PART 1 - FORCE MAIN EXTENSION DIVISION 9 FINISHESdnhiggins.com/docs/Part 1 Force Main - Div...

PART 1 - FORCE MAIN EXTENSION

DIVISION 9

FINISHES

IWSD 04/2010 09900-1 Painting and Coating

AECOM 60096414

SECTION 09900

PAINTING AND COATING

PART 1 – GENERAL

1.01 DESCRIPTION

This section includes materials and application of painting and coating systems for the following

surfaces:

1. Submerged metal.

2. Exposed metal.

3. Buried metal.

4. Concrete and masonry.

5. Metal in contact with concrete.

6. Wood and masonry.

It does not include coating steel water tanks and reservoirs.

1.02 SUBMITTALS

7. Submit shop drawings in accordance with the General Conditions, Section 01300 and the

following.

8. Submit manufacturer’s data sheets showing the following information:

a. Percent solids by volume.

b. Minimum and maximum recommended dry-film thickness per coat for prime, intermediate,

and finish coats.

c. Recommended surface preparation.

d. Recommended thinners.

e. Statement verifying that the specified prime coat is recommended by the manufacturer for

use with the specified intermediate and finish coats.

f. Application instructions including recommended equipment and temperature limitations.

g. Curing requirements and instructions.

9. Submit color swatches.

10. Submit certificate identifying the type and gradation of abrasives used for surface preparation.


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11. Submit material safety data sheets for each coating.

PART 2 – MATERIALS

2.01 PAINTING AND COATING SYSTEMS

The following index lists the various painting and coating systems by service and generic type:

PAINT COATINGS SYSTEM INDEX

No. Title Generic Coating

Submerged Metal Coating Systems

1. Submerged Metal, Raw Water (Nonpotable) or Raw

Sewage

Epoxy

7. Submerged Metal, Potable or Nonpotable Water Epoxy

Exposed Metal Coating Systems

10. Exposed Metal, Corrosive Environment High-build epoxy (two-coat

system)

Buried Metal Coating Systems

21. Buried Metal Epoxy

24. Buried Metal Corrosion-resisting grease

Concrete and Masonry Coating Systems

31. Exposed Concrete and Masonry, Corrosive

Environment

Epoxy

33IET Submerged Concrete, Raw Water or Raw Sewage

Polymorphic Resin

PVC, CPVC, and FRP Coating Systems

41. PVC, CPVC, and FRP, Ultraviolet Exposure Polyurethane

Coating Systems for Nonferrous Metals

51. Aluminum Insulation from Concrete and Carbon

Steel

Bituminous


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These systems are specified in detail in the following paragraphs. For each coating, the required

surface preparation, prime coat, intermediate coat (if required), topcoat, and coating thicknesses

are described. Mil thicknesses shown are minimum dry-film thicknesses.

2.02 SUBMERGED METAL COATING SYSTEMS

A. System No. 1--Submerged Metal—Raw Water (Nonpotable) or Raw Sewage:

Type: Epoxy having a minimum volume solids of 80%.

Service Conditions: For use with metal pipes or structures (such as scum troughs, sluice gates, or

piping) alternately submerged in raw sewage or raw water (nonpotable) and exposed to a moist

saturated hydrogen sulfide atmosphere, as in raw sewage wet wells. Minimum temperature

resistance of the coating shall be 140°F for moist heat conditions.

Surface Preparation: SSPC SP-10.

Prime Coat: ICI Devoe Bar-Rust 233H, 8 mils; Tnemec 104-1211, 8 mils; or equal.

Finish Coat: ICI Devoe Bar-Rust 233H, 8 mils; Tnemec 104-ABO5, 8 mils; or equal.

B. System No. 7--Submerged Metal, Potable or Nonpotable Water:

Type: Epoxy.

Service Conditions: For use with structures, valves, piping, or equipment immersed in potable or

nonpotable water.


Coating System: Apply the manufacturer’s recommended number of coats to attain the specified

minimum coating thickness. Products: Devoe Bar-Rust 233H OR Tnemec 100

C. Exposed Metal Coating Systems

a. System No. 10--Exposed Metal, Corrosive Environment:

Type: High-build epoxy intermediate coat having a minimum volume solids of 60%, with an

inorganic zinc prime coat and a pigmented polyurethane finish coat having a minimum volume

solids of 52%.

Service Conditions: For use with metal structures or pipes subjected to water condensation;

chemical fumes, such as hydrogen sulfide; salt spray; and chemical contact.


Prime Coat: Self-curing, two-component inorganic zinc-rich coating recommended by the

manufacturer for overcoating with a high-build epoxy finish coat. Minimum zinc content shall

be 12 pounds per gallon. Apply to a thickness of 3 mils. Products: Tnemec 90-96, Devoe Catha-

Coat 304 or 304V, International Interzinc 180HS, Ameron Dimetcote 9 or 21-9, Engard 519,

Carboline 11 HS, or equal.


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Intermediate Coat: Tnemec 104, ICI Devoe Devran 224 HS, International Interguard 760HS,

Ameron 385, Engard 460 HS, Carboline 888 or 890, or equal; 5 mils.

Finish Coat: Two-component pigmented acrylic or aliphatic polyurethane recommended by the

manufacturer for overcoating a high-build epoxy coating. Apply to a thickness of at least 2 mils.

