PPI NBR: 63421- 002H (REV 09) DATE: March 30, 2006
PRESERVATION PROCESS INSTRUCTION (PPI) for
WEAR RESISTANT DECK TILE
to be used in conjunction with
CORE PPI 63101-000 with a
1. SCOPE:
1.1 Cleaning, Surface Preparation and Painting Requirements for Wear Resistant Deck Tile Areas. 1.2 RISK STATEMENT:
1.2.1 Risk for installation. If proper surface preparation and application procedures are not adhered to, coating system failure can occur within 3-6 months.
1.2.2 Risk for curing. If overcoat window timeframes are not adhered to, coating system failure is possible within the first 6-9 months of application.
1.2.3 If the PPI checkpoint criteria are met, the following table provides service life expectancy for the listed
systems:
Coating System Life Expectancy:
Surface Preparation Method System Life Expectancy
Cleanliness Level of
SSPC-SP-11 (Minimum) Wear Resistant DeckMIL-PRF-32170 Tile System, 10 years
2. REFERENCES:
2.a. Systems and Specifications, Steel Structures Painting Council, Volume 2 2.b. SSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages
2.c. MSDS and NAVSEA approved manufacturer’s ASTM F 718 and Product Specification/Technical Data sheets, Shipbuilders and Marine Paints and Coating Product / Procedure Data Sheet for Coating System Being Applied.
Prime Coat: --- MIL-PRF-23236, Type VII, Class 17
Wear Resistant DeckTile System:--- Approved Materials IAW NSTM 634, Section 3
Meeting MIL-PRF-32170 Requirements (Underlayment shall be epoxy lightweight, 1 lb/ft2 or less at ¼” thickness),
NAVSEA APPROVED MATERIALS LISTS Manufacturer Specified Epoxy Adhesive
Membrane--- EPMAR EKY-2102 or DEX-O-TEX ELASTAGUARD 2.d. ASTM D 4417, Method C, Standard Test Methods for Field Measurement of Surface Profile of Blast
Cleaned Steel
2.e. OSHA 29 CFR 1915 Subparts C and Z
2.f. SSPC-VIS-3 Visual Standard For Power and Hand Tool Cleaned Steel 2.g. Naval Ships’ Technical Manual Chapter 631
2.h ISO 8502-3, Preparation of steel substrates before application of paint and related products – tests for the assessment of surface cleanliness – Part 3: Assessment of dust on steel surfaces prepared for painting (pressure sensitive tape method)
3. APPENDICES: (REFER TO CORE PPIEXCEPT FOR APPENDICES 5, 6, 8, and 10)
4. REQUIREMENTS: (REFER TO CORE PPI EXCEPT FOR THE FOLLOWING)
4.3.1 REQUIREMENTS FOR COATED AREAS. Coating systems shall be applied by certified painters. Checkpoints and final inspections shall be signed off by certified coating inspectors.
4.3.2 PAINTER CERTIFICATION. The Implementing Contractor shall maintain a current certification in
accordance with the Society for Protective Coatings (SSPC) QP-1 program for the duration of the project. The implementing contractor shall maintain a certification program for painters working on the project IAW SSPC-C-7 and NSTM 631, Section 11.5. The company shall provide adequate records verifying the completion and currency of training for each painter involved in surface preparation and application of the coating. Documentation shall be maintained verifying that only certified painters are used for preservation work. Training shall include all paint application techniques and procedures appropriate to the surface preparation and coating materials used.
4.3.4 COATING INSPECTOR RESPONSIBILITIES: Coating inspectors are responsible for providing reasonable confidence that material storage, surface preparation, paint and tile system application and curing are accomplished IAW the manufacturer’s requirements. These responsibilities require the coating inspector to: inspect material storage facilities; ensure all inspection equipment requiring calibration certification is certified under organization metrology calibration programs; perform in-process inspections of surface preparation, painting and verify successful completion of checkpoints in the application process; and inspect and accept or reject final paint systems.
4.3.5 IN-PROCESS INSPECTIONS: The Responsible Government Representative shall be given a minimum of 4 hours prior notice and shall perform an inspection of each coated area when the following checkpoints are reached: pre-surface preparation & cleaning, contamination containment and masking, surface preparation, paint storage area, prime coat, topcoat of paint applied, free flow test, positive drain test and area ready for final inspection. The Responsible Government Representative is also required to examine all data maintained by the paint foremen concerning environmental conditions, surface cleanliness, surface profile and paint thickness. Data shall be verified, depending on the checkpoint in question, including surface cleanliness, surface profile, dry film thickness and workmanship. Environmental data, such as temperatures, relative humidity and dew point need only be verified if the inspector is doubtful of the recorded values. Deficiencies in personnel training, certification, record maintenance, equipment maintenance or any matter that is not IAW good painting practice shall be recorded. The coating inspector shall verify the successful completion of each checkpoint and sign and date the applicable spaces on Appendix 6.
