FORCE MAIN EXTENSION DIVISION 9 FINISHES - D.N. Higginsdnhiggins.com/docs/Div9 Forcemain...

FORCE MAIN EXTENSION

DIVISION 9

FINISHES

IWSD 01/2011 09900-1 Painting and Coating

AECOM REBID

SECTION 09900

PAINTING AND COATING

PART 1 – GENERAL

1.01 DESCRIPTION

A. 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.

B. It does not include coating steel water tanks and reservoirs.

1.02 SUBMITTALS

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

following.

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

1. Percent solids by volume.

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

intermediate, and finish coats.

3. Recommended surface preparation.

4. Recommended thinners.

5. Statement verifying that the specified prime coat is recommended by the

manufacturer for use with the specified intermediate and finish coats.

6. Application instructions including recommended equipment and temperature

limitations.

7. Curing requirements and instructions.

C. Submit color swatches.


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

preparation.

E. 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

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,


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Devoe Catha-Coat 304 or 304V, International Interzinc 180HS, Ameron Dimetcote 9 or

21-9, Engard 519, Carboline 11 HS, or equal.

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

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.

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

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-


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660, International Intercryl 320WB, Amerlock 400 BF, ICI Devoe Devran 265 BHF,

Sentry 610, or equal.

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).

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

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.


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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, 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

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

1. Abrasives used for preparation of ferrous (excluding stainless steel) surfaces shall

be one of the following:

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

b. 20 to 40 mesh garnet.

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

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

2. Abrasives used for preparation of concrete and masonry surfaces shall be 16 to 30

or 16 to 40 mesh silica sand.

3. 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.


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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.

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%.

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

D. 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.

E. 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:


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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

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


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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 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.

IWSD 01/2011 09900-10 Painting and

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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 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.


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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. 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.

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


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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.

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.


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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.

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.


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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

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.


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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.

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 01/2011 09910-1 Manhole Lining System

AECOM REBID

SECTION 09910

MANHOLE LINING SYSTEM

PART 1 GENERAL

1.01 Summary

A. This specification covers labor, materials, equipment and services to install a manhole

lining system 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:


AECOM REBID

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

training and equipment complies with the Quality assurance requirements specified

herein.

2. Five (5) recent references of coating 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 compatible with coating product(s) including ability to bond to

form a composite system.

C. Utilize equipment for the spray application of the coating product(s) which has been

approved by the coating product manufacturer; and the equipment operator has received

training on the operation and maintenance of said equipment from the coating product

manufacturer.

D. Application 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. Provide 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. Conform to local, state and federal regulations including those set forth by OSHA, RCRA,

and the EPA and other applicable authorities.

B. Provide plans to Engineer for review for confined space entry, flow diversion and/or bypass

plans prior to performing the Work.


AECOM REBID

1.07 Special Warranty

A. Warrant 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. Repair or replace,

within a reasonable time after receipt of written notice, defects in materials or 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 no expense 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 toweled or pneumatically spray applied may be acceptable if

specifically formulated to be suitable for topcoating with the specified coating

product(s).

2.03 Coating Products

A. Manufacturers: Integrated Environmental Technologies, Santa Barbara, California (805)

969-2292 or Raven Lining System, Tulsa, Oklahoma (800) 324-2810.

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

Raven 405 System, a 100% solid ultra high build epoxy coating, meeting the following

minimum characteristics:


AECOM REBID

1. No adhesion-interfering shrinkage upon curing.

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

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

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

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

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

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

8. Adhesive Strength, psi: 1582

9. 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. Spray equipment shall be specifically designed to accurately ratio and apply the coating

products and shall be in good working order 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. Comply with local, state and federal regulatory and other applicable agencies with regard to

environment, health and safety during work.

B. Structures to be coated shall be readily accessible.

C. New Portland cement concrete structures shall have cured 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.


AECOM REBID

F. Shield surfaces to be coated to avoid exposure of direct sunlight or other intense heat

source. Where varying surface temperature does exist, schedule coating installation when

the temperature is falling versus rising.

G. Prior to commencing surface preparation, inspect surfaces 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.

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) shall 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 to 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 3.02. 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.


AECOM REBID

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

with manufacturer guidelines.

E. 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.

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 wet film thickness of 200 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 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. Take measurements, document and attest to results and submit to Engineer.

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

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

NACE RPO 188-99 for performing holiday detection. Detected holidays shall be marked


AECOM REBID

and repaired by abrading the coating surface with grit disk paper or other hand tooling

method. After abrading and cleaning, additional coating shall be hand applied to the repair

area. Touch-up/repair procedures shall follow the coating manufacturer’s recommendations.

