Guide to Protective Coatings:
Inspection and Maintenance
Tom N. Bortak
United States Department of the Interior
Bureau of Reclamation
Se v e r a l R e cl a m a t i o n e m p l o y e e s h e lp e d p r ep a r e t h is g u id e, a n d th eir con tr ib u tio n is gr ea tly ap p re ciate d . The se p eo p le ar e Ku rt F. von Fay, m aterials engineer , w ho set u p fu n d in g an d s h ow e d g re at p a tie n ce ov er th e w r i tin g i n t e r v a l ; D . Th o m a s (T o m ) Jo h n s o n , m ater ials en gine er, for h is corr osion exp ertise co n t r ib u t i on ; G r e g o r y J. M y e r s a n d R ich a r d A . P e p in , m a t e r ia l s e n g i n e e r i n g t e ch n ic ia n s , fo r th eir initial rev iew in ferretin g ou t obv iou s
er r or s; an d Ro b er t Ro od , ed ito r , for h is
n u m e r o u s “ I d o n ' t u n d e r s ta n d ” co m m e n t s th a t f o r ce d m e in t o w r i t in g a c le a r e r , m o r e c o n c is e , a n d u n d er st a n d a b le d o cu m en t.
A d e b t o f g r a tit u d e is ex p r e ss ed t o N A C E Inter n ation al, Society of Pro tective Co ating s, a n d U n iv er sit y of M iss ou r i-Ro lla, C oa tin g In s t it u t e fo r p r o v id in g a l l t h e co u r s e s a n d r e f e r e n c e s t h a t m a d e t h i s g u i d e p o s s ib l e .
In r e c en t y e a r s , co a t in g t e ch n o lo g y h a s ch an g ed d ra m at ically . Th e d riv in g for ce b e h i n d t h e c h a n g e h a s b e e n r e g u la t io n s a f fe c ti n g t h e e n v i r o n m e n t a n d p e r s o n n e l h e a l t h a n d s a fe t y . F o r ex a m p le , r e g u la t io n s r e la t ed t o d u s t p a r t icle s fr o m a b r a siv e b la s tin g , vo latile org an ic com p ou n d (VOC ) em ission s, a n d h a z a r d o u s m a t e r ia ls su ch a s le a d , ch r o m a t e, a n d o t h er h e av y m e t a ls h av e c h a n g e d .
Be fo r e t h e l a t e 19 80 s, c o a t in g m a t e r i a ls w e r e m or e t ole ra n t o f less th an op tim u m su rfa ce p r ep a r a tio n con d itio n s b eca u se p a in t
form u lation contained high VOC s to allow the m ater ial to w et or p en etr ate st eel su rfaces. The m o s t su cce ssfu l w e r e r ed le ad p r im e r s a n d v in y l r es in s ; h o w e v e r , r eg u la tio n s h a v e d isco u r a g ed th e u se of t h es e m a te r ials . Pa in t m an u factu rers reform u lated their coatings to com p ly w ith ne w regu lation s. This has led to th e d ev elo p m en t o f a w id e v ar iety of h igh -tech co a tin g m a te r ials th a t a r e m u ch m or e s en sit iv e t o su r fa ce p r e p a r a t io n a n d e n v i r o n m e n t a l a p p lica t io n p r a ct ice s . T h e Fe d e r a l H ig h w a y A d m in ist r a tio n h a s e st im a te d th a t u p to 80 p e r c en t o f a ll p r e m a t u r e co a t in g f a ilu r e s o n
b r id g e s tr u ctu r es ar e p a r tia lly or com p let ely c a u s e d b y d e fic ie n t s u r fa c e p r e p a r a t io n o r a p p lic a tio n p r a c tic es . Se v e r a l o r g a n i z a t io n s s u c h a s th e A m e r ica n S ocie t y fo r T es t in g a n d M aterials, N A CE Intern ational, and the So c ie t y f o r P r o t e ct iv e C o a t i n g s h a v e is s u e d con se n su s st an d ar d s to m in im ize su rfa ce p rep ara tion a n d ap p lication ina d equ acies.
Th is g u id e is n ot in te n d ed to b e a ll
e n c o m p a s sin g ; r a t h e r , it is in t e n d e d t o b e an in t r o d u ct io n t o sp e c ific r e fe r e n ce st a n d a r d s an d te st p ro ced u re s r ela te d to su rfa ce p r e p a r a t i on , a p p lica t io n , te s tin g , a n d m a in t e n a n c e o f co a t in g s . E xp la n a t io n s a n d p r oc ed u r es of r efe r en ce s ta n d a r d s cit ed w ith in t h i s g u id e a r e a b b r e v i a t e d t o d e v e l o p a w o r k in g b a s i s. T h e u s e r is e n co u r a g e d t o r e ad r e fe r e n ce st a n d a r d s a n d c o a tin g m a n u a ls fo r a m or e t h or ou g h u n d er st a n d in g . Th e g u id e focu se s o n n ew con st r u ctio n coa tin g s, ex ist in g in f r a st r u c t u r e co a t in g m a in t e n a n c e , a n d g a l v a n i z e d c o a t in g s o f fe r r o u s s u b s t r a t e s fo r m et a lw or k ite m s co a te d in th e fie ld . In g e n e r a l , t h i s g u id e fo llo w s t h e Bu r e a u o f Re clam a tio n ’s (Re clam a tio n ) coa tin g g u id e sp ecifications.
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Ch ap te r I— In tro d u cti o n an d Back g ro u n d . . . 1
1. St a n d a r d s . . . 1 2. C o a t i n g R e f e r e n c e s . . . 1 3. T er m in o lo g y . . . 1 4. C o r r o s i o n . . . 1 5. Se r v ice Ex p o s u r e . . . 5 C h a p te r II— M a te ri al s . . . 5 6. C o m p o n e n t s o f C o a t in g s . . . 5 7. C o a t i n g T y p e s . . . 7 8. G e n e r ic C o a t in g s . . . 7 C h ap te r III— S p e ci f icati o n s . . . 11
9. Con stru ction Sp ecification Institu te . . . 11
10. R e cla m a t io n C o a t in g S p e c ific a tio n s . . . 11
11. C o a t i n g T a b u l a t io n s a n d C a t e g o r i e s . . . 12
12. M an u factu rer's Prod u ct Data an d Ap p lication She ets . . . 13
13. A d d e n d u m s a n d M o d ifica tio n s . . . 14 C h a p te r IV — I n s p e c to r's R o l e . . . 15 14. P r i m a r y R e s p o n s i b i li ti e s . . . 15 15. D a i l y Re s p o n s i b i li ti e s . . . 15 16. M a t e r ia l A p p r o v a l . . . 16 17. D o c u m e n t a t io n . . . 16 18. In st r u m en ts , Ga u g es , an d To ols . . . 17 19. Su b s t r a t e In s p e ct io n . . . 17 20. C o a t i n g I n s p e c ti o n C h e c k li st Sh e e t . . . 17
21. P re coa tin g C on fer en ce . . . 17
Ch ap te r V — M ate ria l S to rag e , C o n tai n e rs, an d S h e l f Li f e . . . 19
22. St o r ag e . . . 19
23. C o n t a in e r s . . . 19
24. Sh elf Life . . . 19
C h ap te r V I — S u rf ace Pre p arati o n . . . 21
25. Su rface Conta m inan ts . . . 21
26. P re su r fa ce Tr ea tm e n t . . . 23
27. A b r a s i v e Bla s t M a t e r ia l . . . 23
28. N ozz le Blast Pressu re . . . 24
29. Su r f a ce P r e p a r a t io n M e t h o d s . . . 25
30. P h o t o g r a p h i c In s p e c tio n St a n d a r d s . . . 27
C h ap te r V I I— En v i ro n m e n t al Co n d i ti o n s . . . 33
32. E n v ir o n m e n t a l Fa ct o r s A f fe ct in g C o a t in g s . . . 33
C h a p te r V I II— A p p l i c ati o n a n d C u ri n g . . . 35
33. A p p lic a tio n T e m p e r a t u r e a n d H u m id it y R e st r ic tio n s . . . 35
34. C o a t in g L a y er s . . . 35 35. M ixin g . . . 36 36. A p p lic a tio n M e t h o d . . . 36 37. A p p l ica t io n T ech n i q u e . . . 39 38. D r y in g , Reco a tin g , an d C u r in g . . . 39 C h a p te r IX— Fi e l d I n s p e c ti o n a n d T e s ti n g . . . 41
39. Su rface Prep aration Tests . . . 41
40. W et Film Th ickn es s . . . 42 41. H a r d e n e d P a i n t e d Su r f a ce s . . . 42 42. D e s t r u c t iv e T e s t M e t h o d s . . . 45 C h ap te r X— M a i n te n an c e C o ati n g s . . . 47 43. D e f in i t io n . . . 47 44. Pu rp ose . . . 47 45. R is k E v a lu a t io n . . . 47 46. In s p e ct io n . . . 47 47. Toxic-Based Paints . . . 49
48. W ork er Pr otection from Toxic-Based Paints . . . 50
49. L e a d E x p o s u r e L e v e ls b y R e m o v a l M e t h o d s . . . 50 50. C o r r e c t iv e A c tio n . . . 51 51. M a t e r ia l Se le ct io n F act o r s . . . 52 52. Sch ed u lin g . . . 52 C h a p te r XI— G a l v a n i z i n g . . . 53 53. G a l v a n i z in g M e t h o d s . . . 53
54. Z in c C or r os ion an d Ser v ice L ife . . . 54
55. Z in c C h em i ca l Re actio n s . . . 54
56. Con tam inan ts . . . 54
57. Su r f a ce P r e p a r a t io n . . . 55
58. C o a t in g s . . . 57
Ch ap te r XII— Co ati n g Fai l u re s . . . 59
59. M a t e r ia l Se le ct io n . . . 59 60. F o r m u la t io n . . . 59 61. A d h e s i o n . . . 61 62. Su bstrate . . . 61 63. A p p lic a tio n . . . 62 64. D e s ig n . . . 63 65. E x te r i o r Fo r c e s . . . 67 Bi b li o grap h y . . . 69