4.9 TEMPERATURES TO BE MAINTAINED FOR PAINT/TILE COATING SYSTEMS: Immediately prior to application of each layer of the tile system substrate surface temperature shall be taken. Readings shall be taken in five randomly chosen locations on the deck layer within the space and the highest and lowest surface temperatures measured recorded in Appendix 1. Additionally, readings shall be taken in five randomly chosen locations on the deck layer within the space and the highest and lowest surface
temperatures measured recorded prior to resuming application of a layer of the tile system when there has been a temporary work interruption. Application of the next layer of the tile system shall not commence (or recommence after a temporary work interruption) until all recorded surface temperature readings are within the required range as specified in Ref. 2.c and NSTM 631, Section 6.3. If any reading is outside of the required range, the contractor must take additional action to control the temperature in the space and return the surface temperature readings to within the required range. Additional readings shall be taken a minimum of hourly until the readings are returned to within the required range. If inconsistencies between the acceptable ambient and surface temperature ranges in Ref. 2.c and NSTM 631, Section 6.3 exist, the more stringent requirements shall be followed. If required ambient and surface temperatures are not provided or are unclear, contact Contracting Regional Maintenance Center for resolution.
5. PRE-SURFACE PREPARATION:
5.1 Remove deck strainer plates and retain for reinstallation as applicable. Provide adequate protection to deck drains(s) opening to prevent contamination. Log and provide identification tags for removed strainer plates.
5.2 STRUCTURAL INSPECTION: Prior to commencement of work, the government shall provide an authorized representative to conduct a structural inspection for the entire area to be prepared. Heavily
rusted or corroded areas, damaged metal, and holes in the structure or piping shall be documented and provided to both ship’s force and the Contracting Regional Maintenance Center to determine if further structural evaluation or NDT is warranted, and for possible repair before surface preparation.
5.3 PRE-SURFACE CONDITIONING: Before surface preparation the Contracting Regional Maintenance Center shall have all welds, protrusions, projections and spikes ground smooth and flush with the deck; pits in the welds shall be ground out; all weld splatter shall be removed.
5.4 Remove existing deck covering and underlay using power tools, including pneumatic air chisels. Care shall
be taken as to prevent damage to existing deck plating. For Aluminum decks, grinders and sanders used in deck covering and underlayment removal shall be equipped with 16-grit aluminum oxide abrasive pads. Abrasive materials (pads, belts) must not have been previously used to prepare copper nickel metal for painting or to remove copper base anti-fouling paints. Gouges and cuts into the plating shall be reported immediately to the Contracting Regional Maintenance Center.
5.5 DEGREASE / FRESH WATER WASH DOWN: Prior to surface preparation, remove all surface contaminants
such as grease and oil (hydrocarbons), loose rust, chlorides and all other contaminates. Where required, spot degreasing shall be performed on affected areas with solvent cleaning compound (MIL-C-22230) followed by freshwater rinsing. Use vacuum to remove standing water followed by an adequate period of time to allow the surface to dry prior to surface preparation. SSPC-SP-1 requirements shall be met. Oily wastes and chemicals shall be disposed of per local and State instructions.
5.6 CHECKPOINT (Pre-Surface Preparation Inspection): (REFER TO SECTION 5.4 OF CORE PPI) 6. SURFACE PREPARATION: (REFER TO CORE PPI EXCEPT FOR THE FOLLOWING) NOTE: CONTRACTING REGIONAL MAINTENANCE CENTER SHALL DESIGNATE ONE OF THE
FOLLOWING METHODS TO ACHIEVE A CLEANLINESS LEVEL OF SSPC-SP-11 (MINIMUM) SURFACE PREPARATION:
1) POWER TOOL CLEANING TO BARE METAL
2) ABRASIVE BLASTING WITH ABRASIVE SPONGE MEDIA 6.2 Not Applicable to this PPI
6.3 Not Applicable to this PPI
6.4 Power Tool Cleaning to Bare Metal:
NOTE: GRINDERS AND SANDERS MAY BE USED TO PREPARE COATINGS OR REMOVE PAINT BUT ARE NOT AUTHORIZED FOR SURFACE PREPARATION.
6.4.1 Accomplish the overhaul surface preparation requirements of SSPC-SP-11 and Table 631-11-1, (Surface
Preparation), for the location/area being prepared. Minimum requirement is SSPC-SP-11.