Documentation on areas tested, results and repairs made shall be provided to the Engineer.

C. Visual inspection shall be made by the Engineer and/or Inspector. Deficiencies in the

finished coating shall be marked and repaired according to the specified procedures.

D. Return the sewer system to full operation after final inspection and acceptance of the Work.

END OF SECTION

IWSD 01/2011 09961-1 Fusion-Bonded Epoxy Linings And Coatings

AECOM REBID

SECTION 09961

FUSION-BONDED EPOXY LININGS AND COATINGS

PART 1 - GENERAL

1.01 Description

This section includes materials, application, and testing of one-part, fusion-bonded, heat-cured,

thermosetting, 100% solids epoxy linings and coatings on steel, cast-iron, and ductile-iron

equipment, such as valves, flexible pipe couplings, and structural steel.

1.02 Submittals

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

following.

B. Submit manufacturer's catalog literature and product data sheets, describing the physical

and chemical properties of the epoxy coating. Describe application and curing procedure.

C. Submit coating application test records for measuring coating thickness and holiday

detection for each item or pipe section and fitting. Describe repair procedures used.

PART 2 - MATERIALS

2.01 Piping and Equipment Surfaces

A. Require equipment suppliers to provide equipment that is free of salts, oil, and grease to

the coating applicator.

B. Require pipe suppliers to provide bare pipe that is free of salts, oil, and grease to the

coating applicator.

2.02 Shop-Applied Epoxy Lining and Coating

Lining and coating shall be a 100% solids, thermosetting, fusion-bonded, dry powder epoxy

resin: Scotchkote 134 or 206N, Lilly Powder Coatings "Pipeclad 1500 Red," H. B. Fuller 1F-

3003, or equivalent. Epoxy lining and coating shall meet or exceed the following requirements:


AECOM REBID

Hardness (minimum) Barcol 17 (ASTM D2583)

Rockwell 50 ("M" scale)

Abrasion resistance (maximum

value)

1,000 cycles: 0.05 gram removed

5,000 cycles: 0.115 gram removed

ASTM D1044, Tabor CS 17 wheel, 1,000-gram weight

Adhesion (minimum) 3,000 psi (Elcometer)

Tensile strength 7,300 psi (ASTM D2370)

Penetration 0 mil (ASTM G17)

Adhesion overlap shear, 1/8-

inch steel panel, 0.010 glue line

4,300 psi, ASTM D1002

Impact (minimum value) 100 inch-pounds (Gardner 5/8-inch diameter tup)

2.03 Field-Applied Epoxy Coating for Patching

Use a two-component, 80% solids liquid resin, such as Scotchkote 306.

2.04 Painting and Coating of Grooved-End and Flexible Pipe Couplings

Line and coat couplings the same as the pipe. Color shall match the color of the pipe fusion epoxy

coating.

PART 3 - EXECUTION

3.01 Shop Application of Fusion-Bonded Epoxy Lining and Coating--General

A. Grind surface irregularities, welds, and weld spatter smooth before applying the epoxy.

The allowable grind area shall not exceed 0.25 square foot per location, and the maximum

total grind area shall not exceed 1 square foot per item or piece of equipment. Do not use

any item, pipe, or piece of equipment in which these requirements cannot be met.

B. Remove surface imperfections, such as slivers, scales, burrs, weld spatter, and gouges.

Grind outside sharp corners, such as the outside edges of flanges, to a minimum radius of

1/4 inch.

C. Uniformly preheat the pipe, item, or piece of equipment prior to blast cleaning to remove

moisture from the surface. The preheat shall be sufficient to ensure that the surface

temperature is at least 5°F above the dew point temperature during blast cleaning and

inspection.

D. Sandblast surfaces per SSPC SP-5. Protect beveled pipe ends from the abrasive blast

cleaning.

E. Apply lining and coating by the electrostatic spray or fluidized bed process. Minimum

thickness of lining or coating shall be 15 mils. Heat and cure per the epoxy manufacturer's

recommendations. The heat source shall not leave a residue or contaminant on the metal

surface. Do not allow oxidation of surfaces to occur prior to coating. Do not permit

surfaces to flash rust before coating.


AECOM REBID

3.02 Shop Application of Fusion-Bonded Epoxy Lining and Coating to Pipe--Additional Requirements

A. Apply lining and coating per AWWA C213 except as modified herein.

B. Grind 0.020 inch (minimum) off the weld caps on the pipe weld seams before beginning

the surface preparation and heating of the pipe.