A O r g a n i z a t io n a l So u r c e s fo r S ta n d a r d s a n d R e fe r e n c e s B R e a d i n g S o u r c e s
C Insp ection Ch ecklist
D Re fer en ce St a n d a r d s C ite d in G u id e E I n s p e c t io n E q u i p m e n t F E x a m p l e o f In s p e c ti o n D a i ly C h e c k Sh e e t G P r oc ed u r e fo r D et ect in g M ois tu r e a n d O il in C om p r es se d A ir (A STM D 4285) H P r o c e d u r e fo r D e t e c tin g C h l o r id e s a n d So lu b l e Sa l ts in A b r a s iv e s b y C o n d u c tiv i t y M e t h o d I P r o c e d u r e s fo r D e t e c t in g C h l o r id e Io n i n W a t e r J P r o ce d u r e s fo r D e te r m i n in g Bla s t C le a n in g A i r P r es su r e K D e t er m in a t io n o f E n v ir o n m e n t a l Fa ct o r s L P r o c e d u r e s fo r D e t e c t in g C h l o r id e Sa l t s o n P r e p a r e d o r E x is t in g Su r f a ce s M D eter m inin g Su rface P ro file of Blast-Clean ed Steel Usin g Rep lica Tap e
(N A C E RP 0 28 7 o r A S T M D 4 41 7, M e t h o d C )
N P r oc ed u r es for M ea su r in g W et Film Th ick n es s (A STM D 4414) O W e t Film T h i ck n e s s F o r m u la s a n d E xa m p le C a l cu la t io n s
P P r oc ed u r es for D r y Film Th ick n es s G a u g es (SSPC -P A 2) an d Exa m p le Q P r oc ed u r es for D isco n tin u ity (H olid a y ) Tes tin g (N A C E RP 0188)
R P r oc ed u r e fo r M ech a n ical (P u lloff) A d h es ion Te st in g (A STM D 4541; An n ex A 2) S P r oc ed u r e fo r H y d r a u lic A d h es ion Te st in g (A STM D 4541; An n ex A 3) T P r o ce d u r e fo r M e a s u r in g D r y F ilm T h ick n e s s b y D e s tr u c t iv e M e a n s W i th T o o k e G a u g e (A STM D 4138) U P r o c e d u r e s fo r SSP C - V IS 2 (2 00 0 R e v is io n ) V P r o ce d u r e to D e t er m in e t h e P r es en c e o f So lu b l e Le a d a n d In s o lu b l e Le a d C h r o m a t e in C o a t in g s W P r o ce d u r e to D e t er m in e t h e P r es en c e o f C h r o m a t e in C o a t in g s X D et er m in a tio n of T ox ic M et a ls in H a r d en ed P a in t
Figures
Figure Page 1 C o m p o n e n t s o f co a t in g s . . . 5Tables
T able Page 1 N u m b e r o f s p o t m e a s u r e m e n t s b a s e d o n t o t a l co a t e d s u r f a ce a r e a . . . 44 2 T y p i ca l a n d m a x im u m l ea d e x p o s u r e l e v e ls in m i cr o g r a m s p e r c u b i c m e t e r b y r e m o v a l m e t h o d . . . 51 3 G a l v a n i z in g m e t h o d s . . . 53 4 Fo r m u l a tio n -r e la t ed fa ilu r e s fo r o r g a n ic co a t in g s . . . 60 5 Fo r m u l a tio n -r e la t ed fa ilu r e s fo r in o r g a n i c co a t in g s . . . 61 6 A d h e s i o n - r e la t e d fa i lu r e s . . . 62 7 Su b s t r a t e - r e la t e d fa i lu r e s . . . 63 8 A p p l ic a t io n - r e l a t e d f a il u r e s . . . 64 9 D e s i g n - r e la t e d fa i lu r e s . . . 66 10 F a il u r e s r e l a t e d t o e x t e r i o r fo r c e s . . . 67Introduction and Background
Pro tective or ind u strial coating s are th e p r i m a r y m e a n s e m p lo y e d b y t h e Bu r e a u o f R e cla m a t io n ( Re cla m a t io n ) t o co n t r o l co r r os ion . H y d r a u lic st r u ctu r es ar e t y p ically co n s t ru c t ed w it h fe r r o u s m e t a ls a n d a r e s u b je ct t o co r r o s io n . M a n y R e cla m a t io n s tr u c t u r e s a r e 50 y e a r s o ld , a n d s o m e a r e a p p r o a ch i n g 100 y e a r s. T h e se st r u c tu r e s a r e exp ected to continu e fun ction ing into th e fo r e se e ab le fu t u r e . P r o te ct iv e co a t in g s in flu en ce t h e life, sa fety , op er at in g efficien cy , ap p ear an ce, an d econo m y of th ese stru ctu res.
A coa tin g 's e ffect iv en es s d ep en d s o n se lect in g coating m aterial that correctly m atches th e in te n d ed se r v ice ex p o su r e fo r th e m eta lw o r k . In t h e p a s t, co a t in g m a t e r ia l s e le ct io n w a s b a s e d o n F e d e r a l, m ilit a r y , o r R e cla m a t io n form u lations; how ev er, nea rly all these fo r m u l a tio n s h a v e b e en w it h d r a w n . T od a y , s e le ct io n i s b a s e d o n s e r v i ce e xp o s u r e t y p e a n d th e r es u lts of a ccele r a te d p er for m a n ce t es tin g of com m ercially av ailable p rod u cts.
1. Standards.—F o r m e r ly , R e cla m a t io n p r o v i d e d n a r r a t iv e s t a n d a r d s a n d d e fin i t io n s fo r s p e c ify i n g m a t e r ia l s, s u r f a ce p r e p a r a t io n , a p p lica t io n , a n d in s p e c tio n . H o w e v e r , Reclam ation n ow ad op ts ind u strial stand ard s, w h e r e a p p lic a b le . T h e fo llo w in g o r g a n iz a t io n s (s e e a p p e n d ix A f o r a d d r e s s es , t e le p h o n e n u m b e r s , a n d w e b s i te s ) a r e r e f e r e n c e d t h r o u g h o u t t h i s g u i d e :
• A m e rica n So cie ty fo r Te stin g an d M a te r ials (A STM ). • N A C E In t e r n a t i o n a l (f o r m e r l y ca l le d N a t io n a l A s s o cia t io n o f C o r r o s io n En g in ee r s) (N A C E). • So cie t y fo r P r o te ct iv e C o a tin g s ( fo r m e r l y ca l le d St e e l St r u c t u r e s P a in tin g C ou n cil) (SSPC ).
2. Coating References.—Th e co atin g
insp ector is no t exp ected to h av e th e exp ertise of a coa tin g ch em ical fo r m u lat or or a co a tin g e n g i n e e r , b u t sh o u ld b e r e a so n a b l y fa m ilia r w ith th e m a te r ials b ein g ap p lied . Th is g u id e is in te n d ed to p r ov id ed th e m os t b a sic
b ack g ro u n d on g en er ic m at er ial ty p es , su rfa ce p r e p a r a t io n , a p p lic a tio n , a n d in s p e ct io n m eth od s. The r ead er is en cou rag ed to p u rsu e r ela ted co a tin g r efe r en ce s lis ted in a p p en d ix B.
3. Terminology.—The w ord “coating ” is a gen eric term an d inclu d es “p aint.” In th e m o s t g e n e r a l t e r m s , a “ c o a tin g ” is p r o t e c t io n a g a in s t co r r o s io n , w h e r e a s a “ p a i n t ” m a y h a v e a d d it io n a l p r o p e r t ie s su c h a s co lo r o r u l t ra v io le t s cr e e n in g p ig m e n t s. T h e te r m s “ c o a t in g ” a n d “ p a i n t ” a r e u s e d i n t e r c h a n g e -a b l y t h r o u g h o u t t h i s g u i d e .
O th er ter m s often u sed toge th er a re “ coating s” an d “linin gs.” In g en eral, w he n d escribing the i n t e r io r s u r f a ce s o f p i p e s o r t a n k s , t h e t e r m “ l in i n g s ” i s u s e d t o i d e n t ify t h e i n t e r io r su rfaces an d “coatings” is u sed to iden tify th e ext er io r su r fa ce s. 4. Corrosion.—T h e p r i m a r y r e a s o n f o r c o a tin g s t e e l is t o p r e v e n t co r r o s io n . C o r r o s io n o f m e t a ls is a n e le ct r o ch e m ica l r e a ct io n t h a t c a n b e co n t r o l le d b y i n t e r fe r in g w it h o n e o r m or e o f th e fo u r r eq u ir ed ele m en ts of a co r r os ion cell: (1) an od e (co r r od in g ar ea ); (2) cath od e (non corrod ing ar ea); (3) electrolyte (w a t e r o r m o is t u r e i n a t m o s p h e r e , im m e r s io n , or soil); an d (4) m etallic p ath (betw een tw o d iffe r en t m eta ls o r w ith in th e sa m e m eta l). E li m i n a t e a n y o n e o f t h e f o u r r e q u i r e d e le m e n t s a n d t h e c o r r o s io n p r o c e ss w ill s t o p .
T h e m o s t co m m o n t y p e s o f c o r r o sio n e n c o u n t e r e d o n R e cla m a t io n f e r r o u s m e t a lw o r k a r e :
(a) U niform Co rrosio n.— C o r r o s io n t h a t
oc cu r s m or e o r les s u n ifor m ly an d r es u lts in r u s t a n d m e t a l l o ss o v e r t h e m e t a l s u r f a ce .
(b) G alvanic C orro sion.— C o r r o s io n t h a t
occu rs on the m ore active m etal of tw o d i ss im i la r m e t a ls t h a t a r e e l e ct r i ca l ly c o u p l e d to g eth er in th e sa m e el ect r o ly te (e .g ., w a te r ). T h e m o r e a c t iv e m e t a l w i ll co r r o d e .