6.4.2 Surface preparation accomplished using a surface preparation device such as a disk sander or power
wire wheel that burnishes, polishes or smoothes the surface is not authorized. A minimum average surface profile of 2.0 mils is required, with no individual reading below 1.0 mil.
6.4.3 Feather edges of well-adhered paint in adjacent areas intended to remain after cleaning. 6.5.2.1 Not Applicable to this PPI
6.5.2.2 Not Applicable to this PPI 7. PAINTING REQUIREMENTS:
NOTE: CONTRACTING REGIONAL MAINTENANCE CENTER SHALL DESIGNATE COATING SYSTEM TO BE APPLIED.
NOTE: TO MAINTAIN PROPER SURFACE CONDITIONS AFTER COMPLETION OF THE SURFACE
PREPARATION CHECKPOINT METHODS SUCH AS USE OF DEHUMIDIFICATION EQUIPMENT AND SURVEILLANCE/MONITORING OF THE PREPARED SURFACE SHOULD BE EMPLOYED. COATING APPLICATION SHALL START WITHIN 1 HOUR AFTER SURFACE PREPARATION CHECKPOINT
COMPLETION AND ACCEPTANCE. COATING APPLICATION SHALL BE CONTINUOUS THROUGH COMPLETION OF THE AREA TO BE COATED. IF COATING APPLICATION HAS NOT STARTED WITHIN 1 HOUR OF SURFACE PREPARATION CHECKPOINT COMPLETION THE SURFACE PREPARATION CHECKPOINT WITH THE EXCEPTION OF SURFACE PROFILE SHALL BE REPEATED.
7.1 Not Applicable to this PPI
7.9 PAINT APPLICATION: The use of brush, rollers, and single or plural component spray equipment is
acceptable for application of the paint coat specified below.
7.10 Not Applicable to this PPI
8. PRIMER COAT APPLICATION: (REFER TO CORE PPI)
9. WATERPROOF MEMBRANE FOR DECKS ADJACENT TO WET SPACE BULKHEAD (S):
NOTE: A WATERPROOF MEMBRANE SHALL BE APPLIED IN THE FOLLOWING CIRCUMSTANCE: IN A COMPARTMENT RECEIVING WEAR RESISTANT DECK TILE THAT ADJOINS A WET SPACE WHERE THE COAMING TO DECK JOINT IS NOT 100% SEAM WELDED, THE WATERPROOF MEMBRANE IS TO BE APPLIED TO THE JOINT WHERE THE COAMING IS ATTACHED TO THE DECK PRIOR TO ANY UNDERLAYMENT INSTALLATION IN THIS AREA.
9.2.1 Mix Waterproof Membrane IAW manufacturer’s product specification/technical data sheet, Ref. 2.c. 9.2.2 Apply membrane by brush, roller, squeegee or trowel. Do not allow material to puddle.
9.2.3 If specified by the manufacturer, apply additional coat to applicable areas IAW manufacturer’s product specification/technical data sheet, Ref. 2.c.
9.2.4 CHECKPOINT (Waterproof Membrane): Verify waterproof membrane is applied IAW manufacturer’s product specification/technical data sheet (e.g., verify waterproof membrane has proper consistency, verify area covered completely to a uniform thickness, verify minimum coat application used to avoid excessive deposit of material at the joint), Ref. 2.c.
9.2.5 In order to pass the checkpoint, Appendix 5 shall be up to date and submitted to QA. QA shall sign Appendix 5 in the appropriate places.
10. DECK UNDERLAYMENT SYSTEM:
NOTE: APPLY UNDERLAYMENT TO WELD SEAMS TO FILL IN DEPRESSIONS, TO LEVEL THE DECK, AND TO PROVIDE PROPER SLOPE TO DECK DRAINS IF THEY EXIST.
10.1 BOND COAT:
10.1.1 Mix Bond Coat IAW manufacturer’s product specification/technical data sheet, Ref. 2.c.
10.1.2 Apply with brush and or short nap roller. Refer to manufacturer’s product specification/technical data sheet Ref. 2.c.
10.1.3 CHECKPOINT (Bond Coat): Verify bond coat is applied IAW manufacturer’s product specification/ technical data sheet (e.g., verify bond coat material has proper consistency, verify area covered completely to a uniform thickness, verify minimum coat application used to avoid excessive buildup of material), Ref. 2.c.
10.1.4 In order to pass the checkpoint, Appendix 5 shall be up to date and submitted to QA. QA shall sign Appendix 5 in the appropriate places.
10.2 UNDERLAYMENT (IF APPLICABLE):
NOTE: UNDERLAYMENT MUST BE APPLIED WHILE BOND COAT IS STILL TACKY.
10.2.2 Apply by trowel over bond coat to fair deck irregularities and produce positive slopes toward drains IAW manufacturer’s product specification/technical data sheet, Ref. 2.c.
