: Accomplish IAW Ref 2.b, record measurements in Appendix 4. 7.3 RE-COAT PERIODS: Applicator will not exceed manufacturer’s maximum re-coat periods IAW Ref. 2.c. 7.4 DRY PAINT FOR CHECKPOINTS: Paint shall be dry prior to all paint related checkpoints. Dry shall be

defined as fingernail hard. 7.5 OUT OF SPECIFICATION DRY FILM THICKNESS: Failure to meet minimum dry film thickness

requirements will result in application of an additional coat or coats of paint in deficient areas before the coat can pass the DFT checkpoints.

7.6 Excessive dry film thickness in a coat or cumulative coats shall be determined IAW Appendix 10. If

excessive DFT is determined, the Responsible Implementing Authority shall be contacted on how to proceed.

7.7 CHECKPOINT (Paint Storage): Accomplish a visual inspection of paint storage facilities 24 hours prior to

paint being mixed to verify that the storage temperature complies within the minimum and maximum range allowed IAW Ref. 2.c. The paint storage temperature shall be monitored and recorded once per shift for 24 hours prior to the paint being used. Record measured temperatures in Appendix 1.

7.8 PAINT APPLICATION: The use of single or plural component spray equipment is acceptable for

application of paint coats specified below. 7.9 When applying prime, stripe, and topcoat, each must be of a contrasting color.


7.10 MIXING: If single or plural component spray equipment is used, mix primer, stripe, and topcoat IAW NSTM

631, and Ref. 2.c. 7.11 Monitor environmental conditions throughout painting operations to ensure they meet requirements as

specified in paragraphs 4.8 and 4.9. Record measurements in Appendix 1. 7.12 REPAIRS: 7.12.1 Repairs Made To Paint Within Manufacturer's Overcoating Time Period: 7.12.1.1 Surfaces in which mechanical damage extends into the substrate shall be prepared to SSPC-SP-11 Power

Tool Cleaning. The power tool prepared surface shall be feathered into the surrounding intact paint, creating a smooth transition.

7.12.1.2 Surfaces in which the mechanical damage does not extend into the substrate shall be solvent wiped to clean. 7.12.1.3 Hand brush, or in larger areas airless spray the coating system in accordance with Ref. 2.c. 7.12.2 Repairs Made To Paint Beyond The Manufacturer's Overcoating Time Period: 7.12.2.1 Surfaces in which mechanical damage extends into the substrate shall be prepared to SSPC-SP-11 Power

Tool Cleaning. The power tool prepared surface shall be feathered into the surrounding intact paint, creating a smooth transition.

7.12.2.2 The painted surfaces surrounding the Power Tool Cleaned surface that have exceeded the over coating

time period must be roughened to provide a surface profile. 7.12.2.3 Painted surfaces in which the mechanical damage does not extend into the substrate must have the

surrounding painted surface roughened to provide a surface profile. NOTE: NO PAINT SHALL BE APPLIED TO A PAINTED SURFACE THAT HAS EXCEEDED THE OVERCOAT

PERIOD WITHOUT THE PROPER REACTIVATING PROCEDURES BEING FOLLOWED. NOTE: PAINT ONLY REACTIVATED PAINT SURFACES. 7.12.2.4 Hand brush or in larger areas airless spray the coating system in accordance with Ref. 2.c. 7.12.2.5 Allow for proper drying time as per the manufacturer's instructions after the application of each coat

(including damaged touch-up areas).


7.12.3 Recoating Beyond Manufacturer's Overcoating Period: 7.12.3.1 If overcoat period is exceeded, (see Ref. 2.c for maximum and minimum overcoating times), the following

method shall be followed: 1. Clean affected surface with an approved cleaner. 2. Roughen surface with 60 or 80 grit sandpaper to profile the painted surface.

8. PRIMER COAT APPLICATION: 8.1 Apply prime coat specified in Appendix 10 IAW Table 631-11-1, lll (Painting). During application,

immediately brush out any runs, drips, sags or puddles. 8.2 CHECKPOINT (Prime Coat): Verify prime coat is applied IAW Table 631-11-1, IV (Cure/Post Cure). 8.2.1 (Holiday Inspection): Accomplish a visual holiday inspection of prime coat. 8.2.2 (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b. 8.2.3 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of


8.2.4 In order to pass the checkpoint, Appendices 1, 4, 5 and 7 shall be up to date and submitted to QA. QA will

update Appendix 6. 9. STRIPE COAT APPLICATION: 9.1 Check for evidence of Amine Bloom such as discoloration of paint coating or clear oily film. If evidence of

Amine Bloom is present, perform low-pressure water wash or wipe surfaces clean using ethanol/water mixture.