(c) Crevice Co rrosio n.— Cr ev i ce co r r os ion
is a for m of lo ca lize d cor r os ion th a t o ccu r s in c r e v ic es w h e r e t h e e n v i r o n m e n t d iffe r s fr o m th e su r r ou n d in g bu lk en v ir on m e n t . Th e d iffe r e n t e n v ir o n m e n t s r e s u l t in c o r r o s io n b e c a u s e o f d iffe r e n c e s in c o n c e n t r a t io n (e.g ., oxy g en , p H , an d fer r ic ion s). If th er e is a n o x y g e n c o n ce n t r a t i o n d iffe r e n c e , c o r r o sio n w ill pr oceed at crev ices w h ere th ere is less o xy g en th a n in th e en v ir on m e n t su r r ou n d in g the crev ice. Crev ices are form ed w he n tw o su rfa ces ar e in p ro xim ity to on e a n ot h er , su ch a s w h e n t w o m e t a l s u r f a ce s a r e a g a in s t o n e a n o t h e r , w h e n a g a s k e t is a g a in s t a s u r f a ce , o r w h en a n g le ir o n s a r e p la ce d b a ck to b a ck . Cre vice corro sion can occu r u nd er d ep osits (e .g ., b a r n a c le s , d ir t , g r e a s e , a n d s lim e ) o n a m et al s u rfa ce.
(d) Pittin g corrosio n.— A form of localized
co r r os ion w h er e t h e d ep th of p en et r a tio n is g r e a t er t h a n t h e d ia m e t er o f t h e a ffe ct e d a r e a .
(e) Cavita tion corro sion.— The m etal loss
c a u s e d b y t h e f o r m a t io n a n d c o lla p s e o f v a p o r bu bb les in a liqu id n ear a m etal su rface. The a p p e a r a n ce o f ca v it a tio n is sim ila r t o p i t tin g , e x ce p t t h a t p i t te d a r e a s a r e clo s e ly s p a c e d a n d t h e s u r f a ce is co n s i d e r a b l y r o u g h e n e d .
(f) Erosion-corro sion.— The accelerated
m etal loss from an initial corro sion m echa n ism a s so cia t e d w it h h i g h - v e lo cit y flo w s a n d a b r a s i o n . Er o s i o n - co r r o s i o n i s ch a r a c t e r iz e d b y g r o o v e s , g u l li e s, w a v e s , a n d r o u n d e d r id g e s o r v a lle y s a n d e x h ib it s a d ir e ct io n a l flo w p a t t e r n .
(g) Dealloying o r Selective L eaching.— Th e
s e le ct iv e r e m o v a l o f o n e o f t h e e le m e n t s o f a n alloy b y either p referen tial attack or com p lete d is so lu t i on o f t h e m a t r ix , fo llo w e d b y
red ep osit of th e cath od ic con stitu en t. The elem en t rem ove d is alw ays an od ic to the m atrix. With d ealloying , there is n o m etal loss, d im en sion ch an ges, cracks, or gr oov es;
h o w e v e r , t h e a f fe c te d a r e a m a y b e e v i d e n t b e c a u s e o f a co l o r ch a n g e . T h e a f fe c te d a r e a b e co m e s lig h t e r , p o r o u s , a n d lo s e s it s o r ig in a l m ech a n ical p r op er tie s (i.e., it b eco m es b r itt le a n d lo s e s t e n s ile s t r en g t h ). T w o c o m m o n f o r m s o f d e a l lo y i n g a r e :
De zincifica tion.— T he s e le ctiv e d is s o lu t ion
o f z in c f r o m b r a s s a l lo y s . It is r e c o g n i z e d b y a c o lo r c h a n g e ( e .g ., fr o m it s o r ig i n a l y e llo w b r a s s co lo r t o a d i st in c tly r e d , co p p e r y a p p ea r a n ce).
De grap hitization.— Th e se le ct iv e
d issolu tion o f iron from som e cast iron s, u s u a l ly g r a y c a s t ir o n s . It n o r m a l ly p r o c e e d s u n ifo r m ly in w a r d f r o m t h e s u r fa ce , le a v in g a p o r o u s m a t r ix a llo y t h a t i s c o m p o s e d m o s t ly o f ca r b o n . D e g r a p h i t iz a t io n c an b e r e co g n iz e d b y a c h a n g e f r o m a n o r i g in a l s ilv e r - g r a y c o lo r t o a d ar k g ra y . Th e a ffecte d m et al ca n b e e as ily cu t o r p i e r ce d w i th a k n i fe . 5. Service Exposure.—C o a t i n g s a r e s p e c if ie d by ser vice exposu re or th e env ironm en t the co a t in g w ill b e su b je ct to . T h e fo llo w in g a r e t h e b a sic s er v ice e xp o s u r e s d e fin e d b y R e cla m a t io n : • A tm os p h er ic
N
In d o o r sN
O u t d o o r s • Bu r ia l • Im m e r s io n• C om p let e, p a r tia l, or flu ctu a tin g im m ersion cond ition s
• A tm osp he ric exp osu re su bject to cond en sation , high h u m id ity, sp lash, o r s p r a y
• T h e fo llo w in g s u b e x p o s u r e co n d it io n s m a y a p p l y t o a n y o f t h e a b o v e :
N
D i r ect su n l ig h t o r U V : s e v e r a l co a tin g s, su ch as ep ox ies , w ill d e t e r io r a t e b y c h a l k in g w h e n exp osed to su nlight.N
C h e m i ca l r e s is t a n c e : e x p o s u r e s m a y in clu d e acid ic o r a lk alin e co n c en t r a t io n s , in d u s t r ia l s m o g , a cid r a in , sew a g e, o r sp ecific chem icals.Materials
C o a t i n g fo r m u la t io n i s g e n e r a lly b a s e d o n o r g a n i c, i n o r g a n i c, p o l y m e r , a n d c o -p o l y m e r ch em ist r y . It is n ot th e in te n tio n of t h is chap ter to d iscu ss coating chem istry b u t, r a th er , to p r ov id e a b a sic k n ow led g e o f coa tin g c o m p o n e n t s a n d g e n e r i c c o a t in g t y p e s
s p e c ifie d b y R e cla m a t io n .
6. Components of Coatings.—A ll or g a n ic co a tin g s co n sis t o f t h r ee b a sic co m p o n en ts: (1) so lv en t, (2) r es in , an d (3) p ig m en t. N ot all c o a t in g s co n t a i n s o l v e n t a n d p i g m e n t e d co m p on en ts . Th er e a r e s olv en t-fr ee (100 p ercent solids) coating s an d clear, p igm en t-free coating s, bu t n ot resin -t-free coat ings.
C oa tin g ch em ical fo r m u lat or s co m m on ly gro u p solvent, resin, and p igm en t com p on en ts in t o t w o g e n e r a l ca t eg o r ie s. T h e fir s t ca t eg o r y co m b in es t h e so lv en t a n d th e r esin to g eth er . Th e s olv en t p or tio n is ca lled th e “ v ola tile veh icle,” an d the r esin p ortion is called th e “n on volatile veh icle.” The com bination of the so lv en t a n d th e r es in , w h er e t h e r es in is
d is so lv e d in t h e s o lv e n t , is ca lle d t h e “ v e h i cle .”
The secon d category is the p igm en t. Pigm en ts are ad d itives th at im p art sp ecific pr op erties to the coating an d are su bd ivided into tw o
g e n e r a l ca t e g o r ie s : (1) co lo r a n d (2) in e r t a n d r ein for ced . Figu r e 1 illu st r a te s t h e r ela tio n sh ip of these com p on en ts. W h e n a c o a t in g i s a p p l ie d , t h e s o l v e n t ev a p or a te s d u r in g th e cu r in g p r oc es s, lea v in g o n l y t h e r e s in a n d t h e p ig m e n t c o m p o n e n t s o n t h e s u b s t r a te . T h e r e m a i n in g r e s in a n d p ig m en ts ar e s om et im es calle d th e “ co a tin g s o lid s ,” a n d t h e y f o r m t h e p r o t e ct iv e f ilm fo r co rr osio n p r ote ctio n .
(a) So lvent.— Or gan ic solven ts are form u lated
in t o co a t in g s t o p e r f or m t h r e e e ss e n t ia l fun ction s: (1) dissolve the r esin com p on en t; (2) co n t r o l e v a p o r a t i o n fo r film fo r m a t io n ; a n d (3 ) r e d u c e t h e c o a tin g v is co s it y fo r e a s e o f a p p licat ion . Solv en ts w ill als o a ffect d r y film a d h es ion an d d u r a b ility coa tin g p r op er tie s. In g e n e r a l, r e sin s t h a t a r e le ss so lu b l e w i ll r e q u i re either m ore solven ts or stron ger solven ts to d issolve th e resin s.
T h e te r m s “ s o lv e n t s ” a n d “ t h in n e r s ” a r e o ft e n u s e d i n t er ch a n g e a b ly , b u t t h e r e ar e d ist in ct io n s w ith in a n d b etw een th e tw o te r m s. T h e t e r m “ s o l v e n t ” c a n i m p l y t w o d i ff er e n t u sa g es : (1) th e s olv en t o r so lv en t b len d s in t h e c o a t in g fo r m u l a t io n a t p r e d e t e r m i n e d So lv en t ( Vo l a t il e ) Re sin ( N o n v o l a t il e ) C o l o r Pigm en ts In e rt a n d R e in f o r c e d Ve h icle P ig m e n t C oa tin g
co n cen tr a tio n lev els ; or (2) clea n in g so lv en ts in st r on g con cen tr a tio n st r en g th for clea n in g b r u sh es, r o lle r s, h o se s, a n d o th er eq u ip m en t. The u sage of the ter m “th inn er” (a thin n er is a solven t) is m ost often associated w ith the c o a tin g a p p lic a to r a d d in g a t h in n e r t o a co a tin g con ta in er (n or m a lly ab ou t 1 p in t thin ne r to 1 gallon of coating ) to red u ce the v isco sit y for ea se of a p p licat ion . A d d in g t h i n n e r t o a c o a t in g i n t h e f ie l d i s o ft e n c a ll e d “ fie ld th in n in g .” Th e m a n u fact u r er ’s p r od u ct d a ta sh ee t w ill s p e cify a t h in n e r a n d a m a x im u m a m o u n t to b e u s e d fo r e a c h c o a t in g t y p e . U s e o f a t h i n n e r n o t r e co m m e n d e d b y t h e m a n u fa ct u r e r c a n c a u s e n u m e r o u s a p p lic a tio n p r o b l e m s o r p r e m a t u r e fa i lu r e s s u c h a s s e p a r a t i o n o f c o m p o n e n t s , c o a g u l a t io n , t o o fa s t o r t o o s lo w d r y i n g , c h a n g e s i n flo w c h a r a c te r is t ic s, o r liftin g of p r ev iou s co a ts . Th e fo llow in g c o m m o n t h i n n e r s a r e u s e d w i th t h e a s s o ci a t ed gen eric coatin g ty p es:
T h in n e r s C o a t in g s M ineral sp irits O ils a n d alk y d s A r o m a t i cs (b e n z e n e , x y l o l, t o lu o l e ) Co al tar ep oxies, a l k y d s , c h l o r in a t e d r u b b e r s Keton es (MEK, M IBK) Vinyls, ep oxies, u r e t h a n e s
A lcoh ols (iso p r op y l) P h en olics , in or g a n ic zin cs W a t e r A c r y l ic s, s o m e in or g an ic zin cs So lv e n t s p r o d u ce v a p o r s t h a t a r e h e a v ie r t h a n a i r a n d w i ll co l le c t i n t a n k b o t t o m s o r c o n f in e d a r ea s. Th e k et on es h a v e t h e lo w es t fla sh p oin t o f th e o r g a n i c s o lv e n t s ; h o w e v e r , a n y s o l v e n t in t h e r i g h t co m b in a t io n w it h a ir ca n c r e a te a n e x p l o s iv e c o m b i n a t io n .
