Thank you for downloading this file. If you would like further information on water jetting visit the Lydia Frenzel Conference Series.

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1 Thank you for downloading this file. If you would like further information on water jetting visit the Lydia Frenzel Conference Series. The Advisory Council is a nonprofit, privately funded membership organization that provides a forum for dialogue and the dissemination of information pertaining to the economic and social effects of technological development throughout the world. The Council solicits and makes available pertinent information from both private and public sources, seeks expression of points of view from all who may wish to contribute, advances consensus opinions and selected issues of standards and standards organizations, develops networking to match speaking and information resources with the needs and demands of the community, and promotes specific seminars and symposia. A Primary Mission of the Council is to promote effective means of surface preparation in the maintenance industry using water and water/abrasive blasting techniques. This mission is viewed as important because the conservation of resources, particularly the public infrastructure, has a significant and long lasting economic impact on the well-being of every citizen. The Advisory Council is a sponsor of the Lydia Frenzel Conference Series.

2 PPI NBR: () DATE: August 16, 2002 PRESERVATION PROCESS INSTRUCTION (PPI) CORE CORE PPI, August 16,

3 1. SCOPE: 1.1 Title: Cleaning, Surface Preparation and Painting Requirements for (area to be prepared). 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 manufacturer s ASTM F 718 sheets, Shipbuilders and Marine Paints and Coating Product / Procedure Data Sheet for (Applicable QPL) Coating System Being Applied. 2.d. 2.e. 2.f. 2.g. 2.h. ASTM D 4417, Method C, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel OSHA 29 CFR 1915 Subparts C and Z SSPC-VIS-1-89 Visual Standard For Abrasive Blast Cleaned Steel SSPC-VIS-4 (I) Visual Reference Photographs for Steel cleaned by Water Jetting SSPC-VIS-3 Visual Standard For Power and Hand Tool Cleaned Steel 3. APPENDICES: APPENDICES APPENDIX TITLE APPLICABLE TO THIS PPI 1 QA INSPECTION FORM - ENVIRONMENTAL READINGS Y 2 QA INSPECTION FORM - SURFACE SOLUBLE SALT CONDUCTIVITY LOG Y 3 QA INSPECTION FORM SURFACE PROFILE LOG Y 4 QA INSPECTION FORM DRY FILM THICKNESS MEASUREMENTS Y 5 CHECKPOINTS & MILESTONES COMPLETION LOG Y 6 CERTIFIED COATING INSPECTOR S CHECKPOINT SIGN OFF LOG Y 7 PAINT APPLICATION EQUIPMENT & PAINT CONSUMPTION LOG Y 8 SURFACE CONDUCTIVITY TESTING PROCEDURE Y 9 QA INSPECTION FORM WET FILM THICKNESS MEASUREMENTS (For use with solvent coating systems) N 4. REQUIREMENTS: 4.1 SAFETY: Accomplish the safety precautions as specified in NSTM 631, Section 2; OSHA 29 CFR 1915 Subparts C and Z (Ref. 2.e), and the Job Order during surface preparation and the application of marine coatings. 4.2 WORK NOTICE: The contractor shall post the notice at the ship s quarterdeck or other designated location for each job or separate area at least four hours, but not more than 24 hours, prior to the start of work. The notice shall contain the following information: ship s name and hull number, work item number, compartment or frame number, identification of hazard, date and time of work process and identification of engineering and work practice controls. Deliver notification of work planned for a weekend or Monday following that weekend to the Commanding Officer s representative not later than 0900 on the Friday immediately preceding that weekend. Deliver notification of work planned on a federal holiday and on the day following the federal holiday to the Commanding Officer s representative not later than 0900 on the last working day preceding the federal holiday. CORE PPI, August 16,