9.2 Apply stripe coat specified in Appendix 10 with typical paint equipment IAW Table 631-11-1, lll (Painting).

Stripe coat by brush in areas not accessible by paint spray equipment. During application, immediately brush out any runs, drips, sags or puddles.

9.3 CHECKPOINT (Stripe Coat): Verify stripe coat is applied IAW Table 631-11-1, IV (Cure/Post Cure). 9.3.1 (Holiday Inspection): Accomplish a visual holiday inspection of stripe coat. 9.3.2 (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b. 9.3.3 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of



update Appendix 6.


10. TOPCOAT APPLICATION: NOTE: REMOVABLE SHIP COMPONENTS AND EQUIPMENT TOPCOATED WITH EPOXY PAINTS, SUCH

AS SIGMA EDGEGUARD, SHOULD NOT BE STORED IN LOCATIONS SUBJECT TO DIRECT UV EXPOSURE. FAILURE TO PREVENT SUCH EXPOSURE COULD RESULT IN SIGNIFICANT COLOR CHANGE.

10.1 Check for evidence of Amine Bloom such as discoloration of paint coating or clear oily film. If evidence of

Amine Bloom is present, perform low-pressure water wash or wipe surfaces clean using ethanol/water mixture.

10.2 Apply topcoat specified in Appendix 10 IAW Table 631-11-1, lll (Painting). During application, immediately

brush out any runs, drips, sags or puddles. 10.3 CHECKPOINT (Topcoat): Verify topcoat is applied IAW Table 631-11-1, IV (Cure/Post Cure). 10.3.1 (Holiday Inspection): Accomplish a visual holiday inspection of topcoat. 10.3.2 (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b. 10.3.3 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of



update Appendix 6. 11. FINAL INSPECTION: 11.1 CHECKPOINT (Finished Painted Surfaces): Accomplish IAW Table 631-11-1, IV (Cure/Post Cure). 11.1.1 (Dry Film Thickness): Accomplish final dry film thickness measurements IAW Ref. 2.b. 11.1.2 Coating imperfections found, which may cause premature coating failure, shall be corrected before the

paint system is accepted using appropriate touch-up procedures specified in paragraph 7.12. Slight imperfections in the coating system are allowable, as long as they are not below minimum mils, and will not result in premature failure of the coating in the immediate vicinity of the imperfection. Such slight imperfections should be left intact, as trying to correct them could result in damage to the surrounding coating system.

11.1.3 In order to pass the checkpoint, any Appendices required by the certified coating inspector shall be up to

date or completed and submitted to QA. QA will update Appendix 6. All test inspections noting unsatisfactory conditions shall be corrected.


APPENDIX 1

QA INSPECTION FORM - ENVIRONMENTAL READINGS

SHIP: ________________________________________________________ LOCATION: ___________________________________________________ DATE: ________ PRODUCT BEING APPLIED: ________________________________________________________

MAINTAIN SEPARATE LOG FOR EACH AREA / LOCATION, PREPARED OR PAINTED SURFACE,

WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION

Date Time

Enter Activity Paint Facility,

Surface Preparation,

Prime, Stripe, Intermediate,

Tack, Top Coat, etc.

Measurement Location

Highest & Lowest Surface Temp.

(°F)

Wet Bulb (°F)

Dry Bulb (°F)

% RH

Dew Point (°F)

Eac

h En

try

Shal

l be

Sig

ned

by

Trad

e M

onito

r, Fo

rem

an o

r C

ertif

ied

Pain

t In

spec

tor

Implementing Contractor (Print): __________________________________________ Implementing Contractor (Signature): ______________________________________













APPENDIX 2

QA INSPECTION FORM - SURFACE SOLUBLE SALT CONDUCTIVITY LOG




DATE TEST LOCATIONS CONDUCTIVITY (Microsiemens / Centimeter)

Implementing Contractor (Print): ______________________________________________________ Implementing Contractor (Signature): __________________________________________________


APPENDIX 3

QA INSPECTION FORM - SURFACE PROFILE LOG




Place TESTEX PRESS-O-FILM In Spaces Below, Retain As Permanent QA Record Average Mils

