INDUSTRIAL COATING APPLICATION

DEC 97 APPLICATION OF INDUSTRIAL COATING SYSTEMS GEMS V-1P0

PAGE 1 OF 22©TEXACO GENERAL ENGINEERING DEPARTMENT

TABLE OF CONTENTS

PAGE

1. SCOPE .............................................................. 3

2. REFERENCES ......................................................... 3

2.1 Purchaser Specifications ..................................... 32.2 Purchaser Drawings ........................................... 32.3 Industry Codes and Standards ................................. 3

3. GENERAL ............................................................ 4

4. DEFINITIONS ........................................................ 4

5. SELECTION OF COATING SYSTEM ........................................ 5

6. HANDLING OF COATINGS ............................................... 5

6.1 General ...................................................... 56.2 Mixing of Coating Materials .................................. 5

7. SURFACE PREPARATION ................................................ 6

7.1 Standards .................................................... 67.2 Abrasive Sizes ............................................... 67.3 Inspection ................................................... 67.4 Metal Surfaces for Fireproofing .............................. 67.5 Pretreatments ................................................ 77.6 Wood ......................................................... 77.7 Brick, Tile, and Concrete .................................... 7

8. PARTS REQUIRING COATING AND FINAL COLOR ............................ 8

9. APPLICATION ........................................................ 8

9.1 Factors Affecting Application ................................ 89.2 Application Methods .......................................... 109.3 Galvanizing and Repair ....................................... 129.4 Shop Painting ................................................ 129.5 Field Painting ............................................... 149.6 Maintenance Painting ......................................... 15

10. DRYING AND HANDLING OF COATED STEEL ................................ 16

10.1 Drying ....................................................... 1610.2 Handling ..................................................... 16

11. FIELD STORAGE TANKS ................................................ 16

12. CLEANUP ............................................................ 16

13. SAFETY ............................................................. 17

13.1 General ...................................................... 17



13.2 Open Air Respiratory Protection ..............................1713.3 Confined Space Respiratory Protection ........................1813.4 Dermal Protection ............................................18

TABLES

1 Substrates and Applicable Systems2 System Numbers and Descriptions3 Surface Preparation Standards4 Abrasive Sizes

ATTACHMENTS

V-1P0S1 Data SheetV-1P0I Inspection and Testing Requirements Sheet (ITRS)V-1P0R Documentation Requirements Sheet (DRS)



1. SCOPE

This specification defines minimum technical requirements for:

1. Selection of industrial coating systems.

2. Surface preparation, installation, special application instructions(if necessary), and inspection for painting.

2. REFERENCES

2.1 Purchaser Specifications

This specification contains references to the following Purchaserspecifications:

1. GEMSGC, “General Conditions - General Equipment and MaterialSpecifications”.

2. GEMS S-1M, “Fabrication and Erection of Structural Steel”.

3. GEMS V-1M, “Industrial Coating Materials”.

2.2 Purchaser Drawings

This specification contains references to the following Purchaserdrawings:

None.

2.3 Industry Codes and Standards

This specification contains references to the following industry codesand standards:

2. 3 .1 American Society for Testing and Materials (ASTM)

1. D 610, “Guide to Standard Method of Evaluating Degree ofRusting on Painted Steel Surfaces”.

2. D 4258, “Surface Cleaning Concrete for Coating”.

3. D 4259, “Abrading Concrete”.

4. D 4260, “Acid Etching Concrete”.

5. D 4261, “Surface Cleaning Concrete Unit Masonry forCoating”.

2. 3 .2 NACE International (NACE)

1. 1, “White Metal Blast Cleaning”.

2. 2, “Near White Metal Blast Cleaning”.

3. 3, “Commercial Blast Cleaning”.

4. 4, “Brush-off Blast Cleaning”.

2. 3 .3 Steel Structures Painting Council (SSPC)

1. “Systems and Specifications”, Chapter PA 2.

2. “Systems and Specifications”, Guide PA 3.

3. SP 1, “Solvent Cleaning”.

4. SP 2, “Hand Tool Cleaning”.

5. SP 3, “Power Tool Cleaning”.

6. SP 4, “Flame Cleaning”.

7. SP 5, “White Metal Blast Cleaning”.



8. SP 6, “Commercial Blast Cleaning”.

9. SP 7, “Brush Off Blast Cleaning”.

10. SP 8, “Pickling”.

11. SP 9, “Weathering Followed by Blast Cleaning”.

12. SP 10, “Near White Blast Cleaning”.

13. SP 11, “Power Tool Cleaning to Bare Metal”.

14. VIS 1, “Description of Visual Standard”.

15. VIS 2, “Guide to Standard Method of Evaluating Degree ofRusting on Painted Steel Surfaces”.

2. 3 .4 Swedish Standards Institute (SSI)

1. Sa 1, “Brush Off Blast Cleaning”.

2. Sa 2, “Commercial Blast Cleaning”.

3. Sa 2 1/2, “Near White Blast Cleaning”.

4. Sa 3, “White Metal Blast Cleaning”.

5. St 2, “Hand Tool Cleaning”.

6. St 3, “Power Tool Cleaning”.

3. GENERAL

1. Acceptable products are listed in GEMS V-1M.

2. Thickness of coating or coating system shall be as specified bymanufacturer.

3. Additions or changes to specified types of coating systems shall besubject to approval.

4. Systems are designed and selected on basis of a minimum 10 yearlife before:

a. Topcoat breakdown of 5% to 10% (maximum) occurs.

b. ASTM D 610/VIS 2 Rust Grade 4 is present.