3.03 Shop Application of Fusion-Bonded Epoxy Lining and Coating to Joint Areas of Ductile-Iron and

Cast-Iron Fittings--Additional Requirements

Limit the protective coating thickness in the joints of ductile-iron and cast-iron fittings to

maintain a leak-proof joint. However, the coating thickness in the joint area shall not be less than

4 mils.

3.04 Quality of Lining and Coating Applications

The cured lining or coating shall be smooth and glossy, with no graininess or roughness. The

lining or coating shall have no blisters, cracks, bubbles, underfilm voids, mechanical damage,

discontinuities, or holidays.

3.05 Factory Testing of Coating--General

A. Test linings and coatings with a low-voltage wet sponge holiday detector. Test pipe linings

and coatings per AWWA C213, Section 5.3.3. If the number of holidays or pinholes is

fewer than one per 20 square feet of coating surface, repair the holidays and pinholes by

applying the coating manufacturer's recommended patching compound to each holiday or

pinhole and retest. If the number of pinholes and holidays exceeds one per 20 square feet

of coating surface, remove the entire lining or coating and recoat the item or pipe.

B. Measure the coating thickness at three locations on each item or piece of equipment or pipe

section using a coating thickness gauge calibrated at least once per eight-hour shift. Record

each measured thickness value. Where individual measured thickness values are less than

the specified minimum thickness, measure the coating thickness at three additional points

around the defective area. The average of these measurements shall exceed the specified

minimum thickness value, and no individual thickness value shall be more than 2 mils

below or 3 mils above the specified minimum value. If a section of the pipe, item, or piece

of equipment does not meet these criteria, remove the entire lining or coating and recoat

the entire item or piece of equipment.

3.06 Factory Testing of Lining and Coating of Pipe--Additional Requirements

Check for coating defects on the weld seam centerlines. There shall be no porous blisters, craters,

or pimples lying along the peak of the weld crown.

3.07 Field Repairs

Patch scratches and damaged areas incurred while installing fusion-bonded epoxy coated items

with a two-component, 80% solids (minimum), liquid epoxy resin. Wire brush or sandblast the

damaged areas per SSPC SP-10. Lightly abrade or sandblast the coating or lining on the sides of

the damaged area before applying the liquid epoxy coating. Apply a two-part epoxy coating to

defective linings and coatings to areas smaller than 20 square inches. Patched areas shall overlap


AECOM REBID

the parent or base coating a minimum of 0.5 inch. If a defective area exceeds 20 square inches,

remove the entire lining and coating and recoat the entire item or piece of equipment. Apply the

liquid epoxy coating to a minimum dry-film thickness of 15 mils.

END OF SECTION

IWSD 01/2011 09971-1 Ceramic Epoxy Lining For Ductile-Iron Pipe

AECOM REBID

SECTION 09971

CERAMIC EPOXY LINING FOR DUCTILE-IRON PIPE

PART 1 - GENERAL

1.01 Description

This section includes materials, application, and testing of an amine-cured ceramic epoxy,

formulated for use as an internal lining for ductile-iron pipe and fittings.

1.02 Related Work Specified Elsewhere

A. Section 02674 – Underground Piping Systems.

1.03 Submittals

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

following:

B. Submit manufacturer's data sheets showing the following information:

1. Percent solids by volume.

2. Recommended surface preparation.

3. Recommended thinners.

4. Application instructions including recommended equipment and temperature

limitations.

5. Curing requirements and instructions.

C. Provide submittal identifying the type and gradation of abrasives used for surface

preparation.

PART 2 - MATERIALS

2.01 Ceramic Epoxy Lining

A. The lining shall be high-solids, solvent-free, fast-curing two-component ceramic epoxy

formulated especially to line the interior of ductile-iron pipe. Product: Protecto 401

ceramic epoxy.

B. The material shall be an amine-cured novalac epoxy containing at least 20% by volume of

ceramic quartz pigment.

C. The lining material shall have the following characteristics:


AECOM REBID

1. A permeability rating of 0.00 when tested according to Method A of ASTM E96,

Procedure A with a test duration of 30 days.

2. ASTM B117, Salt Spray (Scribed Panel): Results to equal 0.0 undercutting after two

years.

3. ASTM G95, Cathodic Disbondment: 1.5 volts at 77°F. Results to equal no more

than 0.5 mm undercutting after 30 days.

4. Immersion Testing Rated Using ASTM D714:

a. 20% Sulfuric Acid: No effect after two years.

b. 140°F 25% Sodium Hydroxide: No effect after two years.

c. 160°F Distilled Water: No effect after two years.

d. 120°F Tap Water (Scribed Panel): 0.0 undercutting after two years with no

effect.