Fed er a l, Stat e, co u n ty , city , an d loca l air q u a l it y co n t r o l d i s t r ic ts r e g u l a t e t h e a m o u n t o f v o la tile o r g a n ic s o lv en ts (VO C ) in co a tin g s. A s t h e c o a t in g c u r e s , VO C s e v a p o r a t e i n t o t h e
a tm os p h er e a n d r ea ct w ith su n lig h t a n d air p o llu t a n t s to fo r m o z o n e , a k n o w n h u m a n h ea lth h a z a r d . In r es p on se , coa tin g m a n u fact u r er ’s h a v e r efo r m u lat ed th eir p r o d u c t s w i th l o w e r s o l v e n t c o n t e n t t o m e e t cu rre n t VO C r egu lations.
R ecla m a t io n s p e cifica t io n s r eq u i r e th e co a t in g s t o m e e t th e V O C r e g u la t io n s “ i n -t h e - ca n ” o r “ a s-m a n u fact u r ed ” b efo r e fie ld th in n in g . Field thin nin g of a coating tha t w ill exceed the r eg u la te d VO C m a xim u m is n o t p er m itte d . Reclam ation sp ecifies coating s based on the cu rr en t En v iro n m en ta l Pr ot ect ion A g en cy (EPA) VO C lim its.
(b) Resin.— The resin (frequ ently called
b in d er ) is th e film for m in g com p on en t o f a co a t in g . Re s in s a r e t y p i ca lly a h i g h m o le cu la r w e ig h t s olid p o l y m e r t h a t fo r m s la r g e
rep eatin g m olecu les in th e cu red film . The p rim ary p u rp ose of the resin is to w et the p i g m e n t p a r t i cl e s a n d b i n d t h e p i g m e n t p a r t i cl e s t o g e t h e r a n d t o t h e s u b s t r a t e (h e n c e , t h e t e r m “ b i n d e r ” ). T h e r e s in i m p a r t s m o s t o f t h e c o a tin g p r o p e r t ie s . T h e v a r i o u s t y p e s o f r e s in s fo r m u la t e d i n a co a t in g w ill d is p l a y d i st in c t p r o p e r t i es . T h e s e p r o p e r t i es a r e : • M e ch a n ism a n d t im e o f cu r in g • P e r fo r m a n c e in s e r v ice e xp o s u r e ty p e • P e r fo r m a n c e o n s u b s t r at e t y p e • C o m p a t ib ilit y w i t h o th e r co a t in g s • Flexibility an d tou gh n ess
• Ext er ior w ea th er in g • A d h e s i o n
N o s in g l e r e s in c a n a c h i e v e a h ig h d e g r e e o f su cces s in m ee tin g th e a b ov e co a tin g p r o p e r t i es w i th w i d e v a r i a t io n s a s s o c ia t e d w ith ea ch p r op er ty . Th er efo r e, g en er ic coa tin g t y p e s a re g e n e r ally cla s sifie d b y t h e p r im a r y r esin ty p e u se d in th e co a tin g fo r m u la tio n . Typ ical resin s ar e acry lics, alky d s, and ep oxy p olym ers. (c) Pigm ent.— P ig m e n t s a r e in s o lu b l e an d a r e t h e h e a v i er s o lid p o r t io n o f a co a t in g t h a t ty p ica lly se tt le s t o th e b o tt o m o f th e co n ta in er . P ig m en ts ar e a d d itiv es to th e co a tin g fo r m u la t io n t h a t im p a r t s p e c ific p r o p e r t ie s t o
ach ieve t h e d esired film p ro p ert ies. Th e fo llo w in g p r o p e r t ie s a r e acco r d e d b y p i g m e n t s , a n d a b r i e f d e s cr i p t i o n i s p r o v i d e d fo r e ach . Co lor.— N a tu r a l ea r th p ig m en ts (k a olin c la y , m a g n e s iu m s il ic a t e , c a lc iu m c a r b o n a t e ) p rov id e color stab ility from u ltrav iolet (UV) su nlight d eterioration. N atu ral earth p igm en ts a r e m or e U V s ta b le t h a n sy n th et ic or g a n ic p igm en ts.
Opacity.— Titan ium oxide h ides th e
s u b s t r a t e o r p r e v i o u s c oa t in g c o lo r a n d p r o t e ct s t h e b in d e r fr o m U V s u n l ig h t d e te rio ra tio n .
Wet pa int.— Silica a n d t a lc co n tr ol
v isco sit y , w et film lev elin g , an d se tt lin g b u t p r o v i d e lit tle h id in g ( op a c it y ) p o w e r .
Weath er an d m oisture resistance.—
A lu m in u m lea fs a n d m icac eo u s ir on ox id e (M IO ) in cre as e b ar rie r t h ickn es s a n d for ce m o is tu r e t o d e t o u r a r o u n d t h e se p l at e -lik e ad d itive s.
Co rrosio n resistance.— Pigm en ts ad d ed to
in h ib i tiv e ( p r i m e r ) c o a tin g s i m p e d e co r r o s io n o f fe r r o u s s u b s t r a t e s . P a s t fo r m u la t io n s in clu d ed ch r o m a te a n d le a d p ig m en ts , b u t t h e y a r e s e ld o m u s e d t o d a y b e c a u s e o f en vir on m en tal an d h ealth con cern s. The fo llo w in g c h r o m a t e a n d le a d p ig m e n t s a r e rar ely u sed in cu rre n t coating form u lations:
• R ed le a d • W h i te le a d
• Basic lead silico-chrom ate • Stron tium chrom ate • Zinc chrom ate
Th e fo llow in g ar e a ccep ta b le a lte r n a tiv e inh ibitive p igm en ts:
• Bariu m m etabor ate • Calciu m p ho sp ho silicate • Z in c ox id e
• Zinc p ho sp ha te • Zinc m olybd ate • Zinc p ho sp ho silicate
Mildew resistance.— M ild e w c id e s p r ev en t
m ild e w g r o w t h o n t h e d r y f ilm co a t in g .
Skid or slip resistan ce.— A lu m in u m oxid e
o r m i n er al a gg re ga te is a d d e d in th e form u lation or ap p lied to the w et film to a ch iev e n on slip su r face s. A lu m in u m ox id e is the b etter choice because m ineral agg rega te m a y b e cr u sh e d u n d e r w e ig h t, p r o vid in g m o istu r e a cce ss to th e su b str ate , a n d p r o m o t in g f u r t h e r c o a tin g d e g r a d a t io n a n d co rr osio n .
7. Coating Types.—T h e f o ll o w i n g a r e t h r e e ba sic typ es of coatings:
(a) Ba rrier.— A coating th at form s a
bar rier betw een the m etal sur face an d the ele ct r o ly te a n d el ect r ica lly iso la te s t h e m eta l. Exam p les are ep oxies an d coal tar ep oxies.
(b) Inh ibitive.— P ig m e n t in a co atin g
p r im e r t h a t is slig h t l y so lu b le in w a t e r th a t for m s a ch em ical in h ib ito r an d effe ctiv ely in t e r fe r e s w it h t h e e le ct r o ly t e . E xa m p le s a r e r e d l ea d a n d c h r o m a t e p r i m e r s (n o l o n g e r a ccep ta b le).
(c) Ga lvanic.— Z in c -r ich p r im e r co a t in g s
tha t p rov ide g alvan ic or catho d ic p rotection to fer ro u s m et al (z in c sa crifices itse lf to p ro te ct t h e fe r r o u s m e t a l). G a lv a n i c co a t in g s a r e effe ctiv e o n ly if ap p lied d ir ect ly to b a r e m et a l.
8. Generic Coatings.—Th e fo llow in g g en er ic co a tin g s a n d g en er a l d es cr ip tio n s a r e t y p ically s p e c ifie d b y R e cla m a t io n :
(a) Acrylics.— In w a te r -b or n e a cr y lic
coating s, the r esin is d ispersed in w ater to for m a w at er em u lsion . W at er -bo rn e a cry lics are sp ecified for atm osp h eric expo su res as a p r im e r o r t op co a t a n d h a v e e x ce lle n t co lo r a n d g l o s s r e t e n t i o n . A c r y l ic s c u r e b y c o a le s ce n c e .
(b) Alkyds.— A l k y d s a r e n o r m a lly n a t u r a l
o i ls (s o y a , tu n g , s t y r e n a t e ) t h a t h a v e b e e n c h e m i ca l ly m o d i fi e d t o i m p r o v e c u r e r a t e , ch em ical r es ista n ce, an d h ar d n es s. Ph en olic-m o d ifie d a lk y d s a r e s p e c ifie d a s a p r i olic-m e r , a n d s ilic o n e a lk y d s a r e s p e c ifie d a s t h e t o p c o a t fo r a t m o s p h e r ic se r v i ce e x p o s u r e s . T h e y a r e n o t
s u i ta b le fo r a lk a lin e (co n c re t e o r m a s on r y ) su r face s o r en v ir on m en ts . A lk y d s cu r e b y air oxid ation of d ry ing o ils.