Products: Tnemec Series 1074, ICI Devoe Devthane 379, International Interline 990HS, Ameron

450 HS, Engard 428 HS, Carboline 134 HG, or equal.

D. Buried Metal Coating Systems

a. System No. 21--Buried Metal:

Type: High solids epoxy or phenolic epoxy having a minimum volume solids of 80% (ASTM D

2697).

Service Conditions: Buried metal, such as valves, flanges, bolts, nuts, structural steel, and

fittings.


Coating System: Apply three or more coats of Ameron 400, Tnemec 104 HS, Engard 480 HS,

ICI Devoe Bar-Rust 233H, Carboline 890LT, or equal; 30 mils total. Maximum thickness of an

individual coating shall not exceed the manufacturer’s recommendation.

b. System No. 24--Buried Metal:

Type: Corrosion-resisting grease.

Service Conditions: Buried metal, such as bolts, bolt threads, tie rods, and nuts.

Surface Preparation: SSPC SP-3 or SP-6.

Coating: NO-OX-ID GG-2 as manufactured by Sanchem, Inc. Apply to a minimum thickness of

1/4 inch.

E. Concrete and Masonry Coating Systems

a. System No. 31--Exposed Concrete and Masonry, Corrosive Environment:

Type: Polyamide cured epoxy having a minimum volume solids of 53%.

Service Conditions: Concrete and masonry exposed to corrosive atmospheres, such as hydrogen

sulfide gas, chlorine gas, or chlorinated effluent sprays in wastewater treatment plants.

Surface Preparation: In accordance with Part 3.D.

Prime Coat: Epoxy filler compound or epoxy masonry filler having a minimum solids volume of

60%. Apply one coat to fill voids, pores, and cracks. Products: Tnemec 54-660, International

Intercryl 320WB, Amerlock 400 BF, ICI Devoe Devran 265 BHF, Sentry 610, or equal.


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Intermediate Coat: One coat of Carboline Bitumastic 300M, Tnemec N69-1211, International

Interguard 760HS, Amerlock 400, ICI Devoe Bar-Rust 233 H, Carboline 890, or equal. Apply to

a minimum dry-film thickness of 6 mils (10 mils for Bitumastic 300M).

Finish Coat: Two coats of Carboline Bitumastic 300M, Tnemec N69, International Interguard

760HS, Amerlock 400, ICI Devoe Bar-Rust 233 H, Carboline 890, or equal. Apply to a

minimum dry-film thickness of 6 mils per coat (10 mils for Bitumastic 300M).

b. System No. 33IET--Submerged Concrete, Raw Sewage or Raw Water:

Type: Rapid curing, non-shrinking, 100% solids, two components, modified Isophthalic

Polyester Resin.

Service Conditions: Concrete submerged in raw water or raw sewage and structures containing

moist hydrogen sulfide such as manholes and sewage pumping station wet wells.

Surface Preparation: In accordance with Part 3.D. and the manufacturer’s instruction on surface

preparation.

Prime Coat: DS-101, manufactured by IET Systems, shall be applied at the rate of 5 to 10 mils

per square foot and properly catalyzed. All cracks, spalls, holes, etc., shall be filled by applying

DS-201 Crack & Spall Repair Grout.

Intermediate Coat: DS-301, manufactured by IET Systems, shall be applied over the gelled DS-

101 and DS-201. Thoroughly mix 1 weight IET SYSTEMS Polymorphic Resin with 2 weights

30 or 60 mesh silica sand, 1 weight silica flour, with thixotropy as needed. Intermediate Coat

shall be applied in successive 30 mils passes to a thickness that if combined with the thickness of

prime coat and finish coat will be equal or greater than the minimum specified coating thickness.

Each successive pass shall be tinted whiter than the preceding pass to assured complete

coverage.

Finish Coats: DS-401, manufactured by IET Systems, shall be applied over the gelled DS-301.

The DS-401 shall consist a minimum thickness of 5 to 10 mils of IET Systems Polymorphic

Resin.

Total minimum applied coating thickness will be 125 mils for new structures and 250 mils for

rehabilitated structures.

F. PVC, CPVC, and FRP Coating System

a. System No. 41--PVC, CPVC, and FRP, Ultraviolet Exposure or Color Coding:

Type: Epoxy primer with a minimum volume solids of 54% and a pigmented polyurethane

enamel having a minimum volume solids of 52%.

Service Conditions: Color coding of PVC or CPVC or FRP exposed to sunlight.

Surface Preparation: SSPC SP-1. Then lightly abrade the surface with medium-grain sandpaper.

Prime Coat: One coat of Tnemec Series N69 Epoxoline, International 7510, Ameron 385, ICI

Devoe Devran 224 HS, Sherwin-Williams Macropoxy 646 B58 series, Carboline 888 or 890,


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PPG PITT-GUARD® Direct-to-Rust Epoxy Mastic Coating 97-145 Series, or equal. Apply to a

minimum dry-film thickness of 4 mils.

Finish Coat: One coat of Tnemec Series 1075, International Interthane 990HS, Ameron 450 HS,

ICI Devoe Devran 379, Carboline 134 HG, Sherwin-Williams Hi-Solids Polyurethane B65-300

series, PPG PITTHANE® Ultra Gloss Urethane Enamel 95-812 Series, or equal. Apply to a

minimum dry-film thickness of 3 mils.

G. Coating Systems for Nonferrous Metals

a. System No. 51--Aluminum Insulation from Concrete and Carbon Steel:

Type: Bituminous paint having a minimum volume solids of 68% coal-tar pitch based.