Place PRESS-O-FILM Here

Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils


Reading: _____mils

Implementing Contractor (Print): ________________________________________________________ Implementing Contractor (Signature): ____________________________________________________ Abrasive Manufacturer: (if applicable) ____________________________________________________ Type: (if applicable) __________________________________________________________________ Mesh Size: (if applicable) ______________________________________________________________ Abrasive Blast QPL and Revision # (if applicable) ___________________________________________


APPENDIX 4

QA INSPECTION FORM - DRY FILM THICKNESS MEASUREMENTS

SHIP: ________________________________________________________ LOCATION: ___________________________________________________ DATE: ________ PRODUCT BEING APPLIED: _________________________________________________________


WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION, FOR NUMBER OF MEASUREMENTS TO BE TAKEN SEE NOTES BELOW.

Indicate Coating System

Seq.

Indicate Type 1 or 2 DFT Gage Being Used: ____ Gage Manufacturer: _________________________________________________ Serial Number of Gage Being Used: ____________________________________ Date Last Calibrated: ____________________ Current Calibration Due Date: ________________

1 Prime Coat: Top Coat: Stripe Coat: Other: ____________ Other: ____________ Other: ____________

Spot Measurement

DFT (mils) Avg. of 3 Gage

Readings

Approximate Location

Spot Measurement


Readings


1 1 2 2 3 3 4 4 5 5

Average

Average

Spot Measurement


Readings


Spot Measurement


Readings


1 1 2 2 3 3 4 4 5 5

Average

Average

Spot Measurement


Readings


Spot Measurement


Readings


1 1 2 2 3 3 4 4 5 5

Average

Average Implementing Contractor (Print): ________________________________________________________ Implementing Contractor (Signature): ____________________________________________________

Required Number of Measurements for Conformance to a Thickness Specification:

1. Make five (5) separate spot measurements (average of the gage readings, see SSPC-PA 2, section 4.1.2) spaced randomly over each 10 m2 (100 ft2) area to be measured. The five spot measurements shall be made for each 10 m2 (100 ft2) of area as follows:

a. For structures not exceeding 30 m2 (300 ft2) in area, each 10 m2 (100 ft2) area shall be measured. b. For structures not exceeding 100 m2 (1,000 ft2) in area, three 10 m2 (100 ft2) areas shall be randomly selected and measured. c. For structures exceeding 100 m2 (1,000 ft2) in area, the first 100 m2 (1,000 ft2) shall be measured as stated in 1.b. and for each

additional 100 m2 (1,000 ft2) of area or increment thereof, one 10 m2 (100 ft2) area shall be randomly selected and measured. d. If the dry film thickness for any 10 m2 (100 ft2) area is not in compliance with the requirements of SSPC-PA 2, sections 5.2.1 and

5.2.2, then additional measurements must be made to isolate the non-conforming area.


APPENDIX 5

CHECKPOINT & MILESTONE COMPLETION LOG




ACTIVITY TIME DATE

Date Process Control Procedure (PCP) Demonstrated Implementing Contractor (Print/ Signature): __________________________________________

Date Pre-Surface Preparation and Cleaning Begins Implementing Contractor (Print/ Signature): __________________________________________

Date of Pre-Surface Preparation and Cleaning Checkpoint --Date of Visual and UV Light Inspection Check --Date of Structural and Pre-Surface Conditioning (ensuring de-burring and grinding) Check --Date of Contamination Containment and Masking Check Implementing Contractor (Print/ Signature): __________________________________________

Date Surface Preparation Begins Implementing Contractor (Print/ Signature): __________________________________________

Date of Surface Preparation Checkpoint --Date of Recycling Abrasive Blast Material Check --Date of Surface Profile Measurement Check --Date of Soluble Salt Measurement Check --Date of Environmental Check --Date of Contamination Containment and Masking Check --Date of Inspection of Prepared area (ensuring all areas are properly prepared) Check --Date of Inspection of area cleanliness prior to paint application Check Implementing Contractor (Print/ Signature): __________________________________________

Date Paint Storage Area Inspected Implementing Contractor (Print/ Signature): __________________________________________

Date Prime Coat is Applied Implementing Contractor (Print/ Signature): __________________________________________

Date of Prime Coat Checkpoint Implementing Contractor (Print/ Signature): __________________________________________

Date Stripe Coat Applied Implementing Contractor (Print/ Signature): __________________________________________

Date of Stripe Coat Checkpoint Implementing Contractor (Print/ Signature): __________________________________________

Date Top Coat Applied Implementing Contractor (Print/ Signature): __________________________________________