5. General conditions shall comply with GEMSGC.

4. DEFINITIONS

1. Ambient conditions - Temperature, humidity, and dew point atjobsite.

2. Coatings - Protective, decorative, or functional film applied to asurface. Such materials include paints, topcoats, varnishes,sealers, stains, washcoats, basecoats, enamels, and temporaryprotective coats.

3. Shop painting - Coating of steel surfaces in shop or plant beforeshipment to erection site.

4. Field painting - Onsite coating of new or rebuilt steel structuresbefore, during, or after erection.

5. Maintenance painting - Coating of previously coated steelstructures in service that require touchup or recoating.

6. Manufacturer’s instructions - Written instructions provided bycoating manufacturer (or by coating specification).

7. Boxing - Process of mixing coatings by pouring from one containerto another.



8. Severe environment - Location within 10 miles of coast/salt wateror in presence of heavy industrial fumes/fallout.

9. Moderate environment - Location in presence of low industrialfumes/fallout.

10. Mild environment - Location in rural or urban area with little orno industrial fumes/fallout.

5. SELECTION OF COATING SYSTEM

Coating system shall be selected in accordance with Tables 1 and 2.

6. HANDLING OF COATINGS

6.1 General

1. Coatings shall be delivered to shop or jobsite in the original,sealed, and undamaged containers.

2. Containers shall be clearly marked or labeled to show:

a. Brand identification.

b. Date of manufacture.

c. Batch number.

d. Information required by federal, state, or local law.

3. Coating containers shall remain unopened until required for use.

4. Coating shall be used before its shelf life has expired.

6.2 Mixing of Coating Materials

6. 2 .1 General

1. Before application, paints shall be agitated untilingredients are completely mixed in accordance withmanufacturer’s latest written recommendations.

2. Unless specified otherwise, coatings may be mixed by handor mechanical shakers and mixers.

3. Paint materials that have exceeded manufacturer’s statedpot life shall not be applied or mixed into a new batch.

4. Catalysts, thinners, and other additives shall be:

a. From same manufacturer as paint.

b. Used only with paint manufacturer’s latest writtenrecommendations.

5. If ambient temperature, surface temperature, or painttemperature is below 50°F, paints shall not be preparedfor use, unless specifically permitted in manufacturer’slatest written recommendations.

6. Paint materials shall be prepared for use in strictaccordance with paint manufacturer’s latest writtenrecommendations.

6. 2 .2 Hand Mixing

1. Containers shall not exceed 5 gallons.

2. Most of vehicle shall be poured into clean container.

3. Coating pigment shall be lifted from container bottom withbroad, flat paddle.

4. Lumps shall be broken up.



5. Pigment shall be thoroughly mixed with remaining vehicle.

6. Poured off vehicle shall be returned to coating whilestirring or boxing.

6. 2 .3 Continuous Agitation

If specified by manufacturer, paint materials that have atendency to settle rapidly shall be continuously agitatedduring application.

7. SURFACE PREPARATION

7.1 Standards

Surfaces shall be prepared in accordance with standards listed in Table3.

7.2 Abrasive Sizes

Recommended abrasive sizes are listed in Table 4.

7.3 Inspection

1. Acceptability of abrasive blast cleaning quality shall be byeither:

a. Visual examination using SSPC (VIS 1) or NACE standards.

b. Copper sulfate test.

2. Copper sulfate test shall be conducted as follows:

a. Brush or pour 10% solution of copper sulfate (blue vitriol)onto randomly selected test areas of prepared surface.

b. For “white” abrasive blast cleaning, 99% of individual testareas shall as a minimum turn copper color within 15 seconds.

c. For “commercial” abrasive blast cleaning, 50% of each testarea shall as a minimum turn copper color within 15 seconds.

d. Note: Contaminated portions of test area will appear in darkercontrast to copper color.

3. Areas of discoloration or dark contrast exceeding percentages oftest area specified in paragraphs 2.a. and 2.b. shall be cause forrejection of surface preparation.

7.4 Metal Surfaces for Fireproofing

1. Ungalvanized metal surfaces to be fireproofed shall be cleaned perSSPC SP 10 before prime coat is applied.

2. Abrasive blast cleaning may be performed either in shop or field,whichever is most practical or economical.

3. Vessel Skirts

a. Abrasive blasting and application of priming coat shall beperformed after installation of crimped rod reinforcing.

b. If paragraph 1. is not practical and involves extra cost:

(1) Crimped rod shall be installed after abrasive blastcleaning and priming.

(2) Damaged coating shall be touched up.

(3) Second primer coat shall be applied.



7.5 Pretreatments

1. If specified, surface shall be pretreated prior to application ofprime coat of coating.

2. If chemical pretreatments are used, sufficient time shall elapsebetween pretreatment and application of primer to permit:

a. Completion of chemical action.

b. Surface to dry.

3. Two-component pretreatments shall be applied within specifiedinterval after mixing.

4. Proprietary pretreatments, if used, shall comply withmanufacturer’s instructions.

5. Inhibitive water washes to prevent rusting of cleaned surfacesprior to coating shall not be considered pretreatments.

6. Inhibitive washes may be used only if they:

a. Do not adversely affect adhesion of coating.

b. Are specifically authorized.