Service Conditions: Coat areas of aluminum grating, stairs, structural members or aluminum

fabrications, in contact with concrete or carbon steel with this system.

Surface Preparation: Solvent or steam cleaning per SSPC SP-1; do not use alkali cleaning. Then

dust blast.

Prime Coat: Apply synthetic resin or epoxy primer to metal surface before finish coats. Products:

International Intervinux VTA528/529, or equal. No primer required for Carboline or Tnemec.

Finish Coat: Carboline Super Service Black, Tnemec 46-465, International Intertuf 100, or

equal. Apply two coats to a minimum dry-film thickness of 12 mils each.

H. Abrasives for Surface Preparation

a. Abrasives used for preparation of ferrous (excluding stainless steel) surfaces shall be one of the

following:

16 to 30 or 16 to 40 mesh silica sand or mineral grit.

20 to 40 mesh garnet.

Crushed iron slag, 100% retained on No. 80 mesh.

SAE Grade G-40 or G-50 iron or steel grit.

b. Abrasives used for preparation of concrete and masonry surfaces shall be 16 to 30 or 16 to 40

mesh silica sand.

c. In the above gradations, 100% of the material shall pass through the first stated sieve size and

100% shall be retained on the second stated sieve size.

PART 3 – EXECUTION

3.01 WEATHER CONDITIONS

a. Do not paint in the rain, wind, snow, mist, and fog or when steel or metal surface temperatures

are less than 5°F above the dew point.


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b. Do not apply paint when the relative humidity is above 85%. For Systems Nos. 3 and 14, the

relative humidity shall not exceed 95%.

d. Do not paint when temperature of metal to be painted is above 120°F.

e. Do not apply alkyd, inorganic zinc, silicone aluminum, or silicone acrylic paints if air or surface

temperature is below 40°F or expected to be below 40°F within 24 hours.

f. Do not apply epoxy, acrylic latex, and polyurethane paints on an exterior or interior surface if air

or surface temperature is below 60°F or expected to drop below 60°F in 24 hours.

3.02 SURFACE PREPARATION PROCEDURES

a. Remove oil and grease from metal surfaces in accordance with SSPC SP-1. Use clean cloths and

cleaning solvents and wipe dry with clean cloths. Do not leave a film or greasy residue on the

cleaned surfaces before abrasive blasting.

b. Remove weld spatter and weld slag from metal surfaces and grind smoothly rough welds, beads,

peaked corners, and sharp edges including erection lugs in accordance with SSPC SP-2 and

SSPC SP-3. Grind 0.020 inch (minimum) off the weld caps on pipe weld seams. Grind outside

sharp corners, such as the outside edges of flanges, to a minimum radius of 1/4 inch.

c. Do not abrasive blast or prepare more surface area in one day than can be coated in one day;

prepare surfaces and apply coatings the same day. Remove sharp edges, burrs, and weld spatter.

d. Do not abrasive blast epoxy- or enamel-coated pipe that has already been factory coated, except

to repair scratched or damaged coatings.

e. For carbon steel, do not touch the surface between the time of abrasive blasting and the time the

coating is applied. Apply coatings within two hours of blasting or before any rust bloom forms.

f. Surface preparation shall conform with the SSPC specifications as follows:

Solvent Cleaning SP-1

Hand Tool Cleaning SP-2

Power Tool Cleaning SP-3

White Metal Blast Cleaning SP-5

Commercial Blast Cleaning SP-6

Brush-Off Blast Cleaning SP-7

Pickling SP-8

Near-White Blast Cleaning SP-10

Power Tool Cleaning to Bare Metal SP-11

Surface Preparation and Cleaning of Steel and Other Hard

Materials by High- and Ultrahigh-Pressure Water Jetting

Prior to Recoating

SP-12

Surface Preparation of Concrete SP-13


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g. Wherever the words “solvent cleaning,” “hand tool cleaning,” “wire brushing,” or “blast

cleaning” or similar words are used in these specifications or in paint manufacturer’s

specifications, they shall be understood to refer to the applicable SSPC (Steel Structure Painting

Council), surface preparation specifications listed above.

h. Brush-off blasting of concrete and masonry surfaces is defined as opening subsurface holes and

voids and etching the surface for a coating to bond.

i. For carbon steel surfaces, after abrasive blast cleaning, the height of the surface profile shall be 2

to 3 mils. If this cannot be achieved with the surface preparation named in the painting system,

SSPC SP-5 may be required. Verify the surface profile by measuring with an impresser tape

acceptable to the Owner’s Representative. Perform a minimum of one test per 100 square feet of

surface area. Testing shall be witnessed by the Owner’s Representative. The impresser tape used

in the test shall be permanently marked with the date, time, and locations where the test was

made. Test results shall be promptly presented to the Owner’s Representative.

j. Do not apply any part of a coating system before the Owner’s Representative has reviewed the

surface preparation. If coating has been applied without this review, if directed by the Owner’s

Representative, remove the applied coating by abrasive blasting and reapply the coat in

accordance with this specification.