10.2.3 Curing overnight (12 hours minimum) is recommended prior to application of next coat. 10.2.4 Use low-level lighting to help avoid trowel marks.
10.2.5 CHECKPOINT (Underlayment): Verify underlayment is applied IAW manufacturer’s product specification/technical data sheet (e.g., verify underlayment has proper consistency, verify use of epoxy lighweight underlayment, verify area covered completely to a uniform thickness, verify underlayment properly applied to produce a positive slope toward deck drains, verify minimum coat application used to avoid excessive buildup of material), Ref. 2.c.
10.2.6 In order to pass the checkpoint, Appendix 5 shall be up to date and submitted to QA. QA shall sign Appendix 5 in the appropriate places.
10.3 ADHESIVE APPLICATION: WEAR RESISTANT DECK TILE EPOXY ADHESIVE INSTALLATION: 10.3.1 Substrate temperature must be between 64ºF - 81ºF, relative humidity maximum of 75%. The temperature
and relative humidity shall be stabilized 24 hours prior to and after installation.
10.3.2 Mix the wear resistant deck tile adhesive components IAW manufacturer’s product specification/ technical data sheet, Ref. 2.c.
10.3.3 Apply by notched trowel IAW manufacturer’s product specification/technical data sheet, Ref. 2.c.
10.3.4 CHECKPOINT (Epoxy Adhesive): Verify epoxy adhesive is applied IAW manufacturer’s product specification/technical data sheet (e.g., verify epoxy adhesive has proper consistency, verify
substrate temperature between 64ºF - 81ºF prior to application of epoxy adhesive, verify area covered completely to a uniform thickness, verify minimum coat application used to avoid excessive buildup of material), Ref. 2.c.
10.3.5 In order to pass the checkpoint, Appendix 5 shall be up to date and submitted to QA. QA shall sign Appendix 5 in the appropriate places.
11. WEAR RESISTANT DECK TILE INSTALLATION:
11.1 Post warning signs and placards at all entrances to the space prohibiting entrance for 24 hours after installation, and prohibiting washing of the deck for 48 hours.
11.2 Tiles, adhesive, and sub-floor shall be allowed to stabilize to a temperature as close as practicable to room temperature, but in all cases must be between 64-81o F for a period of 24 hours before, during, and after
installation. Tiles shall be stored flat.
11.3 Do not spring wear resistant deck tiles into position. Tiles requiring hand cutting shall not be cut oversize and then sprung (forced) into position. They shall be cut such that they fit neatly into position without a gap between them and not requiring bending or the application of force. Tiles can be taped together with masking tape to pull joints together while curing of the adhesive.
11.4 The deck shall be rolled initially by hand with a vinyl seam roller. Two to four hours after application of the adhesive, but prior to adhesive setting, the tiled surface shall be rolled with a 100 lb floor tile roller to ensure a good bond between the tiles, adhesive and sub-floor.
11.5 Clean away excess adhesive before it is allowed to dry. Use a soft cloth moistened with denatured alcohol. Do not use mineral spirits, which will cause swelling and have a tendency to curl.
12. Seal all edges of the wear resistant deck tile including penetrations for pipes, foundations, vents, and other
structures with a caulking compound like “Clear Caulk” or equivalent, which is a sandable and paintable acrylic.
13.1 Mechanically clean each deck drain from point of entry to each terminating point, free of foreign matter that could affect performance or damage system components.
13.2 Isolate each component that may be damaged by cleaning.
13.3 Flush each drain after cleaning with clean, fresh water, until free of debris. Test to ensure drains flow free. 13.4 Reinstall each deck drain strainer plate removed in 5.1.
13.5 Retap each hole for each new fastener.
13.6 Install new fasteners, same type and size as those removed in paragraph 5.1.
13.7 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of the checkpoint. At rescheduled checkpoint, QA shall document satisfactory corrective actions taken to correct discrepancy.
13.8 In order to pass the checkpoint, Appendix 5 shall be up to date and submitted to QA. QA shall sign Appendix 5 in the appropriate places.
14. CHECKPOINT (Positive Drain Test):
14.1 Apply a sufficient amount of clean, fresh water throughout compartment deck surfaces to verify that new deck covering slopes to drains and water does not stand or puddle on deck. Water shall flow to drains when applied to deck surfaces.
14.2 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of the checkpoint. At rescheduled checkpoint, QA will document satisfactory corrective actions taken to correct discrepancy.
14.3 In order to pass the checkpoint, Appendix 5 shall be up to date and submitted to QA. QA shall sign Appendix 5 in the appropriate places.