7. Prior to coating entire surface, adhesion of coating shall betested with test patches.

7.6 Wood

1. Wood surfaces shall be sanded and primed.

2. Nail holes shall be filled with putty that is the same color ascoating which will be used for finish coat.

3. Sap streaks and knots shall be coated with shellac before topcoating.

7.7 Brick, Tile, and Concrete

1. Brick, tile, concrete, cement, and cement plaster to be coatedshall be prepared as follows:

a. Treated with solution of 3 to 4 pounds of zinc sulfate to 1gallon of water.

b. Solution shall be applied with bristle brush.

c. Application shall be allowed to dry. Surface shall be brushedwith stiff brush to remove any crystals.

2. Optional treatment of concrete surfaces shall be to wash surfacewith solution of ammonium carbonate. Wash solution shall be made bydissolving 10 pounds of ammonium carbonate in 45 gallons of water.

3. Exterior brick, tile, concrete, and cement walls that are specifiednot to be coated shall be treated with two coats of clear siliconesealer.

4. Mortar joints in new tile or brick walls to be coated shall receivethin coat of shellac or aluminum coating prior to priming.

5. Wall primers, sealers, or sizing compounds shall be used on porousmasonry surfaces to be coated after the pretreatment described toreduce adsorptiveness and porosity of such surfaces.

a. Sealers shall be used on weatherproof cement surfaces andother porous material surfaces to be coated.

b. Choice of wall primers, sealers, and sizing compounds shall bebased on recommendation of manufacturer that furnishescoating.



6. Outside surface of concrete block or hollow clay tile walls to becoated shall be sealed with one coat of waterproofing.

7. If finish color coats of coatings are specified, primers shallcomply with recommendations of coating manufacturer furnishingcoating.

8. PARTS REQUIRING COATING AND FINAL COLOR

1. The following shall be as specified on data sheets:

a. Approved types of coating systems.

b. Equipment, structures, etc., to which coatings shall beapplied.

c. Colors and types of coating for finish coats on typicalfacilities.

2. The following surfaces shall not be prepared, primed, or coated:

a. Nonferrous metal surfaces, such as aluminum, copper, brass, ormonel.

b. Stainless steel (Austenitic), except as noted under insulation(see Table 1).

c. Glass, tile, or ceramic surfaces.

d. Aluminum jacketing on insulation.

e. Nameplates.

f. Machined surfaces and finished metal operating parts ofmachinery, valves, or other equipment, such as valve stems,shafts, and flange faces.

9. APPLICATION

9.1 Factors Affecting Application

9. 1 .1 Temperature

1. Coatings shall not be applied if:

a. Temperature of steel or coating is below 50°F (10°C).

b. Temperature of air is below 50°F (10°C) or above 110°F(43°C).

c. Surface temperature is expected to drop to 50°F (10°C)before coating has dried.

2. Coatings shall not be applied to steel that is at atemperature which will either:

a. Cause blistering or porosity.

b. Be detrimental to coating life.

3. For coatings applied in hot weather or thinned in coldweather, specified coating thickness shall be obtained.

4. With chemically cured coatings, particular attention shallbe devoted to manufacturer's special temperaturerequirements, usually 55°F (13°C) or above.

5. Special coatings designed for use at temperatures below32°F (0°C) shall be applied in strict accordance withmanufacturer's instructions.



9. 1 .2 Moisture

1. Coatings shall not be applied either:

a. In rain, wind, snow, fog, or mist.

b. If steel surface temperature is less than 5°F (3°C)above the dew point.

2. Except for water thinned types, coatings shall not beapplied to wet or damp surfaces.

3. Coatings shall not be applied on frosted or ice-coatedsurfaces.

9. 1 .3 Humidity

Manufacturer’s instructions shall be followed regardingacceptable humidity range for applying moisture-cured coatings.

9. 1 .4 Measure of Ambient Conditions

Ambient conditions at the jobsite shall be measured:

1. At beginning of each work day.

2. Either every 4 hours thereafter or sooner if weatherconditions appear to be changing.

9. 1 .5 Damage

Damaged areas of coatings that are detrimental to service lifeshall be restored by:

1. Removing damaged coating.

2. Preparing surface area for recoating.

3. Recoating with same number of coats of same type asundamaged area(s).

9. 1 .6 Continuity

1. To maximum extent practical, coat shall be applied as acontinuous film of uniform thickness free of pores.

2. Thin spots or areas missed in application shall be:

a. Recoated.

b. Permitted to dry before next coat is applied.

9. 1 .7 Thickness

1. Dry film thickness shall be determined in accordance withSSPC PA 2 (coating thickness is usually specified orimplied) as a minimum.

2. Unless specified otherwise, greater thickness that doesnot detrimentally affect coating appearance or servicelife shall be permitted.

3. Except for inorganic zinc-rich coatings, required minimumthickness shall be achieved by adding coats as needed.

9. 1 .8 Recoating

Time interval between coating applications shall comply withmanufacturer's instructions.

9. 1 .9 Tinting

1. If successive coats of same color are specified,sufficient alternate coats shall be tinted (if practical)to produce contrast required to indicate complete coverageof surface.



2. Tinting shall be performed in a manner that negatesnecessity for tinting final coat.

a. If coating is color of steel, first coat shall betinted.

b. Tinting material shall be compatible with coating andnot detrimental to service life of coating.

c. To the extent practical or possible, coatingsappropriately tinted and labeled by manufacturer shallbe used.