3.03 ABRASIVE BLAST CLEANING

a. Use dry abrasive blast cleaning for metal surfaces. Do not use abrasives in automatic equipment

that have become contaminated. When shop or field blast cleaning with handheld nozzles, do not

recycle or reuse blast particles.

b. After blast cleaning and prior to application of coating, dry clean surfaces to be coated by

dusting, sweeping, and vacuuming to remove residue from blasting. Apply the specified primer

or touch-up coating within the period of an eight-hour working day. Do not apply coating over

damp or moist surfaces. Reclean prior to application of primer or touch-up coating any blast

cleaned surface not coated within said eight-hour period.

c. Keep the area of the work in a clean condition and do not permit blasting particles to accumulate

and constitute a nuisance or hazard.

d. During sandblast cleaning, prevent damage to adjacent coatings. Schedule blast cleaning and

coating such that dust, dirt, blast particles, old coatings, rust, mill scale, etc., will not damage or

fall upon wet or newly coated surfaces.

3.04 PREPARATION OF CONCRETE AND MASONRY SURFACES TO BE COATED

a. Surface preparation of concrete and masonry surfaces shall be in accordance with SSPC SP-13

and the following.

b. Do not apply coating until concrete has cured at least 30 days. Finish concrete surfaces per

Section 030500. Do not use curing compound on surfaces that are to be coated.

c. Concrete and masonry surfaces on which coatings are to be applied shall be of even color, gray

or gray-white. The surface shall have no pits, pockets, holes, or sharp changes of surface

elevation. Scrubbing with a stiff-bristle fiber brush shall produce no dusting or dislodging of


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cement or sand. Sprinkling water on the surface shall produce no water beads or standing

droplets. Concrete and masonry shall be free of laitance and slick surfaces.

d. Detergent clean the concrete or masonry surface with trisodium phosphate per ASTM D 4258.

Then sandblast surfaces (brush-off blast). Floor slabs may be acid etched per ASTM D 4260 in

lieu of sandblasting. After sandblasting, wash surfaces with water to remove dust and salts, per

ASTM D 4258 or D 4261. The grain of the concrete surface to touch shall not be rougher than

that of No. 10 mesh sand.

e. Prior to coating concrete, plaster, and masonry with System No. 31, 33, or 34, determine the

presence of capillary moisture per ASTM D 4263, except as modified below. Tape a 4-foot by 4-

foot sheet of polyethylene plastic to the concrete surface to be coated. Allow the plastic sheet to

remain in place at least 24 hours. After the specified time has elapsed, remove the plastic sheet

and visually examine both the underside of the plastic sheet and the concrete surface beneath it.

There shall be no indication of moisture on either surface. If moisture is indicated, allow

additional curing time for the concrete and then retest. Provide one test sheet for every 500

square feet of concrete surface to be coated. For walls, provide one test sheet for each 10 feet (or

fraction thereof) of vertical rise in all elevations starting within 12 inches of the floor or base

slab.

f. Acceptance criteria for concrete surfaces shall be in accordance with SSPC SP-13, Table 1,

“Severe Service.”

g. Do not apply coatings to concrete when the concrete is outgassing. Apply coatings only when

the concrete surface temperature is stable, not rising.

3.05 PROCEDURES FOR ITEMS HAVING SHOP-APPLIED PRIME COATS

a. After application of primer to surfaces, allow coating to cure for a minimum of two hours before

handling to minimize damage.

b. When loading for shipment to the project site, use spacers and other protective devices to separate

items to prevent damaging the shop-primed surfaces during transit and unloading. If wood spacers

are used, remove wood splinters and particles from the shop-primed surfaces after separation. Use

padded chains or ribbon binders to secure the loaded items and minimize damage to the shop-primed

surfaces.

1. Cover shop-primed items 100% with protective coverings or tarpaulins to prevent deposition

of road salts, fuel residue, and other contaminants in transit.

2. Handle shop-primed items with care during unloading, installation, and erection operations

to minimize damage. Do not place or store shop-primed items on the ground or on top of

other work unless ground or work is covered with a protective covering or tarpaulin. Place

shop-primed items above the ground upon platforms, skids, or other supports.

c. Field Touch-Up of Shop-Applied Prime Coats

1. Remove oil and grease surface contaminants on metal surfaces in accordance with SSPC SP-

1. Use clean rags wetted with a degreasing solution, rinse with clean water, and wipe dry.

2. Remove dust, dirt, salts, moisture, chalking primers, or other surface contaminants that will

affect the adhesion or durability of the coating system. Use a high-pressure water blaster or


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scrub surfaces with a broom or brush wetted with a solution of trisodium phosphate,

detergent, and water. Before applying intermediate or finish coats to inorganic zinc primers,

remove any soluble zinc salts that have formed by means of scrubbing with a stiff bristle

brush. Rinse scrubbed surfaces with clean water.

3. Remove loose or peeling primer and other surface contaminants not easily removed by the

previous cleaning methods in accordance with SSPC SP-7. Take care that remaining primers

are not damaged by the blast cleaning operation. Remaining primers shall be firmly bonded

to the steel surfaces with blast cleaned edges feathered.

4. Remove rust, scaling, or primer damaged by welding or during shipment, storage, and

erection in accordance with SSPC SP-10. Take care that remaining primers are not damaged

by the blast cleaning operation. Areas smaller than 1 square inch may be prepared per SSPC

SP-11. Remaining primers shall be firmly bonded to the steel surfaces with cleaned edges

feathered.

5. Use repair procedures on damaged primer that protects adjacent primer. Blast cleaning may

require the use of lower air pressure, smaller nozzles, and abrasive particle sizes, short blast

nozzle distance from surface, shielding, and/or masking.