15. FINAL INSPECTION:
15.1 CHECKPOINT (Finished Wear Resistant Deck Tile Surfaces):
15.1.1 Tile system imperfections found, which may cause premature tile system failure, shall be corrected before the tile system is accepted. Slight imperfections in the tile system are allowable, as long as they do not penetrate to the underlying epoxy adhesive, and shall not result in premature failure of the tile in the immediate vicinity of the imperfection. Such slight imperfections shall be left intact, as trying to correct them could result in damage to the surrounding tile system.
15.1.2 In order to pass the checkpoint, any Appendices required by the certified coating inspector shall be up to date or completed and submitted to QA. QA shall sign Appendix 5 in the appropriate areas. All test inspections noting unsatisfactory conditions shall be corrected.
16. REPAIR PROCEDURES:
16.1 For minor scuffing / marring:
16.1.1 Using the two-bucket mopping system, apply cleaning solution using a suitable mop that has been well wrung to remove excess liquid. Recommended solutions include Johnsons Stride 1000, Henkel Silky Onyx, Butchers Sundance, Wetrok Remop, Lever Exotol, and British Nova Liquid 99. Recharge the mop frequently and change solution as necessary. Allow to dry thoroughly. If normal maintenance incorporates use of a scrubber-drier, then the hand-held device should be fitted with a blue or green nylon 3M pad and a neutral detergent used, diluted in accordance with manufacturer’s instructions.
16.2 For moderate scuffing / marring:
16.2.1 Prepare a solution of neutral detergent and dispense into a suitable spray canister. Recommended solutions include Johnsons Stride 1000, Henkel Silky Onyx, Butchers Sundance, Wetrok Remop, Lever Exotol, and British Nova Liquid 99. Apply a fine spray of liquid onto approximately 20 ft² of deck. Using a rotary buffing machine (approximately 450 rpm) fitted with a blue or green nylon 3M pad, work in parallel overlapping passes until the floor is clean and just dry. Do not continue the passes after the floor has
dried. Continue to work in 20 ft² areas. 16.3 To repair gouged tile: See Appendix 10 16.4 To replace damaged tile:
16.4.1 Remove damaged tile by inserting a flat surface knife under the corner of the tile and wedge it from surface. Continue to remove tile from underlayment system, this will leave epoxy residue as well as likely damage to the rubber membrane and underlayment surface.
16.4.2 Scrape the damaged underlayment with a razor scraper to remove epoxy and adhesive residue. Restore the damaged area of the underlayment to a smooth surface and remove any dust by either vacuum or soft brush. If damage to underlayment does not exceed ¼” in depth float the membrane material into those cavities vice using additional underlayment. (The underlayment is self-leveling up to ¼”.)
16.4.3 Ensure no debris remains along the edges of the repair area next to remaining tiles.
16.4.4 If damage to underlayment exceeds ¼” in depth apply cement-based compound such as Ardex Feather Finish to restore the underlayment to a smooth and level condition using a flat blade trowel or broad putty knife. Allow to dry for approximately 60 minutes until light gray in color. Recoat with appropriate membrane material (underlay and membrane must be installed at a level that allows the new tile to remain level with the existing).
16.4.5 Reapply the recommended epoxy adhesive with a 1/16x1/16x1/16 v-notched trowel and set the new tile in place.
16.4.6 Once the tile is reset protect from foot traffic for a minimum of 24 hours.
16.4.7 Clean epoxy adhesive residue from the surface of the tile using a soft cloth moistened with denatured alcohol.
APPENDIX 5
CHECKPOINTS & MILESTONES COMPLETION & SIGN OFF LOG
SHIP: ________________________________________JOB ORDER: __________________ DATE: __________________ LOCATION: ________________________________________WORK ITEM: ________________ PARA. NO.: ___________ PRODUCT BEING APPLIED: _________________________________________________________
MAINTAIN SEPARATE LOG FOR EACH AREA/LOCATION, PREPARED OR PAINTED SURFACE. WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION.
ACTIVITY TIME DATE
Date Pre-Surface Preparation and Cleaning Begins
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Pre-Surface Preparation and Cleaning Checkpoint
--Date of Visual and UV Light or Water-Break Inspection Check
--Date of Structural and Pre-Surface Conditioning (ensuring de-burring and grinding) Check --Date of Contamination Containment and Masking Check
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date Surface Preparation Begins
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Surface Preparation Checkpoint
--Date of Surface Profile Measurement Check --Date of Soluble Salt Measurement Check --Date of Environmental Check
--Date of Contamination Containment and Masking Check
--Date of Inspection of Prepared area (ensuring all areas are properly prepared) Check --Date of Inspection of area cleanliness prior to primer application Check
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date Material Storage Area Inspected
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date Paint Mixing Inspected
--Date of Shelf Life Check --Date of Temperature Check --Date of Mixing Check
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date Prime Coat is Applied
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Prime Coat Checkpoint
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
APPENDIX 5 (CONTINUED)
CHECKPOINTS & MILESTONES COMPLETION LOG
SHIP: ________________________________________JOB ORDER: __________________ DATE: __________________ LOCATION: ________________________________________WORK ITEM: ________________ PARA. NO.: ___________ PRODUCT BEING APPLIED: _________________________________________________________
MAINTAIN SEPARATE LOG FOR EACH AREA/LOCATION, PREPARED OR PAINTED SURFACE. WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION.