9. 1 .10 Intercoat Adhesion

1. Undercoats with glossy surface that detrimentally affectsadhesion of subsequent coat shall be treated by mildsurface abrasion, solvent treatment, or other suitableprocesses.

2. Treatment shall not cut through or detract from performanceof underlying coating.

9.2 Application Methods

9. 2 .1 General

1. This section specifies brush, roller, air spray, andairless spray application methods.

2. If no other method is practical, daubers or sheepskins maybe used in areas of difficult access.

3. Other application methods, if specified, shall comply withmanufacturer's recommendations.

4. To the extent possible, spray applications shall beperformed by airless spray method. References in thisspecification to spray applications mean airless spraymethod (which is preferred over conventional air spraymethod).

9. 2 .2 Brush Application

1. Wide, flat brushes, not to exceed 5 inches in width, shallbe used on large flat areas.

2. Round or oval brushes shall be used for rivets, bolts,irregular surfaces, and rough or pitted steel.

3. Coatings shall be worked into crevices and corners.

4. Runs or sags shall be brushed out.

5. Brush marks left in applied coating shall be kept to aminimum.

9. 2 .3 Spray Application (General)

1. Spray application equipment shall:

a. Be suitable for intended purpose.

b. Be capable of properly atomizing coating.

c. Have suitable pressure regulators and gages.

d. Be maintained in proper working condition.

2. During coating application, coating ingredients shall bekept uniformly mixed in spray pots or containers byeither:

a. Continuous mechanical agitation.



b. Intermittent agitation as necessary.

3. Coatings shall be applied in a uniform layer withoverlapping at edges of spray pattern.

4. During application, spray gun shall be held:

a. Perpendicular to surface.

b. At distance which ensures that wet layer of coating isdeposited on target surface.

5. Spray gun trigger shall be released at end of each stroke.

6. Coating runs and sags shall be corrected by either:

a. Brushing out immediately.

b. Removing coating and recoating surface.

7. Cracks, crevices, blind areas of rivets and bolts, andother inaccessible areas shall be coated by brush,daubers, or sheepskins.

8. Hot coatings shall not be applied to cold surfaces.

9. Cold coatings shall not be applied to hot surfaces.

9. 2 .4 Air Spray Application

1. Air caps, nozzles, and needles shall be those recommendedby manufacturer of material being sprayed and equipmentbeing used.

2. Oil and condensed water shall be removed from air withtraps or separators.

3. Traps or separators shall be:

a. Adequately sized.

b. Drained periodically during operations.

4. Air from spray gun impinging against a clean surface shallshow no condensed water or oil.

5. Pressure on material in pot and of air at gun shall beadjusted for optimum spraying effectiveness.

6. Pressure on material in pot shall be adjusted if necessaryfor changes in elevation of gun above pot.

7. Atomizing air pressure at gun shall be:

a. High enough to properly atomize coating.

b. Not so high as to cause excessive fogging, excessiveevaporation of solvent, and loss by overspray.

9. 2 .5 Airless Spray Application

Airless or high pressure spray application of coatings shallensure that:

1. Manufacturer’s instructions regarding proper use ofequipment are followed.

2. Manufacturer’s recommendation for material being sprayedand equipment being used are observed:

a. Fluid tips shall have proper orifice size and fanangle.

b. Fluid control gun shall be of proper construction.

3. Fluid tips are safety type with shields to preventpenetration of skin by high pressure coating stream.



4. Equipment has filters in high pressure line to eliminatedirt, dry paint, and other foreign materials.

5. Air pressure for coating pump provides proper materialpressure to gun for optimum spraying effectiveness.

a. Pressure to gun shall be sufficient to properlyatomize coating.

b. Pressures considerably higher than necessary toproperly atomize coating shall not be used.

6. During spraying, trigger of gun shall be held fully opento ensure proper coating application.

7. Airless coating spray equipment shall be grounded to avoidbuildup of electrostatic charge on gun.

9. 2 .6 Roller Application

1. Roller application may be used on flat or slightly curvedsurfaces.

2. Roller application shall comply with coating manufacturerrecommendations.

3. Roller application shall not be used on irregularsurfaces, such as rivets, bolts, crevices, welds, corners,and edges.

9.3 Galvanizing and Repair

1. Galvanized structural steel shall not be coated.

2. Galvanized coatings damaged during shipment and handling shall befield repaired by:

a. Thoroughly cleaning surface by hand.

b. Applying one coat of epoxy zinc rich primer.

3. Repair coating shall be:

a. Applied over damaged areas to thickness equal to that ofadjoining galvanizing.

b. Carefully blended with adjacent galvanized surfaces.

Note: Galvanizing requirements are defined in GEMS S-1M.

4. Except if mounted on surfaces that require coatings, galvanizedconduit shall not be coated.

5. If not to be otherwise coated, damaged galvanized conduit surfacesshall be repaired with epoxy zinc rich primer.

9.4 Shop Painting

9. 4 .1 Applicability

1. Except for Sections 9.5 and 9.6, this specification shallapply to shop painting.

2. Unless specified otherwise, piping (straight lengths andshop fabricated spools), vessels, structural steel, andother equipment shall be prime coated in shop.