6. After abrasive blast cleaning of damaged and defective areas, remove dust, blast particles,

and other debris by dusting, sweeping, and vacuuming; then apply the specified touch-up

coating.

7. Surfaces that are shop primed with inorganic zinc primers shall receive a field touch-up of

organic zinc primer per System No. 18 to cover scratches or abraded areas.

8. Surfaces that are shop primed shall receive a field touch-up of the same primer used in the

original prime coat.

d. Painting Systems

1. All materials of a specified painting system, including primer, intermediate, and finish coats,

shall be produced by the same manufacturer. Thinners, cleaners, driers, and other additives

shall be as recommended by the paint manufacturer for the particular coating system.

2. Deliver paints to the jobsite in the original, unopened containers.

e. Paint Storage and Mixing

1. Store and mix materials only in areas designated for that purpose by the Owner’s

Representative. The area shall be well-ventilated, with precautionary measures taken to

prevent fire hazards. Post “No Smoking” signs. Storage and mixing areas shall be clean and

free of rags, waste, and scrapings. Tightly close containers after each use. Store paint at an

ambient temperature from 50°F to 100°F.

2. Prepare multiple-component coatings using all of the contents of the container for each

component as packaged by the paint manufacturer. Do not use partial batches. Do not use

multiple-component coatings that have been mixed beyond their pot life. Provide small quantity kits for touch-up painting and for painting other small areas. Mix only the

components specified and furnished by the paint manufacturer. Do not intermix additional

components for reasons of color or otherwise, even within the same generic type of coating.


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f. Procedures for the Application of Coatings

1. Conform to the requirements of SSPC PA-1. Follow the recommendations of the coating

manufacturer including the selection of spray equipment, brushes, rollers, cleaners, thinners,

mixing, drying time, temperature and humidity of application, and safety precautions.

2. Stir, strain, and keep coating materials at a uniform consistency during application. Power

mix components. For multiple component materials, premix each component before

combining. Apply each coating evenly, free of brush marks, sags, runs, and other evidence

of poor workmanship. Use a different shade or tint on succeeding coating applications to

indicate coverage where possible. Finished surfaces shall be free from defects or blemishes.

3. Do not use thinners unless recommended by the coating manufacturer. If thinning is

allowed, do not exceed the maximum allowable amount of thinner per gallon of coating

material. Stir coating materials at all times when adding thinner. Do not flood the coating

material surface with thinner prior to mixing. Do not reduce coating materials more than is

absolutely necessary to obtain the proper application characteristics and to obtain the

specified dry-film thicknesses.

4. Remove dust, blast particles, and other debris from blast cleaned surfaces by dusting,

sweeping, and vacuuming. Allow ventilator fans to clean airborne dust to provide good

visibility of working area prior to coating applications. Remove dust from coated surfaces by

dusting, sweeping, and vacuuming prior to applying succeeding coats.

5. Apply coating systems to the specified minimum dry-film thicknesses as measured from

above the peaks of the surface profile.

6. Apply primer immediately after blast cleaning and before any surface rusting occurs, or any

dust, dirt, or any foreign matter has accumulated. Reclean surfaces by blast cleaning that

have surface colored or become moist prior to coating application.

7. Apply a brush coat of primer on welds, sharp edges, nuts, bolts, and irregular surfaces prior

to the application of the primer and finish coat. Apply the brush coat prior to and in

conjunction with the spray coat application. Apply the spray coat over the brush coat.

8. Before applying subsequent coats, allow the primer and intermediate coats to dry for the

minimum curing time recommended by the manufacturer. In no case shall the time between

coats exceed the manufacturer’s recommendation.

9. Application procedures for System No.33EIT shall follow manufacturer’s instructions.

10. Each coat shall cover the surface of the preceding coat completely, and there shall be a

visually perceptible difference in applied shade or tint of colors.

11. Applied coating systems shall be cured at 75°F or higher for 48 hours. If temperature is

lower than 75°F, curing time shall be in accordance with printed recommendations of the

manufacturer, unless otherwise allowed by the Owner’s Representative.

12. Assembled parts shall be disassembled sufficiently before painting or coating to ensure

complete coverage by the required coating.


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3.06 SURFACES NOT TO BE COATED

a. Do not paint the following surfaces unless otherwise noted in the drawings or in other specification

sections. Protect during the painting of adjacent areas:

Concrete walkways.

Mortar-coated pipe and fittings.

Metal letters.

Glass.

Roofings.

Fencing.

Electrical fixtures except for factory coatings.

Nameplates.

Grease fittings.

Brass and copper, submerged.

Buried pipe, unless specifically required in the piping specifications.

Fiberglass items, unless specifically required in the FRP specifications.

Aluminum handrail, stairs, and grating.

Insulated pipe.

b. Protection of Surfaces Not To Be Painted

Remove, mask, or otherwise protect hardware, lighting fixtures, switchplates, aluminum surfaces,

machined surfaces, couplings, shafts, bearings, nameplates on machinery, and other surfaces not

intended to be painted. Provide drop cloths to prevent paint materials from falling on or marring

adjacent surfaces. Protect working parts of mechanical and electrical equipment from damage during

surface preparation and painting process. Mask openings in motors to prevent paint and other

materials from entering the motors.

c. Surfaces To Be Coated

The exact coating to be applied in any location is not designated by the descriptive phrases in the

coating system titles such as “corrosive environment,” “buried metal,” or “submerged metal.” Coat

surfaces with the specific coating systems as described below:

Coat mechanical equipment, such as pumps, as described in the various mechanical equipment

specifications. Color of finish coat shall match the color of the connecting piping.