5. An abrasion resistance of no more than 3 mils (0.075 mm) loss after one million

cycles using European Standard EN 598, Section 7.8.

2.02 Ceramic Epoxy Joint Compound

Use a brushable novalac epoxy designed for sealing cut ends and repairs when pipes are lined

with ceramic epoxy. Use this material on spigots and in bell sockets only after the pipe or fitting

is lined with ceramic epoxy. Protecto joint compound can be used over Protecto 401 or on bare

substrate. Do not apply Protecto 401 over Protecto joint compound.

2.03 Abrasives for Surface Preparation

Abrasives used for preparation of iron surfaces shall comply with NAPF 500-03-04 and shall be

one of the following:

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

B. 20 to 40 mesh garnet.

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

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

PART 3 - EXECUTION

3.01 Surface Preparation for Ceramic Epoxy Lining

A. Deliver pipe to the lining applicator bare. Because removal of old linings may not be

possible, the intent of this specification is that the entire interior of the ductile-iron pipe or

fitting shall not have been lined with any substance prior to the application of the specified

lining material.


AECOM REBID

B. Abrasive blast the entire pipe surface to be lined per NAPF 500-03-04 (special internal

linings). Abrasive blast the interiors of fittings per NAPF 500-03-05, Blast Clean No. 1.

3.02 Surface Preparation for Ceramic Epoxy Joint Compound

The surface preparation shall be equal to the specifications for the project or as outlined in the

touch-up procedure. Do not apply Protecto joint compound over wet or frozen surfaces.

3.03 Lining Pipe with Ceramic Epoxy

A. After surface preparation and within eight hours, line the entire interior surface up to the

gasket groove, with the exception of the spigot end, with an average of 40 mils, 35 mils

minimum, of ceramic epoxy. If any rusting is apparent prior to lining the surface, reblast

the entire area.

B. Within eight hours of surface preparation, the interior of the pipe shall receive the specified

dry-film thickness of the ceramic epoxy. No lining shall take place when the substrate or

ambient temperature is below 40°F. The surface shall be dry and dust free. If flanged pipe

or fittings are included in the project, do not apply the lining on the faces of the flanges.

3.04 Coating of the Pipe Ends with Ceramic Epoxy – Gasketed Joints

Due to the tolerances involved, coat the spigot end from the gasket area to the end of the spigot

with 6 mils average, 10 mils maximum of Protecto joint compound ceramic epoxy. The ceramic

epoxy coating shall be smooth without excess buildup on the spigot end. Apply the joint

compound by brush to ensure coverage. Coat the gasket seat and spigot ends after the application

of the lining.

3.05 Factory Testing of Lining

A. Check the film thickness of the ceramic epoxy lining using a magnetic film thickness

gauge. Take measurements per SSPC PA2 Section 5.1.

B. Test the coated areas of the pipe from the socket edge area of the spigot back to the bell

face for pinholes using a 2,500-volt pinhole detection test. Repair any pinholes found prior

to shipment.

3.06 Thickness Measurement at Place of Manufacture

A. Test linings per NACE SP0188-2006 with a high-voltage holiday detector set at the voltage

per NACE SP0188-2006, Table 1. If the number of holidays or pinholes is fewer than one

per 25 square feet of coating surface for internal coatings and one per 10 square feet for

external coatings, repair the holidays and pinholes by applying the coating manufacturer's

recommended patching compound to each holiday or pinhole and retest. If the number of

pinholes and holidays exceeds the above criteria, remove the entire lining and recoat the

item or pipe at the place of manufacture. Recoating will be permitted if the material has

cured less than the manufacturer's recommended cure time.

B. Measure the coating thickness on each pipe section using a coating thickness gauge

calibrated at least once per eight-hour shift. Make five separate spot measurements

(average of three readings) spaced evenly over each 100 square feet of area (or fraction


AECOM REBID

thereof) to be measured. Make three gauge readings for each spot measurement of either

the substrate or the paint. Move the probe a distance of 1 to 3 inches for each new gauge

reading. Discard any unusually high or low gauge reading that cannot be repeated

consistently. Take the average (mean) of the three gauge 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 the specified minimum thickness. One of three readings averaged to produce

each spot measurement may under run by a greater amount. If a section of the pipe, item,

or piece of equipment does not meet these criteria, remove the entire coating and recoat the

entire item or piece of equipment.

C. Thickness determinations shall meet the following requirements:

1. No individual reading shall be below the specified minimum.

2. Individual spot readings (consisting of three-point measurements within 3 inches of

each other) shall have an average not less than the specified average thickness.

3. The average of all spot readings shall be equal to or greater than the minimum

thickness specified.