9. 4 .2 Number of Coats and Type of Coating

1. Number of coats, type of coatings, and surfaces to becoated shall be as specified.

2. Except for commodity equipment (valves, general purposepumps, etc.) normally coated by manufacturer, coatings on



equipment and structures shall comply with thisspecification.

3. Except as noted in paragraph 4., commodity equipment shallhave one field finish coat of designated color.

4. Field finish coating shall not be required ifmanufacturer’s coating is:

a. Undamaged.

b. Acceptable in quality.

c. Matched to specified color.

5. Field finish coating shall be applied after fabricationand before surface is damaged by weather or otherexposure.

9. 4 .3 Damage to Shop Paint

1. Coating damaged by shipping and handling shall be repairedin field.

2. Shop paint damaged in fabrication shall be repaired beforeleaving shop (see Section 10.2).

9. 4 .4 Contact Surfaces

1. If contact surface is to be coated, first coat as aminimum shall be applied in shop.

2. Unless specified otherwise, subsequent coats shall beapplied in field before surfaces become inaccessible.

9. 4 .5 Requirements for Welding

1. Steel shall not be coated within 4 inches of areas to bewelded if specified coating is:

a. Harmful to welding operator.

b. Detrimental to welding operation.

c. Detrimental to finished welds.

2. Shop welds and areas within 4 inches of such welds shallbe cleaned in shop using surface preparation methods atleast as effective as those specified for structureitself.

3. As required in SSPC SP 1, welds shall cleansed ofdetrimental welding deposits by either:

a. Blast cleaning.

b. Thorough power wire brushing.

c. Chemical scrubbing.

d. Water scrubbing.

9. 4 .6 Rust Preventive Compounds

Machined surfaces that will not be coated shall be protectedwith rust preventive compound.

9. 4 .7 Erection and Material Identification Marks

Erection and material identification marks shall be applied onareas that have been coated.

9. 4 .8 High Temperature Coatings

1. High temperature coatings required on shop fabricatedequipment shall be shop applied.



2. Care shall be taken to minimize damage to shop appliedprimers during transportation and erection.

3. Damaged areas shall be:

a. Prepared in field.

b. Recoated to original coating specification.

9.5 Field Painting


1. Except for provisions in Section 9.6 and inapplicableprovisions of Section 9.3, field painting shall complywith this specification.

2. Steel stored pending erection shall be:

a. Kept free from contact with ground.

b. Positioned to minimize water-holding pockets, soiling,contamination, and deterioration of coating film.

9. 5 .2 Surface Preparation

1. Previously applied shop coatings shall be dry and free ofdirt, oil, or other contaminants.

2. Manufacturer's instructions shall be followed if specialsurface preparation procedures are required before fieldcoats are applied.

3. Damaged areas of shop applied coatings shall be touched upin accordance with Section 9.5.3.

9. 5 .3 Touch-up of Shop Painted Surfaces

1. Unless specified otherwise, shop coated steel shall betouched up with same type of coating as shop coat.

2. Touchup shall include cleaning and coating of:

a. Field connections.

b. Welds.

c. Damaged or defective coatings and rusted areas.

3. As determined by Purchaser, extensively damaged ordefective coatings and rusted areas shall:

a. Be cleaned.

b. Receive one overall coat of primer for each shop coatin place of touchup or spot coating.

9. 5 .4 Field Painting Procedures

1. Vessels and equipment may be coated on ground beforeerection, provided touchup of damaged areas are coatedwith the same number of coats and kinds of coatings aftererection.

2. Surfaces of fabricated assemblies that are only accessiblebefore erection shall be coated before erection.

3. If possible, field coats shall have contrasting color toensure total coverage and required dry film thickness(DFT).

4. First field coat shall be applied:

a. Within reasonable period after shop coat(s).



b. Before weathering (and required touchup) of shop coatbecomes excessive.

5. Final steel structures coating shall not be applied untilall concrete work is finished.

6. In addition to cleaning specified in Section 7, cement orconcrete spatter and drippings shall be removed beforecoating is applied.

7. Damaged surfaces shall be cleaned and recoated before finalcoat is applied.

8. Wet coatings shall be protected against damage from dust orother detrimental foreign matter.

9. Field welds and areas within 4 inches of welds shall becleaned with surface preparation methods equivalent to oras effective as those specified for base material.

9.6 Maintenance Painting


Except for applicable portions of Sections 9.4 and 9.5,maintenance painting shall comply with this specification.

9. 6 .2 Surface Preparation for Recoating

1. Unless specified otherwise, only loose, cracked, brittle,or nonadherent coating shall be removed.

2. Cleaning shall be performed 2 inches beyond damaged areaseither:

a. In all directions.

b. Until tightly adhered coating is obtained.

3. If remaining paint is thick, exposed edges shall befeathered.

4. Spot cleaning shall be conducted to minimize damage tosound coatings.

a. Rust spots shall be thoroughly cleaned.

b. Edges of old coatings shall be scraped back to soundmaterial.

5. Old coatings shall be removed from areas with excessivedamaged or loose coating.

9. 6 .3 Incompatibility

If coating curls or lifts after application of spot or primingcoating:

1. Coating shall be removed.

2. Area shall be recoated.

9. 6 .4 Surfaces Previously Pretreated

Unless specified otherwise, cleaned areas of surfaces known tohave been pretreated with basic zinc chromate washcoat (washprimer) shall be similarly pretreated before prime coat isapplied.