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Coat aboveground and exposed piping or piping in vaults and structures as described on the

drawings and in the various piping specifications.

Coat submerged steel and ductile iron piping in wet wells per System No.1.

Coat valves as described in the various valve specifications the same as the adjacent piping.

Aboveground valves, or valves in vaults and structures, shall match the color of the connecting

piping.

Coat concrete surfaces where shown in the drawings.

Coat masonry surfaces where shown in the drawings.

Coat aluminum surfaces in contact with concrete per System No. 51.

Coat buried flanges, nuts and bolts, valves, flexible pipe couplings, exposed rebar in thrust blocks,

and valve boxes as specified in the particular specifications for the above items.

Coat aboveground structural steel or structural steel located in vaults and structures as described in

Section 05121.

Coating Schedule:

Surface or Item

Coating

System No.

Pumps (exposed components) 10

Pumps (submerged components) 1

Exposed ferrous piping 10

Submerged ferrous piping 1

Exposed ferrous valves 10

Buried valves 21

Submerged valves 1

Standard Concrete Manholes - Exterior surfaces 31

Standard Concrete Manholes - Interior surfaces 31

Concrete Manhole Adjacent to Wet Well - Exterior surfaces 31

Concrete Manhole Adjacent to Wet Well - Interior surfaces 33IET

Concrete Wet Well - Interior surfaces 33IET

Concrete Valve Vault - Interior surfaces 33IET

Aluminum in Contact with Concrete 51


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d. Dry-Film Thickness Testing

1. Measure coating thickness specified for metal surfaces with a magnetic-type dry-film

thickness gauge. Provide certification that the gauge has been calibrated by a certified

laboratory within the past six months. Provide dry-film thickness gauge as manufactured by

Mikrotest or Elcometer.

2. Test the finish coat of metal surfaces (except zinc primer and galvanizing) for holidays and

discontinuities with an electrical holiday detector, low-voltage, wet-sponge type. Provide

measuring equipment. Provide certification that the gauge has been calibrated by a certified

laboratory within the past six months. Provide detector as manufactured by Tinker and

Rasor or K-D Bird Dog.

3. Measure coating thickness specified for concrete or masonry surfaces in accordance with

ASTM D 4138. Test the finish coat of concrete and masonry surfaces in accordance with

NACE RP-0188-90 or ASTM D 4787. Patch coatings at the points of thickness

measurement or holiday detection.

4. Check each coat for the correct dry-film thickness. Do not measure within eight hours after

application of the coating.

5. For metal surfaces, make five separate spot measurements (average of three readings)

spaced evenly over each 100 square feet of area (or fraction thereof) to be measured. Make

three readings for each spot measurement of either the substrate or the paint. Move the probe

or detector a distance of 1 to 3 inches for each new gauge reading. Discard any unusually

high or low reading that cannot be repeated consistently. Take the average (mean) of the

three readings as the spot measurement. The average of five spot measurements for each

such 100 square foot area shall not be less than the specified thickness. No single spot

measurement in any 100 square foot area shall be less than 80%, nor more than 120%, of the

specified thickness. One of three readings which are averaged to produce each spot

measurement may underrun by a greater amount.

6. For concrete surfaces, make five separate spot measurements spaced evenly over each 100

square feet of area (or fraction thereof) to be measured. The average of five spot

measurements for each such 100-square-foot area shall not be less than the specified

thickness. No single spot measurement in any 100-square-foot area shall be less than 80%,

nor more than 120%, of the specified thickness.

7. Perform tests in the presence of the Owner’s Representative.

e. Repair of Improperly Coated Surfaces

If the item has an improper finish color or insufficient film thickness, clean and topcoat the surface

with the specified paint material to obtain the specified color and coverage. Sandblast or power-sand

visible areas of chipped, peeled, or abraded paint, feathering the edges. Then prime and finish coat in

accordance with the specifications. Work shall be free of runs, bridges, shiners, laps, or other

imperfections.

f. Cleaning

1. During the progress of the work, remove discarded materials, rubbish, cans, and rags at the

end of each day’s work.


AECOM 60096414

2. Thoroughly clean brushes and other application equipment at the end of each period of use

and when changing to another paint or color.

3. Upon completion of painting work, remove masking tape, tarps, and other protective

materials, using care not to damage finished surfaces.

END OF SECTION

IWSD 12/2009 09910-1 IET Coating System

AECOM 60096414

SECTION 09910

IET COATING SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. This specification covers all labor, materials, equipment and services necessary to install the

IET Coating System as herein specified on existing concrete manholes and wetwells and new

precast concrete manholes and wetwells as indicated on the plans.

B. Related sections:

1. Section 01300 – Submittals

1.02 REFERENCES

A. SSPC SP-13/Nace No. 6 – Surface Preparation of Concrete

B. ASTM – The published standards of the American Society for Testing and Materials, West

Conshohocken, PA.

C. NACE – The published standards of National Association of Corrosion Engineers (NACE

International) Houston, TX.

D. SSPC – The published standards of the Society of Protective Coatings, Pittsburgh, PA.

1.03 SUBMITTALS

A. Product Data

1. Technical data sheet on each product used.

2. Material Safety Data Sheet (MSDS) for each product used.

3. Copies of independent testing performed on the coating product indicating the product meets the

requirements as specified herein.