D. Thickness determinations shall be conducted using a Type 1 or 2 thickness gauge as

described in SSPC PA2 specification.

3.07 Repair of Improperly Coated Surfaces at Place of Manufacture

If the item has an insufficient film thickness and the coating material curing time has not been

exceeded, clean and topcoat the surface with the specified repair coating to obtain the specified

coverage. Sandblast or power-sand visible areas of chipped, peeled, or abraded coating,

feathering the edges. Then recoat in accordance with the specifications. Work shall be free of

runs, bridges, shiners, laps, or other imperfections.

3.08 In-Plant Inspection and Testing by Owner's Representative

A. An Owner's Representative may inspect pipe, fittings, and lining and other material during

fabrication at the mill, production plant, or shop. The Owner's Representative shall be

allowed complete and unlimited access to all parts of the work and shall be furnished with

such information and assistance as is required to make a complete and detailed inspection.

Notify the Owner at least seven days prior to beginning of material production and

application.

B. The Owner may conduct tests to determine the integrity of the lining. Pipe and fittings

shall be available onsite and accessible at least three days before installation to allow time

for the Owner's tests. If the test results indicate any manufacturing defect, the material shall

be repaired or replaced at no extra cost to the Owner. The Owner's Representative will

make a determination on whether to repair or reject defective or damaged pipe or fitting.

3.09 Manufacturer Testing and Certification

Deliver every section of pipe and fitting with certified test results of that individual pipe

section or fitting. If a pipe or fitting is not accompanied by such certifications or does not


AECOM REBID

meet the Owner-conducted tests as described above, the pipe or fitting will be rejected.

3.10 Field Repair and Touch Up

A. Repair any areas where damage has occurred due to handling using the same ceramic

epoxy prior to installation as the original lining. Apply at a film thickness of 40 mils dry.

B. Apply product only if the substrate temperature and ambient air temperature is above 45°F

and is expected not to drop below 45°F for at least two hours after application. The

substrate temperature shall be 5°F above the dew point for a period of at least two hours

after application to avoid condensation occurring on wet paint. Do not apply ceramic

epoxy over wet or frozen surfaces. Overcoat with the same material as specified above.

3.11 On-Site Storage

A. Handle pipe with belt slings and padded forks to avoid damage. Pad shipping timbers and

straps when shipping pipe and fittings.

B. The maximum delivery, storage, and installation time allowed for pipe and fitting is 120

days from the date they were lined to the date they are installed. Any pipe not meeting this

requirement will be rejected.

3.12 Handling

Handle lined pipe and fittings only from the outside of the pipe and fittings. Do not place forks,

chains, straps, hooks, etc., inside the pipe and fittings for lifting, positioning, or laying. Do not

drop the pipe or unload by rolling. Do not let the pipe strike sharp objects while swinging or

being off loaded. Do not place pipe on grade by use of hydraulic pressure from an excavator

bucket or by banging with heavy hammers.

3.13 Procedures for Sealing Cut Ends and Repairing Field-Damaged Areas of Lined Pipe and Fittings

A. Remove burrs caused by field cutting of ends or handling damage and smooth out the edge

of the lining if rough. Remove traces of oil, grease, asphalt, dust, dirt, etc.

B. Remove any damaged lining caused by field cutting operations or handling and clean any

exposed metal by sanding or scraping. Sandblasting or power tool cleaning roughening is

also acceptable. Remove any loose lining by chiseling, cutting, or scraping into well-

adhered lined area before patching. Overlap at least 1 inch of lining in the area to be

repaired.

C. With the area to be sealed or repaired clean and roughened, apply a coat of Protecto joint

compound.

D. Coat the entire freshly cut exposed metal surface of the cut pipe end. To ensure proper

sealing, overlap at least 1 inch of the lining with this repair material.


AECOM REBID

3.14 Joint Installation

A. Push ductile-iron pipe lined with ceramic epoxy only when using a restrained joint system

that does not allow the spigot to contact the bell shoulder. The pipe may be pulled using

restrained joint pipe or restraining gaskets as restraints. Do not push the restraining gaskets.

Do not home pipe all the way to the bell shoulder with restraining gaskets. Do not push or

pull ductile-iron pipe lined with ceramic epoxy using any technique that may damage the

lining.

B. Do not pull metal mandrels through ceramic-epoxy lined ductile-iron pipe.

3.15 Pipe Cleaning

Do not use pressure washing techniques to clean pipe lined with ceramic epoxy.

END OF SECTION

FORCE MAIN EXTENSION DIVISION 9 FINISHES - D.N. Higginsdnhiggins.com/docs/Div9 Forcemain...

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