10. DRYING AND HANDLING OF COATED STEEL

10.1 Drying

1. Minimum drying time between coats shall comply with manufacturer'sinstructions.

2. Maximum practical time shall be allowed for coat to dry beforerecoating.

3. Coats that dry too hard for good adhesion of subsequent coats shallbe recoated within manufacturer’s recommended time period.

4. If not recoated within specified time, previously applied coatingsshall be treated prior to recoating (see Section 9.1.10).

5. Coatings shall not be force dried under conditions that causechecking, wrinkling, blistering, formation of pores, ordetrimentally affect their protective properties.

6. No drying agent shall be added to the coating unless specificallyset forth in the manufacturer's instructions.

7. To fullest extent possible, coatings shall be protected from rain,condensation, contamination, snow, and freezing until dry.

10.2 Handling

1. Except as necessary in turning for coating or stacking for drying,coated steel shall not be handled, loaded for shipment, or shippeduntil coating has dried.

2. Coatings that are damaged in handling shall be:

a. Scraped off.

b. Touched up with same number of coats and kinds of coatings aswere previously applied or specified.

11. FIELD STORAGE TANKS

1. Unless specified otherwise, tank plates shall be abrasive blastcleaned and primed in shop.

2. After fully cured, primed steel shall be stacked or loaded forshipment.

3. To prevent damage between large plates, lathes shall be placedbetween plates at edge and at least two points between long end.

4. Lathes shall as a minimum:

a. Be 1 inch by 1 inch in size.

b. Sufficiently long enough to cover 2/3 of shortest platedimension.

5. Lathes shall be kept between plates during shipment and sitestorage.

6. Primed pieces shall be handled carefully to prevent damage to shopapplied primer.

7. Plates shall not be dragged, dropped, or otherwise abused.

8. After hydrostatic test is complete and water drained, tank shall befield coated.

12. CLEANUP

Upon completion of painting and special coatings defined in thisspecification, entire job shall be made ready for acceptance, including:



1. Removal of painter's equipment, surplus materials, and debris frompremises.

2. Cleaning inside and outside of glass.

3. Cleaning paint markings and overspray from other surfaces andfixtures.

13. SAFETY

13.1 General

1. Safety requirements and volatile organic chemical (VOC) limitationsshall include:

a. Those stated in this specification.

b. Applicable federal, state, and local rules and requirements.

c. Instructions of coating manufacturer.

2. Proper safety precautions shall be observed to protect againstflammability and potential toxicity of coatings.

3. Safe handling practices shall be required and include SSPC PA Guide3.

4. Coating material shall be considered a health hazard if it candirectly or indirectly cause injury or incapacitation, eithertemporary or permanent, from exposure by contact, inhalation, oringestion.

5. The following compounds shall be considered to be health hazards:

a. Ethylene Glycol Monoethyl Ether.

b. Ethylene Glycol Monomethyl Ether.

c. Ethylene Glycol Monobuthyl Ether.

d. Ethylene Glycol Monoethyl Ether Acetate.

e. Ethylene Glycol Monomethyl Ether Acetate.

NOTE: This list does not include all hazardous chemicals that maybe in coating products.

6. If products containing above compounds are used, coatingapplicators shall have appropriate personal respiratory and dermalprotection.

7. Crystalline Silica

a. Silica sands and other naturally occurring blast materials maycontain crystalline silica, which can lead to the lung diseasesilicosis.

b. Strict adherence to safety procedures and use of respiratoryprotection shall be required to ensure safe use of blastmaterials containing crystalline silica in abrasive blastingwork.

c. Because of the hazard crystalline silica presents, silica sandor other blasting agents shall not contain more than 1%crystalline silica.

d. Abrasive blasting of concrete structures may generate highcrystalline silica exposures regardless of abrasive blastingmaterial used.



13.2 Open Air Respiratory Protection

1. For spraying coatings in open air, applicators shall wear NIOSHapproved, full-face paint spray respirator to prevent eye contactwith glycol ethers.

2. Respirator cartridges shall have fabric prefilter followed byactivated charcoal bed to prevent inhalation of vapors or mist.

13.3 Confined Space Respiratory Protection

1. For spraying coatings in confined spaces, applicators shall wearNIOSH approved, full-face positive pressure, air suppliedrespirators.

2. If vapor concentrations in confined spaces can reach levelsimmediately dangerous to life or health, applicators shall have 5minute escape bottle as an alternative air supply should primaryair supply be interrupted.

13.4 Dermal Protection

1. Applicators shall wear neoprene gloves and clothing as protectionagainst skin absorption of glycol ethers.

2. Because neoprene protection is diminished if material is abraded,cut, or otherwise deteriorated, protective clothing shall be:

a. Inspected frequently to ensure that integrity of materials ispreserved.

b. Rinsed off after each work shift to remove residual glycolethers and prolong garment life.

3. Gloves or clothing that have become saturated or have remained inprolonged contact with liquid containing glycol ethers shall bediscarded or replaced.

CAUTION: Because of their hydrocarbon solvent content, somecoatings specified herein may not comply with some air pollutionregulations.