4. Technical data sheet and project specific data for repair materials to be topcoated with the

coating product(s) including application, cure time and surface preparation procedures.

B. Contractor Data:

1. Current documentation from coating product manufacturer certifying contractor’s training and

equipment complies with the Quality assurance requirements specified herein.


AECOM 60096414

2. Five (5) recent references of Contractor indicating successful application of coating product(s)

of the same material type as specified herein, applied by spray application within the municipal

wastewater environment.

1.04 QUALITY ASSURANCE

A. Coating product(s) shall be capable of being installed and curing properly within a manhole

environment. Coating product(s) shall be resistant to all forms of chemical or bacteriological attack

found in municipal sanitary sewer systems; capable of adhering to the manhole structure substrates.

B. Repair product(s) shall be fully compatible with coating product(s) including ability to bond

effectively forming a composite system.

C. Contractor shall utilize equipment for the spray application of the coating product(s) which have

been approved by the coating product manufacturer; and, Contractor shall have received training on

the operation and maintenance of said equipment from the coating product manufacturer.

D. Contractor shall be certified by the coating product manufacturer for the handling, mixing,

application and inspection of the coating product(s) to be used as specified herein.

E. Inspectors shall be trained in the use of testing or inspection instrumentation and knowledgeable of

the proper use, preparation and installation of coating product(s) to be used as specified herein.

F. Contractor shall initiate and enforce quality control procedures consistent with the coating

product(s) manufacturer recommendations and applicable NACE or SSPC standards as referenced

herein.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Materials are to be kept dry, protected from weather and stored under cover.

B. Protective coating materials are to be stored between 50° F and 90° F. Do not store near flame, heat

or strong oxidants.

C. Protective coating materials are to be handled according to their material safety data sheets.

1.06 SITE CONDITIONS

A. Contractor shall conform with all local, state and federal regulations including those set forth by

OSHA, RCRA, and the EPA and any other applicable authorities.

B. Confined space entry, flow diversion and/or bypass plans shall be presented by Contractor as

necessary to perform the specified work.

1.07 SPECIAL WARRANTY

A. Contractor shall warrant all work against defects in materials and workmanship for a period of ten

(10) years, unless otherwise noted, from the date of final acceptance of the project. Contractor shall,

within a reasonable time after receipt of written notice thereof, repair defects in materials or


AECOM 60096414

workmanship which may develop during said ten (10) year period, and any damage to other work caused by such defects or the repairing of same, at his own expense and without cost to the owner.

PART 2 PRODUCTS

2.01 EXISTING PRODUCTS

A. Standard Portland cement or new concrete (not quick setting high strength cement) must be cured a

minimum of 28 days prior to application of the coating product(s).

B. Remove existing coatings prior to application of the coating product(s) which may affect the

performance and adhesion of the coating product(s).

C. Thoroughly clean and prepare existing products to effect a seal with the coating product(s).

2.02 REPAIR AND RESURFACING PRODUCTS

A. Repair products shall be used to fill voids, bugholes, and/or smooth transitions between components

prior to the installation of the coating product(s). Repair materials must be compatible with the

specified coating product(s) and shall be used and applied in accordance with the manufacturer’s

recommendations.

B. Resurfacing products shall be used to fill large voids, lost mortar in masonry structures, smooth

deteriorated surfaces and rebuild severely deteriorated structures.

C. The following products may be accepted and approved as compatible repair and resurfacing

products for use within the specifications:

1. 100% solids, solvent-free epoxy grout specifically formulated for polyester resin topcoating

compatibility.

2. Factory blended, repair setting, high early strength, fiber reinforced, non-shrink repair mortar

that can be trowelled or pneumatically spray applied may be approved if specifically formulated

to be suitable for topcoating with the specified coating product(s).

2.03 COATING PRODUCTS

A. Manufacturer: Integrated Environmental Technologies, Santa Barbara, California (805) 969-2292.

B. Product: IET – 100% solids, two component, highly modified polyester resin system, exhibiting the

following characteristics:

1. Product Type: polymorphic resin

2. No adhesion-interfering shrinkage upon curing.

3. Compressive Strength, psi (ASTM D695): 15,000 (minimum)


AECOM 60096414

4. Tensile Strength, psi (ASTM D638): 4,900 (minimum)

5. Flexural Modulus, psi (ASTM D790): 8,600 (minimum)

6. Impact Resistance (Specimen with Knotch): 10.0 Inch-Pounds

7. Impact Resistance (Specimen without Knotch): 4.5 Inch-Pounds

8. Barcol Hardness (Impressor #L25): 72 (minimum)

9. Adhesive Strength, psi: 1582

10. Chemical Resistance all types of service for:

a. Municipal sanitary sewer environment

b. Sulfuric acid, 25%

c. Hydrogen Sulfide Gas, All concentrations

d. Sodium hydroxide, 5%

2.04 COATING APPLICATION EQUIPMENT

A. IET Systems Spray Unit and IET Systems Spincaster spray equipment shall be utilized to create a

monolithic, seamless lining.

B. Hard to reach areas, primer application and touch-up may be performed using hand tools.

PART 3 EXECUTION

3.01 EXAMINATION

A. Appropriate actions shall be taken by contractor to comply with local, state and federal regulatory

and other applicable agencies with regard to environment, health and safety during work.