4 4.3 QUALITY ASSURANCE REQUIREMENTS: REQUIREMENTS FOR COATED AREAS. Surface preparation shall be accomplished by certified blasters. Coating systems shall be applied by certified painters and test / inspection records maintained IAW the requirements of NSTM 631, Section 11. Checkpoints and final inspections shall be signed off by certified coating inspectors BLASTERS AND PAINTER CERTIFICATION. The implementing contractor shall maintain a certification program for blasters and painters working on the project IAW NSTM 631, Section COATING INSPECTOR CERTIFICATION: The implementing contractor shall maintain a certification program for coating inspectors working on the project IAW the requirements of NSTM 631, Section At a minimum, coating inspectors shall be certified and maintain certification to the National Association of Corrosion Engineers (NACE) Session I, or the NAVSEA Basic Paint Inspector Course (NBPI) COATING INSPECTOR RESPONSIBILITIES: Coating inspectors are responsible for requirements listed in NSTM 631, Section Responsible Government Representative certified coating inspector shall verify checkpoints and sign all applicable Appendices Implementing Contractor shall perform all in-process inspections and checkpoints The Responsible Government Representative shall be present for and verify all in-process inspections / checkpoints Implementing Contractor shall participate in a joint Ship s Force and SUPSHIP personnel safety brief, when directed by the SUPERVISOR, prior to the start of recommended PCP. NOTE: ALTHOUGH SOME SPACES ARE NOT CRITICAL COATED AREAS AS DEFINED IN NSTM CHAPTER 631, PPI S WILL USE NSTM 631 SECTION 11 EXCERPTS TO COVER CONTROLS ON THE PRESERVATION PROCESS IN-PROCESS INSPECTIONS: Inspections are to be completed in critical coated areas listed in NSTM 631, Section 11, plus the following areas; High Traffic Decks, Freeboard and Superstructure, Exterior Topsides, Bilges, Well deck Overheads, Sanitary Space (Head) Bulkheads, AFFF Stations Deck and Foundations, Overboard Discharges, Mixing Rooms, Vent Plenums Ducts and Trunks, Fire Zone Bulkheads, and Rast Track as listed in NSTM 631, Section 11. Responsible Government Representative certified coating inspector shall be given prior notice and shall perform an inspection of each coated area when the following checkpoints are reached: process control procedure, pre-surface preparation & cleaning, contamination containment and masking, surface preparation, paint storage area, prime coat, between each successive coat of paint, topcoat of paint applied and area ready for final inspection. The inspector is 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 DEVIATIONS: All surface preparation and coating applications shall be IAW delineated guidance herein. Any deviation will require NAVSEA approval and Contracting Officer (or representative) sign-off A TYCOM / NAVSEA authorized representative will provide QA oversight of this process. Implementing Contractor shall provide the Government QA inspector a minimum of four (4) hour notification of all checkpoints prior to accomplishing the checkpoint. CORE PPI, August 16,

5 4.3.8 DEVELOP AND ACCOMPLISH PROCESS CONTROL PROCEDURE (PCP): Submit two legible copies of each PCP not later than seven working days prior to start of the process required by the procedure to the Responsible Implementing Authority. The procedure shall contain the following minimum information: -Contractor s name and address, -Process title, number, and date developed, -Description of process, including critical factors which have direct bearing on the process quality and safety, -Qualification requirements for the personnel performing the work, -Inspection and documentation forms, -Acceptance and rejection criteria for checkpoints, -The method utilized to ensure personnel accomplishing the procedure have direct knowledge of the requirements prior to beginning work. A copy of the procedure shall be at the work site during the performance of work, -Develop PCP matrix to include the entire job process with start dates, surface preparation dates, coating application dates, etc., -Weekly, update matrix as needed based on schedule changes, until completion / closure of each space or job item, -The method utilized to control the procedure, -Identification of hazardous materials which will be used in the process or hazardous waste that will be generated by the accomplishment of the process and the methodology, which will be utilized to minimize the quantity of these materials, which will require control and disposal, -Approval signature and title of the contractor s representative and the date of submission CHECKPOINT (PCP): Provide to responsible QA representative for review and comment on the PCP five (5) days prior to commencement of this process. 4.4 RECORD KEEPING: RECORD KEEPING DURING SURFACE PREPARATION / PAINT APPLICATION: A permanent record of environmental conditions, surface preparation and paint application operations shall be maintained. Data shall be entered on Appendices 1-5. Environmental information on Appendix 1 shall be updated every 4 hours, posted at the job site and an updated copy provided to the coating inspector at each checkpoint for review. The record shall include dates and times of surface preparations and painting operations, air temperatures, surface temperature, relative humidity and dew point. Enter on Appendix 3 the abrasive blast media QPL, manufacturer, type and size of abrasive used (when used), along with the TESTEX PRESS-O-FILM tapes used to measure surface profile REVIEW OF RECORDS FOR FINAL COATING EVALUATION: A certified paint inspector authorized to represent NAVSEA shall review the Appendices of each critical area to ensure adequate quality control of the painting process. Records shall include all the test and inspection data required by NSTM 631 Table Failure to produce such records, or records which indicate that surface preparation and painting was not done IAW governing specifications/instructions, will be grounds for rejection Ensure process control documentation provides a record of the data required to control and determine satisfactory completion of the process Submit updated or changed PCP procedures to the SUPERVISOR at least three working days prior to implementation. 4.5 TEMPORARY SERVICES: The project will require temporary services such as, but not limited to, lighting, compressed air, ventilation, fresh water, electrical services, and crane service. Ensure all equipment is IAW safety requirements delineated in NSTM 631, Section FORWARDING APPENDICES AND RETENTION OF RECORDS: After the project is completed, forward two copies of the completed Appendix forms to the TYCOM, Supervisor of Shipbuilding and Responsible Implementing Authority. Records shall be maintained by the Supervisor for a period of 3 years. CORE PPI, August 16,