TABLE 1SUBSTRATES AND APPLICABLE SYSTEMS

Continuous Mild Environment Moderate Environment Severe EnvironmentSubstrate Temperature Preferred Alternate Alternate Preferred Alternate Alternate Preferred Alternate Alternate

oF System #1 #2 System #1 #2 System #1 #2Carb. Steel-Factory Coated -20 to 150 XEU-052 XEE-054 XEA-052 XEU-055 XEE-054 XEU-052 XEE-054

151 to 400 ZXS-302 ZXX-300 SXS-202 ZXS-302 ZXX-300 SXS-202 ZXS-302 ZXX-300 SXS-202401 to 750 ZXS-301 ZXX-300 SXS-101A ZXS-301 ZXX-300 SXS-101A ZXS-301 ZXX-300 SXS-101A751 to 1000 SXS-101H PXP-101 SXS-101H PXP-101 SXS-101H PXP-101

Carbon Steel-Fireproofed -20 to 150 EXX-500 EXE-303 Galvanize EXX-500 EXE-303 Galvanize EXE-303 EXX-500 GalvanizeCarbon Steel-Galvanized -20 to 150 None XZU-032 None XZU-032 None XZU-032Carbon Steel-Insulated -20 to 250 EXE-505A EXE-505P EXE-505N EXE-505A EXE-505P EXE-505N EXE-505A EXE-505P EXE-505N

251 to 750 ZXX-300 ZXP-301 ZXX-300 ZXP-301 ZXX-300 ZXP-301751 to 1000 None PXP-101 None PXP-101 None PXP-101

Carb. Steel-Floating Roofs -20 to 150 EXE-505 EXE-505 EXE-505Carbon Steel-Uninsulated -20 to 150 EXU-502 EXE-504 EXA-502 EXU-505 ZXE-304 ZXU-305 EEU-552 ZEE-344 ZEU-342

151 to 400 ZXS-302 ZXX-300 SXS-202 ZXS-302 ZXX-300 SXS-202 ZXS-302 ZXX-300 SXS-202401 to 750 ZXS-301 ZXX-300 SXS-101A ZXS-301 ZXX-300 SXS-101A ZXS-301 ZXX-300 SXS-101A751 to 1000 SXS-101H PXP-101 SXS-101H PXP-101 SXS-101H PXP-101

Concrete-Formed Walls Ambient EEU-152 EEE-154 EEA-152 EEU-152 EEE-154 EEA-152 EEU-152 EEE-154Concrete-Masonry Ambient AXA-F02 AXA-F02 EEU-F52 EEU-F52Concrete-Poured Floors Ambient EEE-154 EEE-154Drywall Ambient AAA-122 AEE-122 AOO-122 AAA-122 AEE-122 AOO-122 AAA-122 AEE-122 AOO-122Stainless Steel-Insulated -20 to 250 EXE-505A EXE-505P EXE-505N EXE-505A EXE-505P EXE-505N EXE-505A EXE-505P EXE-505N

251 to 750 None SXS-101A PXP-101 None SXS-101A PXP-101 None SXS-101A PXP-101751 to 1000 None PXP-101 None PXP-101 None PXP-101

SS-Uninsulated -20 to 150 None EXE-504 EXU-502 None EXE-504 EXU-502 None EXE-504 EXU-502Wood Ambient AXA-202 EXE-202 OXO-202 AXA-202 EXE-202 OXO-202 EXE-202 AXA-202 0X0-202

LEGEND:A - AcrylicE - EpoxyO - AlkydP - PolysiloxaneS - SiliconeU - UrethaneX - None or By ManufacturerZ - Zinc Richdft- Dry Film ThicknessF - FillHB - High Build (>3 mils)TF - Thin Film (<4 mils)WB - Water Borne



TABLE 2SYSTEM NUMBERS AND DESCRIPTIONS

New Construction RepairApprox.