B. All structures to be coated shall be readily accessible to Contractor.

C. New Portland cement concrete structures shall have endured a minimum of 28 days since

manufacture prior to commencing coating installation.

D. Any active flows shall be dammed, plugged or diverted as required to ensure all liquids are

maintained below or away from the surfaces to be coated.

E. Temperature of the surface to be coated should be maintained between 40° F and 120° F.

F. Specified surfaces should be shielded to avoid exposure of direct sunlight or other intense heat

source. Where varying surface temperature does exist, coating installation should be scheduled

when the temperature is falling versus rising.


AECOM 60096414

G. Prior to commencing surface preparation, Contractor shall inspect all surfaces specified to receive

the coating and notify Owner, in writing, of any noticeable disparity in the site, structure or surfaces

which may interfere with the work, use of materials or procedures as specified herein.

3.02 SURFACE PREPARATION

A. Oils, grease, incompatible existing coatings, waxes, form release, curing compounds, efflorescence,

sealers, salts, or other contaminants which may affect the performance and adhesion of the coating

to the substrate shall be removed.

B. Concrete and/or mortar damaged by corrosion, chemical attack or other means of degradation shall

be removed so that the only sound substrate remains.

C. Choice of surface preparation method(s) should be based upon the condition of the structure and

concrete or masonry surface, potential contaminants present, access to perform work, and required

cleanliness and profile of the prepared surface to receive the coating product(s).

D. Surface preparation method, or combination of methods, that may be used include high pressure

water cleaning, high pressure water jetting, abrasive blasting, shotblasting, grinding, scarifying,

detergent water cleaning, hot water blasting and others described in NACE no. 6/SSPC SP-13.

Whichever method(s) are used, they shall be performed in a manner that provides a uniform, sound

clean neutralized surface suitable for topcoating with the coating product(s).

E. Infiltration shall be stopped by using a material which is compatible with the repair products and is

suitable for topcoating with the coating product(s).

F. Termination points of the coating product(s) shall be made at the bottom of the manhole frame, and

a minimum of 1” interfacing with each pipe penetration. The manhole frame and casting shall not

be coated.

3.03 APPLICATION OF REPAIR AND RESURFACING PRODUCTS

A. Areas where rebar has been exposed and is corroded shall be first prepared in accordance with

Section 3.2. The exposed rebar shall then be abrasive blasted and coated with coating product

specified.

B. Repair products shall be used to fill voids, bugholes, and other surface defects which may affect the

performance or adhesion of the coating product(s).

C. Resurfacing products shall be used to repair, smooth or rebuild surfaces with rough profiles to

provide a concrete or masonry substrate suitable for the coating product(s) to be applied. These

products shall be installed to minimum thickness as recommended within manufacturers published

guidelines.

D. Repair and resurfacing products shall be handled, mixed, installed and cured in accordance with

manufacturer guidelines.

E. All repaired or resurfaces shall be inspected for cleanliness and suitability to receive the coating

product(s). Additional surface preparation may be required prior to coating application.


AECOM 60096414

3.04 APPLICATION OF COATING PRODUCT(S)

A. Application procedures shall conform to the recommendations of the coating product(s)

manufacturer, including environmental controls, product handling, mixing, application equipment

and methods.

B. Spray equipment shall be specifically designed to accurately ratio and apply the coating product(s)

and shall be in proper working order.

C. Contractors qualified in accordance with Section 1.04 of these specifications shall perform all

aspects of coating product(s) installation.

D. Prepared surfaces shall be coated by spray application of the coating product(s) described herein to

a minimum dry film thickness of 175 mils.

E. Subsequent topcoating or additional coats of the coating product(s) shall occur within the products

recoat window. Additional surface preparation procedures will be required if this recoat window is

exceeded.

F. Coating product(s) shall interface with adjoining construction materials throughout the manhole

structure to effectively seal and protect concrete or masonry substrates from infiltration and attack

by corrosive elements. Procedures and materials necessary to effect this interface shall be as

recommended by the coating product(s) manufacturer.

G. Termination points of the coating product(s) shall be made at the bottom of the manhole frame, and

a minimum of 1” interfacing with each pipe penetration. The manhole frame and casting shall not

be coated.

H. Manhole inverts shall be coated.

I. Sewage flow shall be stopped, bypassed or diverted for application of the coating product(s) to the

invert and interface with pipe material.

3.05 TESTING AND INSPECTION

A. During application a wet film thickness gauge, meeting ASTM D4414-Standard Practice for

Measurement of Wet Film Thickness of Organic Coatings by Notched Gages, shall be used.

Measurements shall be taken, documented and attested to by Contractor for submission to Owner.

B. After the coating product(s) have set in accordance with manufacturer instructions, all surfaces shall

be inspected for holidays with high voltage holiday detection equipment. Reference NACE RPO

188-99 for performing holiday detection. All detected holidays shall be marked and repaired by

abrading the coating surface with grit disk paper or other hand tooling method. After abrading and

cleaning, additional coating can be hand applied to the repair area. All touch-up/repair procedures

shall follow the coating manufacturer’s recommendations. Documentation on areas tested, results

and repairs made shall be provided to Owner by Contractor.


AECOM 60096414

C. Visual inspection shall be made by the project Engineer and/or Inspector. Any deficiencies in the

finished coating shall be marked and repaired according to the procedures set forth herein by

contractor.

D. The municipal sewer system may be returned to full operational service as soon as the final

inspection has taken place.

END OF SECTION

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