6 4.7 LOG OF EQUIPMENT & MATERIAL USED: Record equipment information and material used in Appendix 7. Compare materials used, to paint materials and abrasive blast media (when used), specified in work order or contract. 4.8 ENVIRONMENTAL CONDITIONS: Maintain environmental conditions IAW Ref. 2.c and NSTM 631, Sections 6, 7, and 8. Record measurements in Appendix Do not exceed the Maximum Relative Humidity levels after satisfactory soluble salt conductivity level has been attained and satisfactory visual substrate surface condition has been achieved for specific areas as follows; tanks, voids, and vent plenums - 50%; all other areas - 85% The application of Euronavy ES 301 is exempt from relative humidity and dew point requirements since it may be applied on damp surfaces If environmental conditions are not provided or are unclear, contact Responsible Implementing Authority for resolution. 4.9 TEMPERATURES TO BE MAINTAINED FOR PAINT COATING SYSTEMS: Ensure temperatures are within acceptable limits as specified IAW Ref. 2.c and NSTM 631, Section 6.3. If inconsistencies in temperatures exist, NSTM 631 will supersede Ref. 2.c. If temperatures are not provided or are unclear, contact Responsible Implementing Authority for resolution CONTAMINATION CONTAINMENT AND MASKING FOR SURFACE PREPARATION AND PAINTING OPERATIONS: The following requirements shall be observed, in addition to the specific requirements of the Job Order, for maintaining cleanliness of the ship, ship s equipment, components, and spaces for the duration of the availability Prevent contamination and surface damage of the ship s equipment, components, and spaces during contamination-producing operations Plug, blank, wrap, cover, seal, and mask equipment, components, cables, wire ways, boats, and openings using fire retardant/ water repellent materials, and prevent entry of contaminants to machinery, winches, rigging, machinery surfaces, weapons systems, electrical equipment, electronic equipment, valves, vents not in use, and other openings Install covering conforming to A-A and/or fire retardant plywood Install fire retardant industrial filter material on the intake of supply and exhaust end of ventilation systems which will be in use Remove existing and install new filter or clean the filter material when airflow is restricted All protective measures are to be in place prior to start of any contamination-producing operations and shall remain in place until the contamination-producing operations are complete Install double curtain baffles at the entrances of each access where airborne contamination could occur during contamination-producing operations. Install a dirt-collecting mat on the deck directly inside each access. The SUPERVISOR will select a maximum of four doors. Tag out doors not designated for access Temporary coverings shall not be removed during contamination-producing operations without permission of the SUPERVISOR PROTECTIVE COVERING: Inspect the integrity of the protective covering at the beginning of each shift in which contamination-producing operations will be accomplished. Ensure that equipment and machinery have not been infiltrated by contaminants. Notify the SUPERVISOR immediately by verbal means, followed on the next workday in writing, if contamination or surface damage has occurred. Reseal to prevent further entry of contaminants or surface damage. CORE PPI, August 16,