ACTIVITY TIME DATE
Date Waterproof Membrane is Applied (If Applicable)
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Waterproof Membrane Checkpoint (If Applicable)
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date Bond Coat is Applied
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Bond Coat Checkpoint
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date Epoxy Lightweight Underlayment is Applied (If Applicable)
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Epoxy Lightweight Underlayment Checkpoint (If Applicable)
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date Epoxy Adhesive is Applied
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Epoxy Adhesive Checkpoint
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
APPENDIX 5 (CONTINUED)
CHECKPOINTS & MILESTONES COMPLETION LOG
SHIP: ________________________________________JOB ORDER: __________________ DATE: __________________ LOCATION: ________________________________________WORK ITEM: ________________ PARA. NO.: ___________ PRODUCT BEING APPLIED: _________________________________________________________
MAINTAIN SEPARATE LOG FOR EACH AREA/LOCATION, PREPARED OR PAINTED SURFACE. WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION.
Date of Free Flow Test
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Positive Drain Test
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
Inspector #: _________________ Certification Expiration Date: ______________ Date of Finished Wear Resistant Tile Surfaces Checkpoint
Implementing Contractor (Print/ Signature): __________________________________________ Certified Inspector (Print): ________________________________________________________ Certified Inspector (Signature): ____________________________________________________ NACE Session I Certification NBPI Certification
APPENDIX 6
PAINT APPLICATION EQUIPMENT AND PAINT CONSUMPTION LOG
SHIP: ________________________________________JOB ORDER: __________________ DATE: __________________ LOCATION: ________________________________________WORK ITEM: ________________ PARA. NO.: ___________ PRODUCT BEING APPLIED: _________________________________________________________
MAINTAIN SEPARATE LOG FOR EACH AREA/LOCATION, PREPARED OR PAINTED SURFACE. WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION.
Prime Coat
Bond
Coat Underlayment
Waterproof
Membrane Adhesive Tile
Airless Paint Hose Size N/A N/A N/A N/A N/A Airless Paint Hose Length N/A N/A N/A N/A N/A Airless Tip Orifice Diameter / Fan
Width
N/A N/A N/A N/A N/A
Plural Airless Airless Pump
Used & Model Conventional Airless
N/A N/A N/A N/A N/A
Airless Pump Ratio If plural component: Fixed or Variable
N/A N/A N/A N/A N/A
Temperature Setting At
Heater
N/A N/A N/A N/A N/A
If Using Inline Heater
Temperature in Fº
(Fahrenheit) Temperature At Tip
N/A N/A N/A N/A N/A
Product Applied Product Manufacturer Expiration Date Color Applied Product VOC Base Portion Batch №
(Part A)
Base Portion Batch №
(Part A) Expiration Date Hardener Portion Batch №
(Part B)
Hardener Portion Batch №
(Part B) Expiration Date Gallons Used per Coat Square Feet Painted
APPENDIX 8
COATING SYSTEMS
Coating EuroNavy ES 301 K/L Interbond 998 Alocit 28.15 Primer 6 – 8 mils DFT 6 – 8 mils DFT 6 – 8 mils DFT
NAVSEA APPROVED ASTM-F-718 SHEETS MAY BE OBTAINED BY SELECTING THE NAVY COMMUNITY TAB ON THE WWW.NSTCENTER.COM WEBSITE AND FOLLOWING THE DIRECTIONS TO THEIR LOCATION.
APPENDIX 10
Repair Procedure For Gouged TileMATERIAL AND EQUIPMENT USED
Material Required
• Any Router which has adjustable depth-of-cut and is compatible with an inlay kit. Use a router which can handle both 1/4” and 1/2” shafts. A variable speed router might reduce some of the minor problems caused by the plastic (DEC tile) melting, but is not essential. The demonstration project used a Porter Cable 6902 router.
• 1/2” diameter plunge Router (Carbide Tip is preferable if several templates are to be made).
• An inlay kit (The demonstration was made with a 43900 Porter Cable Inlay Kit (Tool crib Part No.: 43900)). Obtain a few of the inlay kits and several of the bits for shipboard use.