(c) Bitumin ous.— Bit u m in o u s co a t in g s a r e
h ea v y -bo d ied m at er ials a p p lied w ith a cu tb ack s o lv e n t . T h e y h a v e g o o d m o i st u r e b a r r i e r re sist an ce a n d fair to g oo d ch em ical r es ista n ce b u t a r e n o t r es is t an t t o so lv e n t s . C o m m e r cia l b i t u m i n o u s p r o d u c t s a r e s p e c if ie d o n a l im i te d b a s is b y R e cla m a t io n f o r p r o t e c t io n o f
alum inu m su rfaces in contact w ith
cem en tit iou s m a te r ial o r st ee l an d cop p er cab le w e ld co n n e c tio n s . Bit u m in o u s co a t in g s cu r e b y so lv en t e va p o ra tio n .
(d) Ep oxy, Am ine.— A m in e e p o x ie s a r e
t w o - co m p o n e n t co a t i n g s t h a t a r e c a t a l y z e d (hard en ed ) by an am ine cur ing ag en t to p r o d u ce a h a r d , t ig h t l y b o n d e d , ch e m ica l r esis ta n t (a lk a li, a cid , a n d so lv en t) p r o d u ct , b u t t h ey a re m o is tu r e a n d t em p e r a tu r e se n sit iv e d u r i n g a p p lic a tio n . Th e y a r e s p e cifie d fo r b u r i a l a n d im m e r sio n s e rv ice e xp o s u r e s, b u t th ey w ill fa d e a n d ch a lk in d ir ect su n lig h t. A m in e e p o x ie s cu r e b y c h e m ic a l r e a c tio n .
(e) Ep oxy, Polyam ide.— Polyam ide ep oxies
a r e t w o c o m p o n e n t co a t i n g s t h a t a r e c a t a l y z e d b y a p oly am id e cu rin g ag en t to p ro d u ce su p erior r esistance to w ater an d salt solution s, b u t t h e y d o n o t p r o v i d e t h e c h e m ica l
r e s is t a n c e o f t h e a m i n e e p o x y . P o l y a m i d e s h a v e a g r ea te r flexib ility th a n th e a m in e e p o x ie s . T h e y a r e sp e cifie d fo r b u r ia l a n d im m er sio n se r v ice e xp os u r es , bu t t h ey w ill fad e a n d ch a lk in d ir ect su n lig h t. P oly a m id e e p o x ie s cu r e b y c h e m ic a l r e a c tio n .
(f) Epo xy, Coal Tar.— C o a l t a r ep o x ie s a r e
ge n era lly a n am ine o r p olya m id e ep oxy m o d i fi e d w i th c o a l t a r p i t ch r e s in t o p r o d u c e a h i g h -b u ild film t h a t h a s g o o d c h e m ica l
r e s is t a n c e a n d e x ce l le n t w a t e r r e s i st a n c e . T h e y h a v e a t e n d e n c y to b e co m e b r it t le w it h a g e a n d d ela m in a te b et w ee n coa ts or b en ea th r ep a ir p a t ch e s . T h e y a r e sp e cifie d fo r b u r ia l a n d im m er sio n se r v ice e xp os u r es , bu t t h ey w ill fa d e a n d ch a l k in d ir e ct su n l ig h t . C o a l t a r e p o x ie s cu r e b y c h e m ic a l r e a c tio n .
(g) Epoxy, Fusio Bo nde d.— F us io
n-b o n d e d e p o x ie s (c o m m o n l y c a ll e d p o w d e r c o a t in g s ) a r e c o m p l e te c o a t in g s in p o w d e r form . The re a re tw o ap p lication m eth od s, flu idized -bed an d electrostatic. In the flu i d i z ed -b e d m e t h o d , t h e m e t a l it e m s a r e p r eh e ate d to a fu s io n te m p e r atu r e a n d im m er se d in th e p ow d er -ep ox y so lu tio n . In t h e e l e ct r o s t a t ic m e t h o d , t h e e p o x y p o w d e r p a r t icle s a r e ch a r g e d w it h h i g h v o l ta g e , a n d t h e m e t a l it e m i s t h e n s p r a y e d . A ft e r s p r a y in g , t h e i te m is p l a ce d in a n o v e n t o c u r e a t a b o u t 3 50 t o 65 0 d e g r e e s Fa h r e n h e i t (F ). F u s io n -b o n d e d e p o x ie s a r e s p e c ifie d fo r -b u r ia l a n d im m er sio n se r v ice e xp os u r es , bu t t h ey w ill fa d e a n d c h a lk in d ir e ct su n lig h t a n d a r e b r i t t le . A n e w m a t e r i a l i s fu s io n - b o n d e d n y l o n . Th i s m a t e r i a l is s u p e r io r t o t h e fu s io n -bon d ed ep oxy an d w ill be incorp orated into Re clam a tio n 's s p ecifica tio n . Po w d er coa tin g s cu r e b y fu sio n (h ea t).
(h) Ino rgan ic Zinc Prim ers.— In or g a n ic
z in c s a r e p r im e r s t h a t in c o rp o r a t e a h ig h lo a d in g ( p o u n d s p e r g a l lo n ) o f m e t a llic z in c fo r p ig m e n t a t io n ( h e n c e, t h e t er m “ z in c -r ich ” ) a n d a r e e ith er so lv en t o r w a te r b a se d . D ep en d in g on th e s olv en t a n d r es in s u se d , th e co a tin g m ay be a zinc-rich ep oxy o r u reth an e. Th ese c o a t in g s a r e e x cl u s i v e ly p r i m e r s b e c a u s e t h e y p r o v i d e g a l v a n i c o r c a t h o d i c p r o t e c t io n t o s t e e l s u b s t r a t e. In o r g a n i c z in c s a r e sp e cifie d fo r atm osp h eric and im m ersion serv ice exp osu res, b u t t h ey can b e t op co a te d to ex te n d th eir s e r v ic e life . Su it a b le t o p c o a t m a t e r ia l s e le ct io n is requ ired to p rev en t ou t-gassing from the in or g a n ic zin c th a t p r od u ces sm a ll p in h ole s in th e t op co a t. Re clam a tio n sp ecifie s in or g a n ic z i n c co a t i n g s o n l y t o f r a y i n g s u r f a ce s o r h e a t e d tre ated m etalw or k (A STM A 325 or A STM A 4 90). A p p lica t io n r e q u ir e s sp e cia l s k ills a n d k n o w l e d g e . In o r g a n i c z i n c s c u r e b y e it h e r r e a c tio n t o w a t e r (s o lv e n t r e d u c ib l e ) o r r ea ctio n to car b on d iox id e (w a te r r ed u cib le).
(i) Organic Zinc Prim ers.— O rg an ic zin cs
a r e p r im er s t h a t in co r p or a te a h ig h loa d in g (p o u n d s p e r g a l lo n ) o f m e t a llic z in c fo r p igm en tation w ith a w ide v ariety of solven ts a n d r esin s. D ep e n d in g on th e so lv en t a n d
re sin s u se d , th e co at in g m ay b e a zin c-rich a l k y d , d r y i n g o i l , e p o x y , o r m o i st u r e - cu r e d u r et h a n e. Th es e co a tin g s a r e e xclu siv ely p r im er s b eca u se th ey p r ov id e g a lv a n ic
p rotection to steel substr ate or th ey ar e u sed to r e p a i r d a m a g e d g a l v a n i z e d c o a t i n g s o n s t e e l s u b s t r a t es . O r g a n i c z in c s a r e sp e cifie d fo r at m os p h er ic, bu ria l, an d im m er sio n se rv ice exp osu res bu t are n orm ally top coated to ex te n d th e s er v ice life of t h e co a tin g . Su ita b le top coat m aterial selection is requ ired to p r ev en t o u t-g a ss in g fr o m th e o r g a n ic z in c. O u t-gassing p rod u ces sm all p inh oles in th e t o p c o a t . T h e w a y o r g a n i c z i n c s c u r e d e p e n d s o n t h e c o a t in g t y p e .
(j) Polyu rethane .— T ech n i ca lly ,
p o ly u r e t h a n e is a s u b c la s s o f u r e t h a n e . A t w o -co m p o n e n t p o ly u r e t h a n e is cr e a te d b y ch e m ica lly c om b in i n g a p o ly is o y a n a t e a n d a p o ly o l to p r o d u c e a n i s o cy a n a t e t h a t h a s a t w o -m o d e cu r e -m e ch a n is-m o f so lv en t e va p o ra tio n a n d c h e m i ca l r e a ct io n . R e cl a m a t i o n s p e c i fi e s p o ly u r eth a n es fo r to p co a tin g co m p a tib le (i.e ., sa m e m a n u fact u r er ) am in e a n d p oly a m id e e p o x ie s t o p r o t ect a g ain s t d i r ect su n lig h t o r U V a n d to p r o v id e sp ecific co lo r s. P oly u r et h a n es ar e s p ecifie d for at m os p h er ic an d p ar tia l or flu ctu at in g im m er sio n se rv ice exp osu res.
(k) Urethane .— U r e t h a n e co a t in g s v a r y
w id ely in for m u lat ion s for sp ecific ser v ice en v ir o n m en ts a n d a p p lica tio n r eq u ir em en ts . Reclam ation sp ecifies sing le-com p on en t, m o is t u r e - cu r e d u r e t h a n e s . T h e y c u r e f r o m m o i st u r e i n t h e a t m o s p h e r e a n d c a n b e a p p l ie d t o d a m p s u r f a ce s t h a t d o n o t h a v e fr e e
m o is tu r e p r e se n t . T h e se u r e t h a n e s a r e fo r m u la t e d w it h v a r i o u s p i g m e n t a t io n s a n d a r e s p ecifie d in se v er a l com b in a tio n s t o s u it th e inten d ed serv ice exp osu re. These
u r et h a n es ar e s p ecifie d for at m os p h er ic, bu r ial, an d im m ersion exp osu res.