7 Maintain cleanliness of the work site free from accumulation of industrial debris caused by contractor and /or subcontractor employees on a continuous basis throughout the availability. Workspaces include those areas immediately under and adjacent, and those areas where service lines are run Area cleaning shall be accomplished no later than at the end of each shift, on a daily basis and prior to any checkpoints Remove and dispose of industrial debris from the ship on a daily basis Accomplish an initial walk-through of all locations aboard ship where contractor responsible work will take place, to observe cleanliness conditions. The inspection shall be made jointly with the SUPERVISOR and the ship s Commanding Officer s representative, and shall take place prior to the commencement of any work by the contractor Submit four legible copies of a written report of any unclean sites/spaces to the SUPERVISOR and Commanding Officer of the ship within 72 hours after completion of the inspection Accomplish a cleanliness inspection on a daily basis whenever work is in progress. The inspection shall be made jointly with the SUPERVISOR and the designated representative of the ship s Commanding Officer. During inspection the responsible party shall be assigned. A written report of any unclean work sites/spaces shall be prepared by the contractor and copies distributed to the SUPERVISOR and Commanding Officer of the ship within four hours after completion of the inspection. The inspection report shall list the responsible activity (contractor, ship, etc.) for each unclean site/area. Unclean sites/areas determined as contractor responsible shall be immediately cleaned Inspections and reporting shall be accomplished during the daily fire prevention and housekeeping inspections COVERING REMOVAL: Remove protective covering upon completion of contamination-producing operations and inspect for presence of contamination or surface damage. Notify the SUPERVISOR immediately by verbal means, followed on the next workday in writing, if contamination or surface damage has occurred, prior to removal of the contamination and repair of damage Remove from the ship and dispose of debris and foreign matter generated as a result of work being accomplished on this ship and from work being accomplished on other naval and private ships. Comply with the requirements of federal, state, and local laws, codes, regulations, and ordinances or as specified elsewhere in the Job Order ISOLATION, BLANKING AND TAGGING REQUIREMENTS: Notify the Commanding Officer s representative in writing of equipment, systems, circuits, components, piping, and valves that require isolation to accomplish work in the Work Item before any work is started on each individual Work Item so that tag-outs can be accomplished as required by ship s instructions After ship s force install tags; verify use of sufficient tags to prevent operation of equipment, systems, circuits, components, piping, or valves from all stations that could exercise control A contractor s representative shall print name, badge number, identify company, and sign on a ship s tag-out record sheet and tags after installation, indicating repair activity satisfaction with the completeness of the tagout and alerting personnel removing tags that contractor concurrence is required Post warning signs and barriers and install temporary positive means to prevent closure or movement of component that create a safety hazard Do not disturb, modify, remove, energize, or operate any switch, fitting, valve, or other equipment affixed with a ship s isolation or DANGER tag Do not remove or relocate ship s isolation or DANGER tags. CORE PPI, August 16,

8 Notify the Commanding Officer s representative immediately when the contractor s work is complete and the system, piping, or circuit is ready for activation to accomplish removal of tags The contractor s representative shall sign the ship s tag-out log sheet to show concurrence in tag removal and clearance before removal Verify removal and clearance of all isolation or DANGER tags in accordance with ship s instruction before the equipment is operationally tested or operated. 5. PRE-SURFACE PREPARATION: 5.1 STRUCTURAL INSPECTION: Prior to commencement of work, the government will provide an authorized representative to conduct a structural inspection for the entire area to be prepared. Heavily rusted or corroded area, damaged metal and holes in the structure or piping shall be documented and provided to ship s force and Responsible Contracting Authority to determine if further structural evaluation or NDT is warranted and for possible repair before surface preparation. 5.2 PRE-SURFACE CONDITIONING: Before surface preparation the Responsible Implementing Authority shall have all welds, protrusions, projections and spikes ground smooth; pits in the welds shall be ground out; all weld splatter shall be removed. If using a non-edge retentive coating radius all edges, flanges, cutouts, angles, pipe hangers and foot/hand holds to a minimum radius of 3mm. NOTE: RADIUSING OF EDGES, FLANGES, CUTOUTS, ANGLES, PIPE HANGERS, AND FOOT/HAND HOLDS IS NOT REQUIRED WHEN USING APPROVED EDGE RETENTIVE COATINGS. 5.3 DEGREASE / FRESH WATER WASH DOWN: Prior to surface preparation, remove all surface contaminants such as sea salts, grease and oil (hydrocarbons), loose rust; mud and marine growth with 3,000-psi minimum fresh water wash down. 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. 5.4 CHECKPOINT (Pre-Surface Preparation Inspection): NOTE: ULTRAVIOLET LIGHTS SHALL NOT BE USED IN MERCURY EXCLUSION AREAS (Visual and Ultraviolet (UV) Light): Conduct a visual inspection to verify all surfaces within the scope of the project are free of hydrocarbons, and other contaminants such as sea salts, loose rust, mud, and marine growth, which could become imbedded in the surface to be prepared. Inspect surface using a UV light (approx. 60 Å) to detect hydrocarbons on the surface. The ultraviolet light will not allow the proper detection of hydrocarbons on the surface if the surface being inspected is exposed to day or artificial light. Therefore for proper UV light hydrocarbon detection, lights must be off for interior spaces, and the inspection must be conducted during darkness for surfaces exposed to sunlight. Take appropriate safety measures to prevent worker hazards in the darkened space When hydrocarbons are present, the hydrocarbons will fluoresce as bright green, lime green, or blue/violet on the surface To remove detected contaminants or hydrocarbons, accomplish a solvent wipe on affected areas. Follow SSPC-SP-1 to remove contaminants and hydrocarbons If contaminants or hydrocarbons are detected on the surface after attempting to solvent spot repair, the Responsible Implementing Authority shall require the surface be de-greased again as directed in paragraph (Structural and Pre-Surface Conditioning): Verify all surfaces within the scope of the project are IAW paragraphs 5.1 and (Contamination Containment and Masking): Verify all surfaces within the scope of the project are IAW paragraphs 4.10 through CORE PPI, August 16,