System Surf. DFT Surf.Number Prep. Primer Midcoat Topcoat mils Prep. Primer

AAA-122 Sand Acrylic, WB Sealer Acrylic, WB Gloss Acrylic, WB Gloss 4 Sand Acrylic, WB PrimerAEE-122 Sand Acrylic, WB Sealer Epoxy, WB Epoxy, WB 4 Sand Epoxy, WBAOO-122 Sand Acrylic, WB Sealer Alkyd, Primer Alkyd, Gloss 4 Sand Alkyd, PrimerAXA-202 Sand Acrylic, WB Primer Acrylic, WB Gloss 4 Sand Acrylic, WB PrimerAXA-F02 D4261 Acrylic, Block Fill Acrylic, WB Gloss 15 SP 3 Acrylic, WB PrimerEEA-152 D4258 Epoxy, 100% Sealer Epoxy, HB Surf. Tol. Acrylic, WB Gloss 8 SP 3 Epoxy, HB Surf. Tol.EEE-154 D4260 Epoxy, 100% Sealer Epoxy, HB Surf. Tol. Epoxy, HB Top 10 SP 3 Epoxy, HB Surf. Tol.EEU-152 D4258 Epoxy, 100% Sealer Epoxy, HB Surf. Tol. Urethane, Acrylic 8 SP 3 Epoxy, HB Surf. Tol.EEU-552 6 Epoxy, HB Surf. Tol. Epoxy, HB Surf. Tol. Urethane, Acrylic 12 SP 3 Epoxy, HB Surf. Tol.EEU-F52 D4261 Epoxy, Block Fill Epoxy, HB Surf. Tol. Urethane, Acrylic 25 SP 3 Epoxy, HB Surf. Tol.EXA-502 6 Epoxy, HB Surf. Tol. Acrylic, WB Gloss 7 SP 3 Epoxy, HB Surf. Tol.EXE-202 Sand Epoxy, WB Epoxy, WB 4 Sand Epoxy, WBEXE-303 10 Epoxy, TF Primer Epoxy, TF Primer 6 SP 3 Epoxy, HB Surf. Tol.EXE-504 6 Epoxy, HB Surf. Tol. Epoxy, HB Top 9 SP 3 Epoxy, HB Surf. Tol.EXE-505 6 Epoxy, HB Surf. Tol. Epoxy, HB Surf. Tol. 10 SP 3 Epoxy, HB Surf. Tol.EXE-505A 10 Epoxy, Amine Adduct Epoxy, Amine Adduct 10 SP 10 Epoxy, Amine AdductEXE-505N 10 Epoxy, Novolac Epoxy, Novolac 10 SP 10 Epoxy, NovolacEXE-505P 10 Epoxy, Phenolic Epoxy, Phenolic 10 SP 10 Epoxy, PhenolicEXU-502 6 Epoxy, HB Surf. Tol. Urethane, Acrylic 7 SP 3 Epoxy, HB Surf. Tol.EXU-505 6 Epoxy, HB Surf. Tol. Urethane, HB Top 10 SP 3 Epoxy, HB Surf. Tol.EXX-500 6 Epoxy, HB Surf. Tol. 5 SP 3 Epoxy, HB Surf. Tol.OXO-202 Sand Alkyd, Primer Alkyd, Gloss 4 Sand Alkyd, PrimerPXP-101 10 Polysiloxane Polysiloxane 3 SP 10 PolysiloxaneSXS-101A 10 Silicone, Air Set Silicone, Air Set 3 SP 10 Silicone, Air SetSXS-101H 10 Silicone, Heat Set Silicone, Heat Set 3 SP 10 Silicone, Heat SetSXS-202 10 Silicone, Acrylic Silicone, Acrylic 4 SP 10 Silicone, AcrylicXEA-052 3 By Manufacturer Epoxy, HB Surf. Tol. Acrylic, WB Gloss 7 SP 3 Epoxy, HB Surf. Tol.XEE-054 3 By Manufacturer Epoxy, HB Surf. Tol. Epoxy, HB Top 9 SP 3 Epoxy, HB Surf. Tol.XEU-052 3 By Manufacturer Epoxy, HB Surf. Tol. Urethane, Acrylic 7 SP 3 Epoxy, HB Surf. Tol.XEU-055 3 By Manufacturer Epoxy, HB Surf. Tol. Urethane, HB Top 10 SP 3 Epoxy, HB Surf. Tol.XZU-032 3 By Manufacturer Zinc, Epoxy Urethane, Acrylic 5 SP 3 Zinc, EpoxyZEA-342 10 Zinc, Inorganic Epoxy, HB Primer Acrylic, WB Gloss 9 SP 3 Epoxy, HB Surf. Tol.ZEE-344 10 Zinc, Inorganic Epoxy, HB Primer Epoxy, HB Top 11 SP 3 Epoxy, HB Surf. Tol.ZEU-342 10 Zinc, Inorganic Epoxy, HB Primer Urethane, Acrylic 9 SP 3 Epoxy, HB Surf. Tol.ZXE-304 10 Zinc, Inorganic Epoxy, HB Top 7 SP 3 Epoxy, HB Surf. Tol.ZXP-301 10 Zinc, Inorganic Polysiloxane 4 SP 10 Zinc, InorganicZXS-301 10 Zinc, Inorganic Silicone, Air Set 4 SP 10 Zinc, InorganicZXS-302 10 Zinc, Inorganic Silicone, Acrylic 5 SP 10 Zinc, InorganicZXU-305 10 Zinc, Inorganic Urethane, HB Top 8 SP 10 Epoxy, HB Surf. Tol.ZXX-300 10 Zinc, Inorganic 3 SP 10 Zinc, Inorganic



TABLE 3

SURFACE PREPARATION STANDARDS

Standards Type of Preparation

SSPC SP 1 Solvent cleaningSSPC SP 2, SSI St 2 Hand tool cleaningSSPC SP 3, SSI St 3 Power tool cleaningSSPC SP 4 Flame cleaningSSPC SP 5, SSI Sa 3, NACE 1 White metal blast cleaningSSPC SP 6, SSI Sa 2, NACE 3 Commercial blast cleaningSSPC SP 7, SSI Sa 1, NACE 4 Brush-off blast cleaningSSPC SP 8 PicklingSSPC SP 9 Weathering followed by blast

cleaningSSPC SP 10, SSI Sa 2 1/2, NACE 2 Near white blast metal cleaningSSPC SP 11 Power tool cleaning to bare

metalASTM D 4258 Surface cleaning concreteASTM D 4259 Abrading concreteASTM D 4260 Acid etching concreteASTM D 4261 Surface cleaning concrete unit

masonry for coating



TABLE 4

RECOMMENDED ABRASIVE SIZE

AnchorPattern(mils)

SilicaSand

SteelGrit

SteelShot Garnet

AluminumOxide

1 30/60 mesh G-80 S-110 80 mesh 100 mesh1 1/2 16/35 mesh G-50 S-170 36 mesh 50 mesh2 16/35 mesh G-40 S-230 36 mesh 36 mesh2 1/2 8/35 mesh G-40 S-280 16 mesh 24 mesh3-4 8/20 mesh G-25 S-330 16 mesh 16 mesh

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