• 1/4” or 1/2” thick fine-grained plywood (e.g. AX finish) for template, suggested size of 2’ X 1’ (This could be almost any fairly hard, routable, material, such as plywood, PVC, or masonite; patches and holes will be better if “clean” edges can be milled with a router). Instead of using the router to create the template, the template could be created by milling a piece of 1/8” or 1/4” metal or hard plastic.
• Wood backing plate for cutting patches (flat surface, which the router can cut into without dulling the router bit significantly). This should be about the same size as the template plate. This should be at least 1/2” thick.
• Three (minimum) or four “C” or other type of clamps, appropriate for assembling the backing plate, tile, and template into an immovable sandwich while routing.
• “Guides” for cutting straight grooves and right angles in the template. Four pieces will be required, and this might be 1/4” X 1” flat metal bar, 1” X 3” X 2’ (nominal) wood, etc.
• Pieces of DEC tile which match the color and pattern of the floor tile being repaired.
• T-square (right angle) or right angle triangle, for checking perpendicularity of guide bars.
• Flashlight or portable lamp to check progress of routing directly underneath router while in operation, and to help with “zeroing” the depth gage on the router.
• Sandpaper, preferably a fixed drum/disc sander for cleaning up the edges of the patches for the proper fit into the holes.
Optional, but useful
• Air jet for blowing debris from tile groove, during cutting (The tile material tends to melt around the spinning bit – if the tile debris can be dislodged as it is milled, it will leave a smoother cut and require less clean-up.
INTRODUCTION
Repairing gouge in tile has three steps, as shown in Figure 3:
• Creation of the template, which is essentially a cookie cutter – this is fabricated once, and will probably last
for thousands of patches, since it should have no wear. The template should be about 4” to 5” larger in any dimension than the gouge being prepared – e.g. to use a 1” X 6” patch (for a 1/2” X 5” gouge), the template size should be approximately 11” X 16”. Any shape of template could be used, but it is probably easiest to create a rectangle with rounded corners. Use of a relatively large router bit (e.g. 1/2”) helps this step go quickly. Figure 3A is a schematic of this. Figure 1 provides more detailed information on this setup.
• Cutting the patch Apatch is cut from the DEC tile. The patch needs to be at least slightly larger than the
gouge to be repaired. To cut the patch, the template, a loose piece of DEC tile, and a backing plate are clamped together in a “sandwich”, which is secured appropriately for use of a router. Cutting each patch will require 1-2 minutes. For wear resistant deck tile (i.e., Stratica tile), the depth of cut was set to 9/64”, which
insured going completely through the tile and slightly into the backing plate. The inlay template does not use the bushing (collar). See Figure 3B
• Cutting the hole in the floor In order to achieve having the patch flush with the original floor, tight depth
control on the depth of the groove cut in the floor is essential. Too shallow a groove depth will result in the patch being higher than the surrounding floor, and vice versa. The template will need to be secured
appropriately to the floor, the depth of the router bit “zeroed” at the tile surface, and the depth of cut set to go through the adhesive layer, without going into the underlayment below. (7/64” depth of cut with wear resistant deck tile (i.e., Stratica tile)). The bushing is used on the inlay tool, to make the hole in the flooring. See Figure 3C
DETAILED PROCEDURE Creation of the template
Tile patches need to be slightly larger than the grooves they cover. Since creation of many sizes of templates would be tedious, creation of a single size of patch which is slightly larger than the largest gouge seems appropriate. In order to avoid interference of the router with clamps during the cutting of the patch step, the sheet which the template is cut from should be 4” to 5” larger in all dimensions than the patch.
It is not necessary to make detailed dimensional calculations before cutting a template and making patches. Detailed dimensional calculations were not required to set up the demonstration. Figure 1 shows the setup for creation of the template.
1.
Based on the size requirement of the patches, cut the template plate to its required size. (Figure 1A) The demonstration template plate was 9-1/4” X 16-1/2” X 5/8” thick BX plywood, which had a 1-1/4” X 8-1/2” groove cut in it. This yielded a 0.75” wide patch.2.
Mark (use pencil or pen) on the template plate where one long side of the groove will go (note there is no requirement that the groove be exactly centered within the plate. (Figure 1A)3.
Using the router with the appropriate bit (e.g. 1/2”), position the first of the long guides in its final position (Figure 1B). It is appropriate to mark this position on the template plate.4.