9 6. SURFACE PREPARATION: 6.1 Monitor environmental conditions throughout surface preparation operations to ensure they meet requirements as specified in paragraphs 4.8 and 4.9. Record measurements in Appendix 1. NOTE: IMPLEMENTING AUTHORITY WILL DESIGNATE SURFACE PREPARATION METHOD TO USE, METHOD 1 ABRASIVE BLASTING, OR METHOD 2 UHP WATER JETTING. 6.2 METHOD 1, ABRASIVE BLASTING: Accomplish the overhaul surface preparation requirements of Tables or and , ll (Surface Preparation), for the location/area being prepared. Minimum requirement is SSPC-SP-10. The blast media must meet the requirements specified in NSTM 631, or have written authorization for use from NAVSEA 05M. 6.3 METHOD 2, UHP WATER JETTING: Accomplish the overhaul surface preparation requirements of Tables or and , II (Surface Preparation), for the locations/area being prepared. Minimum requirement is SSPC-SP 12, UHP WJ-2L The conductivity level of the water is to be checked daily prior to the start of UHP water jetting to ensure levels are below 70 microsiemens/cm for non-immersed applications and 30 microsiemens/cm for immersed applications For UHP water jetted area a blow down is required; using dry, oil free compressed air, blow down all horizontal and vertical surfaces, starting at the top working downward. 6.4 POWER TOOL CLEANING ON SURFACES INACCESSIBLE TO METHODS 1 or 2: Accomplish the requirements of SSPC-SP-11 Power Tool Cleaning to Bare Metal to remove all the existing coating and corrosion products. 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 Feather edges of adherent paint in adjacent areas remaining after cleaning The Responsible Implementing Authority shall have the authority to reject this method in any area if the surface can be shown to have adequate accessibility for Abrasive Blasting or UHP Water Jetting. 6.5 SURFACE PROFILE: For areas prepared to SSPC-SP-10 accomplish a surface profile of 2-4 mils (50-100µ) For areas prepared to SSPC-SP-12, UHP water jetted surfaces will retain the surface profile prior to surface treatment. In areas where the substrate may have been smoothed, a profile producing power tooling may be required to achieve the required profile For areas prepared to SSPC-SP-11, accomplish a surface profile of 1 mil minimum For areas prepared to an SSPC-SP-11, feather edges of well-adhered paint in adjacent areas remaining after cleaning. 6.6 CHECKPOINT (Surface Preparation): Accomplish IAW Table , II (Surface Preparation). The record shall show the extent of the inspection and detailed results. The degree of surface cleanliness shall be IAW the NACE/SSPC surface preparation standard specified; surface profile, soluble salt measurements, and adequacy of cleanup operations shall be recorded. The inspections shall be conducted to standardized acceptance criteria. Visual aids, such as SSPC-VIS-1-89 (Visual Standard for Abrasive Blast Cleaned Steel) (Ref. 2. f) or SSPC-SP-12 visual surface preparation of WJ-2 with light flash rust (Ref. 2.g) or SSPC-VIS-3, (Visual Standard for Power and Hand Tool Cleaned Steel, SSPC 93-04) (Ref. 2.h) may be used to ensure quality standards are met. Enter data on all applicable Appendices. CORE PPI, August 16,