Specifications
R e cl a m a t i o n c o n s t r u c t io n jo b s a r e a d v e r t i s e d t o co n t r a ct o r s t o p e r fo r m t h e r eq u i r e d w o r k , a n d con tr a cto r se lect ion is m a d e b y a b id p r o c e ss . T h e m o s t co m m o n b i d t y p e s a r e lo w p r ice , n eg o tia te d , fixe d co st , a n d so le so u r ce . O n ce Re cla m a tio n a cce p ts a co n tr a ct o r ’s b id , a contra ct exists betw een Reclam ation an d the c o n t r a c t o r . T h e c o n t r a c t is o ft e n c a ll e d a s p e c if ic a t io n . T h e s p e c if ic a t io n c a n b e d e fi n e d a s a w r i tt e n , d e t a ile d , t e ch n ic a l d e s cr i p t io n o f w o rk to be p er fo rm e d , d e scr ib in g th e m a te r ia ls, q u a n tities, a n d m o d e o f co n str u ctio n . Sp e cific a tio n s a r e d iv i d e d in t o m a n y d iv i s io n s t o d e s cr ib e t h e v a r io u s jo b r e q u i r e m e n t s a n d m a y in clu d e ge n er al jo b d e scr ip t io n , su bm ittals, p re-existin g con d ition s,
e n v i r o n m e n t a l r e q u i r e m e n t s , a n d t e ch n ica l a r ch ite ctu r a l, civil, e lect r ical, m ech a n ical, co a tin g , a n d ca th o d ic p r o te ct io n d isc ip lin es. E a ch d iv i sio n i s s o m e t im e s ca lle d a t e ch n ica l p a r ag ra p h o r se ctio n .
9. Construction Specification Institute.—
Re clam a tio n h a s ch a n g ed fro m a n a r r a tiv e p a r a g r a p h f o r m a t t o th e C o n s t r u c t io n Sp e cific a tio n I n s t it u t e ( C SI) fo r m a t fo r
sp ecifications. CSI form at style is m ore concise an d u se s im p er at iv e la n g u ag e. Refe re n ce s t a n d a r d s a r e s p e c ifie d t o d e s c r ib e q u a l it y o f m a t e r ia ls , w o r k m o d e , t e st m e t h o d s , a n d a c ce p t a n c e c r it e r i a th a t a r e a r e c o g n i z e d in d u s t r y p r a c t ic e, t h u s r e d u c in g t h e n e e d fo r len g th y v er b iag e. Th e m os t co m m on re fer en ce s ta n d a r d s u s ed in t h e co a t in g s in d u s t r y a r e A ST M , N A C E , a n d SSP C . C S I s p e c ific a tio n s a r e d iv i d e d in t o 1 6 d iv i s io n s fo r a l l t h e b u ild in g t r a d e s , a n d e a ch d iv i s io n m a y b e fu r th er d iv id ed in to sp ecia lit y se ct io n s. F in i sh e s a r e D iv i sio n 9 , a n d p a in t a n d p ro te ctiv e co at in g s a re Sectio n 09900. Ea ch se ctio n is su b d iv id ed in to th e fo llow in g b a sic p arts:
P a rt 1 : G e nera l .—Includ es cost,
r efe r en ce s, s u b m itta ls, q u a lit y a ss u r a n ce , d elive ry , stora ge, ha n d lin g, an d restr ictions.
P a rt 2: P rod uct .—Includ es requ irem en ts
f o r m a t e r i a ls t o b e u s e d
P a rt 3 : Execut i o n.— I n clu d e s m o d e o f
co n s t r u c t io n , te s t m e t h o d s , a cce p t a n c e cr it e r ia , a n d r e p a i r
10. Reclamation Coating Specifications.—
T h e T e ch n i ca l Se r v i c e C e n t e r (T SC ) in D e n v e r m a in ta in s C SI g u id elin e co a tin g sp ecifica tio n s. The g u ideline coating sp ecification s are th e b a s is fo r s p e c ific p r o je ct r e q u i r em e n t s a n d a r e b a se d o n h ist o r ica l Re cla m a tio n st r u ct u r es. Th e g u id elin e s p ecifica tio n s co n ta in
instru ction al notes an d footnotes to aid the sp ecification w riter in p rep aring the sp ecificat ion s to m ee t sp ecific p ro ject r eq u ir em en ts . Th e g u id elin e co a tin g
sp ecifica tio n s a r e a v a ila b le o n Recla m a tio n ’s in tr a n et w eb sit e: <h tt p :/ / in tr a .u sb r .g o v > . Reclam ation u ses the follow ing sp eciality s e ct io n s f o r c o a t in g s a n d h a z a r d o u s b a s e d -p aints:
Sect io n 09902.—C oa tin g s fo r n ew m et a llic
su b st r a te s t h a t in clu d e: st ee l, cas t o r d u ctile ir o n ; g a lv a n iz e d , a lu m in u m ; b r a s s ; b r o n z e ; o r c o p p e r Sect io n 09908.— M a i n t e n a n c e co a t in g s f o r p r e v io u s l y co a t e d m e t a llic s u b s t r a t es th a t i n c lu d e : s t e e l, c a s t o r d u c t il e i r o n ; g a l v a n i z e d , a l u m i n u m ; b r a s s ; b r o n z e ; o r c o p p e r Sect io n 09980.— C o a t in g s fo r co n c r e te a n d m a s o n r y s u b s t r a t e s
Sect io n 13283.— H a n d lin g an d d isp o sin g
o f p a in t c o n ta in in g h ea v y m eta ls (i.e ., ch r o m a te , le a d , et c. . .)
(a) Pa rt 1: G ene ral.— P ar t 1 in clu d e s th e
f o ll o w i n g g e n e r a l o u t l in e :
• C o s t p r o v is io n s f o r e it h e r l u m p s u m o r b i d i t e m
• R efe r e n ce s fo r in d u s t r ia l s ta n d a r d s u s e d i n t h e s p e cific a tio n s e c tio n
• Su bm ittals are req u ired to en su re th e c o n t r a c t o r is s u p p l y in g t h e s p e c if ie d m a te r ials . Th e fo llow in g su b m itt a ls a r e e ss en tia l:
"
M a n u fa ctu r er ’s p r o d u ct d a ta an d ap p lication sheets"
M a n u fa c tu r e r ’s ce r t ific a tio n o f co m p lian ce, s ta tin g th a t m a te r ials w er e m an u fact u re d in acco rd an ce w ith qu ality assu ran ce and qu ality p ro g ra m s to in clu d e b at ch n u m b e r s , q u a n t i t y , a n d c o lo r"
P u r ch a se or d e rs, e n su r in g th a t th e c o n t r a c t o r u s in g a p p r o v e d m at er ials t o in clu d e b at ch n u m b e r s , q u a n t i t y , a n d c o lo r • Q u ality as su ra n ce• D eliv er y , sto r a g e, a n d h a n d lin g
• En v iro n m en ta l re str iction s for su rfa ce p r e p a r a t io n a n d a p p lic a tio n
(b) Pa rt 2: P rod ucts.— P ar t 2 in clu d e s th e
f o ll o w i n g m a t e r i a l r e q u i r e m e n t s o u t li n e :
• A b r a s i v e s • M IO • C o a t in g s
(c) Part 3: E xecu tion.— P ar t 3 in clu d e s th e
follow ing ou tline requ irem en ts to com p lete w o r k :
• P r ot ect ion an d r ep a ir of e xist in g s u r f a ce s
• Em bed d ed m etalw ork in concrete
• Su r f a ce p r e p a r a t io n m e t h o d s
• A p p lica tio n eq u ip m e n t
• Coa ting ap p lication requ irem en ts
• In sp ect ion m et h od s a n d acce p ta n ce cr ite r ia • Re p a ir of d a m a g ed an d n on a ccep ta b le co a t e d a r e a s • C o a t i n g t a b u l a t io n s a n d c a t e g o r ie s (s e e fo llo w in g s e c t io n ) • C olo r sch ed u le
11. Coating Tabulations and Categories.—
T h e fo r m a t o f t h e co a t in g t a b u la t io n s a n d ca t eg o r ie s in t h e C SI s p e cifica t io n s w ill b e sim ila r to th e o ld n a r r a tiv e p a r a g r a p h fo r m a t. T h e co a t in g t a b u l a tio n s a n d ca t eg o r ie s ch a n g e ov er tim e becau se of low er VO C r egu lations, l e a d - a n d c h r o m a t e -f r e e r e q u i r e m e n t s , n e w c o a t in g t e ch n o l o g y d e v e l o p m e n t s , a n d o t h e r factors. The follow ing section s d escribe th e tab u lations an d categor ies.
(a) Coating Tabulatio ns.— Th e co atin g
t a b u la t io n s a r e b a s e d o n R e cla m a t io n ’s h i st o r ica l e xp e r i en c e w it h co a t in g m e t alw o r k ite m s, se r v ice e xp os u r e, a n d m a te r ials u se d in d a m s a n d w a t er co n v ey an ce p ro je cts. Th e tabu lation s are in th e follow ing tab le form at:
• I te m s t o b e co a t e d a r e i d e n t if ie d .
• Coa ting m aterials are id en tified in the f ir s t co l u m n b y a n a l p h a n u m e r i c l a b e l fo r a m a n u f a ct u r e r ’s b r an d n a m e o r a Fe d er a l/ m ilit a r y sp ecifica tio n n u m b er . Sev er a l eq u iv a len t co a tin g m a te r ials m a y b e lis t ed w it h in t h e s a m e m a t e r ia l o p tio n n u m b e r. M o r e th a n on e c o a t in g m a t e r i a l o p t io n m a y b e l is t e d in the tabu lation . For sm all jobs, the co lor m a y b e s p ecifie d in th is co lu m n .
• N u m b e r o f co a t s (p r i m e r ,
of e a ch ap p lied coa t, a n d to ta l d r y film t h i ck n e s s (D F T ) o f th e c o a t i n g s y s t e m a r e id en tifie d in th e s eco n d colu m n .
• Su r f a ce p r e p a r a t io n m e t h o d s a r e id en tifie d b y let te r or alp h a n u m er ic la b e l in t h e t h ir d co lu m n a n d a r e d e fin e d in t h e e x ec u t io n p a r t fo r s u r f a ce p r e p a r a t io n .
• In s t r u c t io n a l n o t es , if s p e c ifie d , a r e l o ca t e d a t e it h e r t a b l e f r o n t o r e n d .