Date of Top Coat Checkpoint Implementing Contractor (Print/ Signature): __________________________________________

Date Finished Painted Surfaces Checkpoint Implementing Contractor (Print/ Signature): __________________________________________


APPENDIX 6

CERTIFIED COATING INSPECTOR’S CHECKPOINT SIGN OFF LOG

Must Be Signed By Certified Coating Inspector To Pass Checkpoints




Process Control Procedure Demonstrated Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________

Date: ___________ Time: ___________

Pre-Surface Preparation and Cleaning Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________

Date: ___________ Time: ___________

Surface Preparation Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________

Date: ___________ Time: ___________

Paint Storage Area Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________

Date: ___________ Time: ___________

Prime Coat Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________

Date: ___________ Time: ___________

Stripe Coat Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________

Date: ___________ Time: ___________

Top Coat Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________

Date: ___________ Time: ___________

Finished Painted Surfaces Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________

Date: ___________ Time: ___________


APPENDIX 7

PAINT APPLICATION EQUIPMENT AND PAINT CONSUMPTION LOG




Prime Coat

Stripe Coat

Top Coat

Airless Paint Hose Size

Airless Paint Hose Length

Airless Tip Orifice Diameter / Fan Width

Plural Airless Airless Pump Used & Model Conventional

Airless

Airless Pump Ratio If plural component: Fixed � or Variable �

Temperature Setting At

Heater

If Using Inline Heater Temperature in Fº (Fahrenheit) Temperature

At Tip

Product Applied

Product Manufacturer

Expiration Date

Color Applied

Product VOC

Base Portion Batch № (Part A)

Hardener Portion Batch № (Part B)

Gallons Used per Coat

Square Feet Painted


APPENDIX 8


APPENDIX 10

COATING SYSTEMS COATINGS FOR BALLAST TANKS

Coating Sigmaguard BT Sherwin Williams Dura-Plate UHS Ameron Amercoat 133/333 Prime 4 – 5 mils DFT Amber 5404 4 - 8 mils DFT 3 - 5 mils DFT 133 Stripe 8 – 12 mils DFT Gray 5411 8 - 12 mils DFT 6 - 8 mils DFT 333 Topcoat 10 – 12 mils DFT Aqua 5411 10 - 12 mils DFT 10 – 16 mils DFT 333

14 –17 mils DFT 14 – 20 mils DFT 13 - 21 mils DFT System DFT

22 - 29 mils DFT for Stripe Coat Areas 22 - 29 mils DFT for Stripe Coat Areas 19 - 29 mils DFT for Stripe Coat Areas Coating EuroNavy ES 301 K, L and S International Intergard 143 F150 Series Type IV

Prime 4 - 6 mils DFT (ES 301 K or L) 4 - 8 mils DFT (142/148 Off-White) 4 - 6 mils DFT (150) Stripe 6 - 8 mils DFT (ES 301 S) 8 - 12 mils DFT (143/148 Buff) 2 - 4 mils DFT Topcoat 6 - 8 mils DFT (ES 301 S) 10 - 16 mils DFT (144/148 Gray) 4 - 6 mils DFT (152)

10 –14 mils DFT 14 - 24 mils DFT 8 – 12 mils DFT System DFT

16 – 22 mils DFT for Stripe Coat Areas 22 - 36 mils DFT Stripe Coat Areas 10 – 16 mils DFT for Stripe Coat Areas


APPENDIX 13

QA INSPECTION FORM – CLEANLINESS OF RECYCLED FERROUS METALLIC ABRASIVE




Non-Abrasive Residue (Not to exceed 1% by weight of Working Mix Sample)

Lead Content (Not to exceed .1% ppm)

Water-Soluble Contaminants (Not to exceed 1000 micromhos / cm)

Oil Content (No presence of oil)

A Non-Magnetic Residue Weight.

B #100 sieve fines Weight

C Total Weights of Rows A and B (Working Mix)

D Multiple Total of Row C (Working Mix) by 1%

Add Rows C and D

Weight of Initial Sample

Reclean working mix if it exceeds weight of initial sample by 1%.

A Non-Magnetic Residue Weight.

B #100 sieve fines Weight

C Total Weights of Rows A and B (Working Mix)

D Multiple Total of Row C (Working Mix) by 1%

Add Rows C and D

Weight of Initial Sample

Reclean working mix if it exceeds weight of initial sample by 1%.

Implementing Contractor (Print): _____________________________________________________________________ Implementing Contractor (Signature): ________________________________________________________________

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