Use the appropriate shim stock and the router base plate to set the second longitudinal guide bar (Figures 1Ci and 1Cii). For the demonstration with a 1/2” diameter router bit and a desired groove width of 1.25”, 3/4” shim stock (a piece of nominal 1” X 3” wood) was appropriate.5. Clamp guidebars on top of the longitudinal guidebars, and insure the appropriate parallel/perpendicular nature of the guidebars (utilize right triangle or “L” ruler). (Figure 1 D)
6. Secure (clamp) the guidebars, the template plate, and a backing plate to an appropriate worktable. (Figure 3A)
7. Position the router within the template guidebars and zero the depth of the router gauge with first contact of the router bit (1/2” plunge router) with the surface of the template plate. (Figure 2A)
8. Energize the router and increase the depth of cut to 1/8”. Rout the groove within the guide bars.
9. Increase the router depth of cut by 1/8”, and continue milling out groove. Continue with milling, 1/8” at a time, until the groove is completely through the template plate.
Cutting the patch
11. Assemble the inlay kit and bit on the router (For the demonstration, I used the 1/8” bit and guide of the Porter Cable 43900). Do not use the external bushing on the router. (Figure 2B)
12. Secure (clamp) the template plate, a free piece of DEC tile, and a backing plate onto an appropriate work table. (Figure 3B)
13. Position the router directly over the template. Zero the router bit depth gauge at first contact of the router bit with the DEC tile.
14. Wrapping the OD of the inlay guide with two layers of electrical tape reduced some of the subsequent patch clean up required. (See step 30 of Cut groove in floor) This will have the effect of making the patch bushing
diameter about 0.015” larger, and the patch correspondingly smaller.) Use of a lower speed variable router might change this somewhat.
15. Before energizing the router, the router must be held in position so that the inlay guide is along the inner edge of template groove.
16. If available, begin the air jet to sweep away routing debris.
17. Energize the router (hold it firmly enough to avoid the router jumping as it is turned on.) Increase depth of cut to 1/8”.
18. Rout a 1/8” groove completely around the inside periphery of the plate. Try to use the air jet as much as possible to blow away melting plastic router debris as it forms. Since the plastic will partially melt into the backing plate, it is better to make two complete circuits of the template in order to get a fairly clean separation of the patch from the tile. Do not leave the router bit turning in the same area for a significant amount of time - that will burn/damage the tile, and make too large a hole.
19. Shut the router off, and lift it from the work surface.
20. Remove clamps from the template, and remove the patch from the backing plate (A chisel or screwdriver may be required to lift it from the surface of the backing plate.)
21. Clean up the patch – remove the solidified molten debris from the patches outer edge. (Use of a variable speed router at a lower speed might help reduce the extent of melting and possible damage; this study did not include evaluation of that)
22. Repeat steps 12-21 until all necessary patches are routed.
Cutting the hole (Groove) in the floor tile
The demonstration project made use of the 43900 inlay kit for routing the floor tile as well as cutting the patch. It might be possible to reduce the time required for the grooving the floor, with the use of a larger bit, but this was not pursued in the demonstration. Each 8-1/2” X 3/4” groove/hole in a floor tile required about 4-5 minutes to cut with the 1/8” bit of the 43900 kit.
Be careful of the router bit and or chuck interfering with the inlay kit as the bit is lowered. If the bit is lowered so that the chuck (collet) rubs against the inlay kit, the chuck and inlay kit will rapidly be heated by friction to glowing red heat, and there may the usual sparks of metal grinding.
23. Remove any tape from the router bushing guide (step 14 above) and install the bushing on the inlay guide. (Figure 2 C)
24. Secure the template as appropriate to the floor at a gouge (e.g. have 1 or 2 assistants stand on one corner of the template). (Figure 3C)
25. Extend the depth of the router bit, and zero the depth indicator gauge of the router at first contact of the bit with the surface of the DEC tile.
26. Begin an air jet as available to assist in blowing away router debris.
27. Holding the router in place with the bit in the template, energize the router. Increase depth of cut to 7/64” * 1. 28. Completely mill out the template area. Do not keep the router bit in one position for more than a second or
two, especially at the periphery of the cut – this can burn a bigger hole than is desired. 29. Turn off the router. Remove the template.
30. Try to fit a patch into the hole (best if not to fit the entire piece in at once – it might be difficult to remove) to assess tightness of fit. The patch should not be so tight as it requires “snapping” into position. The residual stress from that tight a fit would eventually cause the patch to buckle up. As necessary clean up the edges of the patch with sandpaper so that the fit is snug but not tight. It might be necessary to experiment with the number of wraps (thickness) of the electrical tape used on the bushing guide in step 14, to minimize this patch cleanup time.
* 1 This depth of cut should remove as much as possible of the tile adhesive as possible, without starting to cut into the underlayment layer below. For the tile adhesive in the demonstration tiles, (7 to 8)/64” depth of cut was appropriate.