(b) C oating C ategories.— Th e co atin g
categories spe cify, by a lph an u m eric labels, the m a n u fa c tu r e r ’s b r a n d n a m e o r t h e F ed e r a l o r m ilita r y sp ecifica tio n n u m b er of t h e co a tin g m a t er ia l liste d in th e ta bu la tio n s. Th e categories are su bd ivided accord ing to th e follow ing th ree esse n tial ch ara cteristics:
C o m p o s i t i o n.— L is t t h e g e n e r ic ch e m ica l
co a t in g n a m e
P hy si ca l cha ract eris t ics .— W e i g h t p e r
g a l lo n , V O C c o n t e n t , m in i m u m a p p lic a tio n te m p er a tu r e, cu r in g tim es at sp ecific te m p er at u re an d h u m id ity , etc.
P erform ance requi rement s .— A c ce l er a t e d
A STM te st in g an d acc ep ta n ce cr ite r ia
12. Manufacturer's Product Data and Application Sheets.—R e cla m a t io n sp ecification s requ ire the su bm ittal of the coating m an u factu rer’s p rod u ct da ta (s o m e t i m e s ca lle d t e ch n ica l d a t a ) a n d a p p licat ion sh ee ts . Th es e s h ee ts sp ecify t h e m a n u fa ct u r e r ’s in s t r u c t io n s a n d r eco m m en d a tio n s. Th e m a n u fact u r er 's in s t r u c t io n s a n d r e co m m e n d a t io n s h a v e becom e sp ecification requ irem en ts, u nless the sp ecificat ion s a re m or e r es tr ictiv e. P ro d u ct d a t a a n d a p p lic a tio n s h e e t s s h o u ld b e k e p t fo r fu t u r e r efe r e n ce to v e r ify t h e m a t e r ia l t y p e a p p lie d . T h e p r o d u c t d a t a a n d a p p lic a tio n s h e e t s v a r y in c o n t e n t a n d fo r m a t fr o m m a n u fa c tu r e r t o m a n u fa c tu r e . So m e m a n u f actu r er s co m b in e p ro d u ct d a ta an d ap p lication into on e sheet. H ow ever , the sheets p rov ide u seful inform ation for th e sp ecific m a te r ial.
(a) Pro duc t Da ta Sh eet.— T h e fo llo w in g a r e
the m ost com m on item s on th e p rod u ct da ta sh eets:
• G e n e r i c ch e m ica l co a t in g n a m e ( a cr y l ic , a l k y d , e p o x y , p o l y u r e t h a n e )
• Typ ical u ses, such as on br id ges, p i p e s , o r w a t er t a n k s
• Ser v ice ex p os u re for at m os p h er ic, b u r ial, im m er sio n (fre sh w a te r or sa lt w at er ), an d ch em ical r es ista n ce
• Color an d gloss availability
• P h y sica l or te ch n ical p ro p er ties , su ch a s w e ig h t p e r g a llo n , s o lid s b y v o l u m e , V O C c o n t e n t , p i g m e n t ad d itiv es , flash p oin t, an d se rv ice te m p er at u re re sist an ce
• Re co m m en d ed d r y or w et film th ickn ess
• T h e o r e t ic a l c o v e r a g e r a t e p e r g a l lo n
• M ix r a tio (if m u ltico m p on en t s y st em ), p ot life, a n d in d u ctio n or sw ea t-in tim e (elap sed tim e interv al to allow the c h e m ic a l r e a c tio n t o b e g i n f o r m u l t ico m p o n e n t m a t e r ia ls b efo r e a p p lica tio n )
• D r y , re co a t, cu r in g , an d fu ll cu r e t im e p eriod s at tem p eratu re an d hu m idity r a n g e s • P e r f o r m a n c e te s t r e s u l t s (a c ce l er a t e d A S TM t e s ts th a t m a y o r m a y n o t b e l is t e d ) • Sh elf life • Sa fe t y p r e c a u t io n s • Sh ip p in g d a ta
• W arr an ty an d lim itation s of liability
(b) Applica tion S hee t.— The follow ing ar e the
• Su b st r a te ty p es th a t a r e co m p a tib le w ith th e co a tin g m a te r ia l (e .g .,
a lu m in u m , con cr et e, g a lv a n ize d , ste el, cast iron , or existin g coated su rfaces)
• Su r face p r ep a r a tio n m et h od , n or m a lly list ed as a m in im u m
• Thinn er p rod u ct nam e an d am ou nt to b e a d d e d • Pot-life-tim e of m u lticom p on en t c o a tin g m a t e r ia l a t v a r i o u s t e m p e r a t u r e a n d h u m i d i t y r a n g e s • Lo w e r a n d u p p e r te m p e r atu r e a n d h u m id ity ra n ge re str ictio n s d u r in g a p p lica tio n • M o st m a n u fa ctu r er ’s sta te th a t th e c o a t in g i s t o b e a p p l ie d o n l y w h e n t h e su bs tr at e te m p er at u re is 5 d eg re es F, m i n im u m , a bo v e th e d ew p o in t • D r y i n g , r e co a t , a n d cu r in g t i m e s a t va riou s tem p eratu re an d hu m idity r a n g e s
• A p p l ica t io n m e t h o d : b r u s h , ro lle r , conv en tiona l airless sp ray , or airless sp r a y . M a y in clu d e s p ecific
equ ipm en t at re com m en d ed p ressu res, h os e d iam et er siz es , sp r a y g u n , n oz z le tip siz es , etc.
13. Addendums and Modifications.—
Sp e c if ic a t io n s a r e s o m e t im e s ch a n g e d t o a l te r d esig n s, co r r ect er r o r s, o r r ed r ess o m iss io n s. The follow ing tw o gen eral m etho d s are u sed to rev ise spe cifications: (1) ad d en d u m s (also called a m en d m en ts) are w ritten p age inser ts t h a t ch a n g e p a r t (s ) o f t h e sp e c ifica t io n b e fo r e b id d in g o c cu r ; a n d (2) m o d i fica t io n s a r e w ritten p age inser ts that m od ify p art(s) of the sp ecifica tio n a fter th e co n tr a ct is a w a r d ed . M o d ifica tio n s ca n in cu r co st a d ju s tm e n t s to th e contr act an d are often called chan ge o rd ers.
Inspector's Role
The coating insp ector ensu res th at: (1) the w or k is a cco m p lish ed in a t im ely m a n n er in a c co r d a n c e w it h t h e s p e cific a tio n s ; (2 ) w o r k a ctiv itie s a r e d oc u m en te d ; an d (3) w or k is p erform ed safely. The coating insp ector at the jobsite is eithe r th e contra cting officer’s or th e f ie l d e n g i n e e r ’s r e p r e s e n t a t i v e .
The insp ector shou ld n ot ver bally cha ng e the r eq u ir em en ts or r eq u ir e m or e r ig id
r e q u i r em e n t s o n t h e co n t r a ct o r th a n w e r e or ig in a lly sp ecifie d . Th e in sp ect or sh ou ld contact his su p erv isor for reso lution if the s p e c ifica t io n s a r e in a d e q u a t e . C o n t r a c to r s m a y r e q u e s t a v a r ia n t fr o m s p e c ifica t io n s t h a t m a y o r m a y n o t b e s i g n i fic a n t . R e g a r d l e s s o f v a r ian t s ig n ifican ce, t h e in sp ect or sh ou ld i n fo r m h i s s u p e r v i s o r o f a n y r e q u e s t e d c h a n g e s . If a c o a tin g a p p lic a to r i s n o t fo llo w in g t h e s p e c ific a tio n s , t h e i n s p e c t o r sh o u ld n o t c o n fr o n t t h e a p p lica to r . In st ea d , h e sho u ld a sk th e coating contra ctor su p erv isor to d et er m in e w h y th e s p ecifica tio n s a r e n ot b ein g fo llo w e d . In s o m e ca s e s, a d e v ia t io n m a y h a v e b e e n a l lo w e d o r t h e c o a tin g c o n t r a c t o r
s u p e r v i so r m a y n e e d t o co r r e c t h i s o w n w or k er ’s p ra ctices .
14. Primary Responsibilities.—Th e fo llow in g a r e p r im a r y r esp o n sib ilit ie s o f t h e in sp ect o r :
• Ve r ify in w r itin g th a t co a tin g w or k is being p erform ed in accord an ce w ith t h e s p e c ific a tio n s
• M on itor w ork activity on a d aily basis, inclu d ing d eviations from the
s p e c ific a tio n s
• Rep ort an d record d eficien cies to the fie ld e n g i n e e r fo r r e s o lu t io n
• En su r e w or k is co n d u cte d in a s a fe m a n n e r
15. Daily Responsibilities.—Th e fo llow in g is a p artial list of d aily in sp ection resp on sibilities:
(a) Pre paratory.—
• En su r e s p ecifica tio n s co n ta in all a d d e n d u m s a n d m o d i fica tio n s • E n s u r e a ll s p e c ifica t io n s u b m it t a l r e q u i r e m e n t s a r e m e t (b) Presurface P reparation.— • E n s u r e w e a t h e r co n d it io n s a r e c o n d u c iv e t o b l a st in g o p e r a t io n s • D e t e r m in e p r e b l a st s u r f a ce co n d it io n fo r r u s t g r a d e • E n s u r e t h a t t h e s u r f a ce is fr e e o f irreg u larities (w eld sp atter , slag bu rrs, s h a r p e d g e s , p i ts , l a m i n a t io n s , o r o t h e r objectiona ble irreg u larities)
• E n s u r e t h a t a b r a s i v e s m e e t
s p e cifica t io n r e q u i r em e n t s a n d a r e w ithin contam ination lim its
• E n s u r e t h e a ir c o m p r e s s o r is fr e e o f m o is t u r e a n d o il c o n t a m in a t i o n (c) Postsurface Preparation.— • E n s u r e t h e s u r f a ce p r e p a r a t io n m e t h o d m e e t s s p e c ific a tio n s requ irem en ts
• En su r e t h e s u r face (an ch or ) p r ofile m ee ts sp ecifica tio n s r eq u ir em en ts
• E n s u r e t h e s u r f a ce is fr e e o f
conta m inan ts an d m eets cleanliness sp ecification s requ irem en ts
(d) Precoating Applicatio n.—
• E n s u r e a ll co a t in g m a t er ia ls a re a p p r o v e d
• C h e c k s to r a g e a r e a f o r p r o p e r en viron m en tal and safety requ irem en ts
• E n s u r e e n v i r o n m e n t a l co n d it io n s (am bien t an d su rface tem p era tu res, h u m i d i t y , a n d d e w p o i n t ) m e e t sp ecification s requ irem en ts
• E n s u r e m i xi n g a n d t h i n n i n g m e e t m an u factu rer’s requ irem en ts
(e) Coating A pplica tion.—
• E n s u r e a p p l ic a t io n m e t h o d s m e e t m an u factu rer’s requ irem en ts
• E n s u r e in t e r m e d ia t e co a t a n d t o p c o a t a p p licat ion s a r e w ith in r eco a t t im e interv al for tem p eratu re an d hu m idity r an g es a n d th a t th e y m e e t th e
sp ecifica tio n s o r th e m a n u fa ctu r er ’s requ irem en ts
• C h eck am b ie n t te m p e r atu r e a n d h u m id it y d u r i n g c u r i n g p e r io d
(f) Postcoating A pplica tion.—
• Ensu re th e d ry film thickness m eets sp ecification requ irem en ts
• I n s p e c t d r y f il m f o r h o l id a y ( p i n h o l e ) d efects
• E n s u r e t h a t d e fe ct iv e , d a m a g e d , a n d d e fi ci e n t a r e a s a r e r e p a i r e d t o m e e t sp ecification r equ irem en ts.
F o r a m o r e co m p r e h e n s iv e l is t o f resp on sibilities, see ap p en d ix C.
16. Material Approval.—C o n t r a ct o r su b m itt ed coa tin g m a te r ials ar e n or m a lly r e v i e w e d b y t h e R e cl a m a t i o n o f fi ce t h a t e i t h e r p r e p a r e d o r i s su e d t h e s p e c if ic a t io n s . Th e
resp on sible rev iew ing office is listed in the r eq u ir ed su b m itt a l n u m b er (RSN ) ta b le in Sec tio n 01330 (Su b m itta ls) o f th e C SI sp ecifications.
Th e co a tin g in sp ect or is n ot u su a lly r es p on sib le fo r ap p r ov in g or d isa p p r ov in g contra ctor su bm itted m aterial. H ow ever , the in s p e ct o r sh o u ld t r a ck c on t r a c to r a n d
R ecla m a t io n c o r r es p o n d e n c e t o e n s u r e t h a t o n ly ap p r o v ed m a te ria ls a re u se d o n th e jo b s i t e.
If the TSC in the Den ver Office is the r es p on sib le s p ecifica tio n r ev iew in g office , it w ill p r o v i d e a co n t r a c t o r su b m it t a l w it h o n e o f th e follow ing r esp on ses:
A p p rov ed .— In d ica t es m a t e r ia l ca n b e
p u r c h a s e d a n d a p p l ie d .
Co nd it io na ll y a p p rov ed .—Ind icates the
m at er ial se lectio n is a ccep ta b le a n d th e m a t er ia l m a y b e p u r ch a se d ; h o w e v er , th e su b m itt a l is in co m p let e o r is m iss in g
d o c u m e n t a t io n . Re s u b m it t a l o f in c o m p le t e o r m iss in g d o cu m en ta tio n is r eq u ir ed . C on d itio n a l ap p r ov a l d oe s n ot im p ly a c ce p t a n c e fo r m a t e r ia l a p p lic a tio n . N o t a p p rov ed .— I n d i ca t e s t h e s e le c te d m a t er ia l is n o t a p p r ov ed fo r a p p lica tio n . T h e in s p e ct o r s h o u ld c h e ck b a t c h n u m b e r s o n m a t e r i a l c o n t a i n e r s a g a i n s t t h e a p p r o v a l le t t e r batch n u m bers for m aterials tha t arrive o n th e jo b s it e . C o n t a in e r s w it h b a t ch n u m b e r s th a t d o n o t co r r e s p o n d t o th e a p p r o v e d m a t e r ia l b atch n u m b er s sh o u ld b e re m o v ed fr om t h e jo b s i t e.
17. Documentation.—Th e in sp ect or sh ou ld acqu ire th e follow ing d ocu m en ts:
• Sp e c if ic a t io n s t h a t in c l u d e a d d e n d u m s a n d m o d i fica tio n s
• T h e m a n u fa ct u r e r ’s p r o d u ct d a t a , ap p lication , an d M aterial Safety Data Sh eet (M SD S)
• Referen ce stand ard s referred to in th e sp ecifica tio n s t h a t r ela te to th e fie ld in s p e ct io n • Re fer en ce s ta n d a r d s a r e d iscu ss ed in m or e d et a il for th e p er tin en t in sp ect io n m eth o d in o th er ch a p te r s. A p p e n d ix D lis ts r efe r e n ce st a n d a r d s c it e d i n t h i s d o c u m e n t
18. Instruments, Gauges, and Tools.—Th e
insp ector shou ld a cqu ire the equ ipm en t, in st r u m en ts , an d in st r u ctio n a l m a n u a ls n ece ss a r y to p er fo r m th e in sp ect io n w o r k . Sp a r e b a tt er ies sh ou ld b e a v a ilab le if e lect r on ic in s t r u m e n t s a r e u s e d . T h e t y p e s o f
in st r u m en ts w ill be d iscu ss ed in th e fo llow in g cha p ter s an d ar e listed in a p p en d ix E.
(a) Conflicts.— A t t im e s, t h e r e a r e
d isa gr ee m e n ts b etw e en th e co n tr acto r a n d th e in s p e ct o r o v e r in s t r u m e n t r e a d i n g s s u c h a s su r fa ce a n ch o r p r o file s o r d r y film th ick n ess es. Th er e m ay b e r ea so n ab le e xp lan at ion s for su ch d is cr e p a n c ie s. T h e se d i scr e p a n c ie s s h o u l d b e investigated to av oid futu re conflicts and to d evelop a w ork ing relationsh ip w ith the c o n t r a ct o r . T h e fo llo w in g a r e s o m e p ossibilities for instr u m en t d isagree m en ts:
• T h e t w o p a r t ie s a r e n o t u s i n g t h e s a m e typ e of instru m en t sets:
"
O n e in s t r u m e n t m a y b e m a lfu n ctio n in g"
O n e in s t r u m e n t m a y b e o u t o f c a lib r a t i o n • T h e t w o p a r t ie s a r e u s in g t h e s a m e typ e of instr u m en ts bu t:"
T h e y a r e u s in g d i ff er e n t p r o c e d u r e s"
T h e y a r e ta k in g r e a d in g s a t d iffe re n t lo ca tio n s"
O n e in s t r u m e n t m a y b e o u t o f c a lib r a t i o n 19. Substrate Inspection.—T h e in s p e ct o r s h o u l d i n sp e c te d t h e s u b s t r at e s u r fa ce b e fo r e su rface prep aration . Ferrou s su bstrates w ith localized ru st or m ill scale are m ore p ron e to p r em a tu r e co a tin g failu r e. Ru st an d m ill sca le a r e a s s h o u ld b e in s p e ct e d m o r e t h o r o u g h l y f o r clea n lin es s a fte r su r face p r ep a r a tio n . If m ill s ca l e is n o t e d a n d a b r a s iv e b l a s tin g i s n o t sp ecified , notify the field en gine er b ecau se ab ra siv e b las tin g is r eq u ire d . For m ain te n an ce c o a t in g w o r k w h e r e o v e r c o a t i n g i s sp e c if ie d , t h e ex is tin g c o at in g m a t er ia l s h o u l d b einsp ected for loose coatings by scrap ing w ith a sh a r p en ed p u tt y k n ife. O v er co a tin g loo se ly a d h er in g ex ist in g coa tin g w ill re su lt in p r e m a t u r e f a il u r e .
Fo r ite m s co a te d in a s h op , th e co a tin g s s h ou ld b e in s p e ct e d a n d id e n t ifie d fo r d a m a g e a n d faile d coa tin g ar ea s t h a t w ill re q u ir e r ep a ir e it h e r b e f o r e o r a ft e r in s t a lla t io n .
20. Coating Inspection Checklist Sheet.—
R e cla m a t io n s p e cific a tio n c o a t in g t a b u la t io n s (see cha p ter III, su bsection 11) id en tify th e item s to be coated , coatin g m ater ials, the D FTs, an d th e su rface p rep ara tion m eth od s;
h o w e v e r , t h e i n s p e c t o r m a y w is h t o e x p a n d o n th e co a tin g ta b u lat ion s b y cr ea tin g a co a tin g in sp ect ion ch eck list u n iqu e t o t h e job . Sin ce sp ecifica tio n coa tin g ta b u lat ion s ca n id en tify se v er a l ite m s t o b e co a te d w ith in a s in g le t a b u la t io n , a n i n s p e c t io n s h e e t c a n p r o v i d e fo r the in d ividu al coating op eration s an d for the co m p l e te d i n s p e ct io n fo r a sin g l e it e m t o b e co a t e d , s u c h a s a p i p e lin e i n t er io r o r a r a d i a l g a t e . T h e ch e c k lis t ca n b e c o m e a p e r m e a n t r e co r d o f th e jo b . A c h e ck lis t e xa m p l e ap p e a r s in ap p en d ix F.
21. Precoating Conference.—R e cla m a t io n c o a t in g s p e c i fi ca t i o n s d o n o t r e q u i r e a p r eco a tin g co n fe r en ce w ith th e co n tr a ct o r . H ow ever , a m eeting w ith the con tractor to d is cu s s co a t in g - r ela t ed is su e s w o u l d b e h e l p f u l . A p r e c o a tin g c o n f e r e n c e w ill a llo w the con tractor to kn ow w ha t is exp ected an d to ou tlin e t h e w or k p r og r a m . Th is m ee tin g sh ou ld es ta b lish a w or k in g r ela tio n sh ip be tw een th e con tra ctor a n d Reclam ation . The fo llo w in g a r e p o s sib le it e m s f or d is cu s sio n a t t h e m e e t in g :