10 6.6.1 (Surface Profile Measurements): Accomplish IAW Ref. 2.d. Record one measurement every 200 ft² randomly dispersed over the entire prepared area. Abrasive manufacturer, type and mesh size used shall be entered on Appendix 3 along with the TESTEX PRESS-O-FILM tapes used to measure surface profile (Soluble Salt Measurements Conductivity Testing): Accomplish conductivity tests IAW the method described in Appendix 8. Use HORIBA B-173 or equivalent NAVSEA approved test equipment. Measurements shall be made randomly over the prepared surface. Take five (5) measurements every 1,000 ft² (90m²). Areas less than 1,000 ft² (90m²) shall have (5) measurements made. For immersed applications, conductivity due to soluble salts (total ionic) shall not exceed 30µS/cm (microsiemens/cm). For non-immersed applications, conductivity due to soluble salts (total ionic) shall not exceed 70µS/cm (microsiemens/cm) If conductivity measurements for surfaces prepared to an SSPC-SP-10 exceed the respective values, water wash using a minimum of 3,000 PSI fresh water. Soluble salt conductivity limit of the fresh water shall not exceed 200µS/cm (microsiemens/cm). To ensure effective low-pressure water washing, the operator shall maintain the wand within a maximum distance of 12 inches to the substrate. The angle of the wand relative to the substrate shall be maintained between 45º - 90º. Remove all standing water, dry the area, and retest. If flash rusting has occurred, or/and soluble salt conductivity still exceed limits rewash, dry the area and retest. If the soluble salt conductivity limit is not reached after 2 washes, then perform water wash to the affected areas using water that is below 30µS/cm (microsiemens/cm) for immersed applications or below 70µS/cm (microsiemens/cm) for non-immersed applications. Repeat water wash and retest until satisfactory levels are obtained. If flash rusting has occurred, reblast the area and retest If conductivity measurements for surfaces prepared to an SSPC-SP-12 exceed the respective values, repeat SSPC-SP-12 to the affected areas. Remove all standing water, dry the area, and retest. If flash rusting has occurred, reblast the area and retest. Repeat SSPC-SP-12 until satisfactory levels are obtained. If flash rusting has occurred, reblast the area and retest If conductivity measurements for surfaces prepared to an SSPC-SP-11 in an isolated area exceed the respective values, circle area and perform spot solvent cleaning (Super High Flash Naphtha) followed by retest For SSPC-SP-11 prepared surfaces not practical for the spot cleaning method, water wash with copious amounts of fresh water using hand scrub brush. Soluble salt conductivity limit of the fresh water shall not exceed 200µS/cm (microsiemens/cm). Remove all standing water and dry the affected area. Disk sand using # 36 disk to remove all rust. Perform an SSPC-SP-1 solvent wipe on all sanded areas and retest. If the soluble salt conductivity limit is not reached after 2 washes, then perform water wash to the affected areas using water that is below 30µS/cm (microsiemens/cm) for immersed applications or below 70µS/cm (microsiemens/cm) for non-immersed applications. Repeat necessary steps until satisfactory levels are obtained (Environmental): Verify environmental conditions were monitored and maintained IAW paragraphs 4.8 and (Contamination Containment and Masking): Verify all surfaces within the scope of the project are IAW paragraph 4.10 prior to the application of paint. Surfaces must be clean and free of debris and dust 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 In order to pass the checkpoint, Appendices 1-3 and 5 shall be up to date and submitted to QA. QA will update Appendix 6. CORE PPI, August 16,

11 7. PAINTING REQUIREMENTS: NOTE: NOTE: IMPLEMENTING AUTHORITY WILL DESIGNATE COATING SYSTEM TO BE APPLIED. IF A SILICON ALKYD IS TO BE APPLIED DIRECTLY ON TOP OF A SOLVENT FREE COATING, THE SOLVENT FREE COAT SHALL BE ALLOWED TO CURE FOR MINIMUM OF 24 HOURS BEFORE APPLICATION OF SILICON ALKYD. 7.1 WET FILM MEASUREMENTS: During application, spray applicators shall monitor wet film thickness using wet film gauges. Random wet film thickness (WFT) measurements shall be taken during the application process to ensure the specified dry film thickness (DFT) is achieved. 7.2 DRY FILM THICKNESS MEASUREMENTS: Accomplish IAW Ref 2.b, record measurements in Appendix RE-COAT PERIODS: Applicator will not exceed manufacturer s maximum re-coat periods IAW Ref. 2.c. 7.4 DRY PAINT FOR CHECKPOINTS: Paint shall be dry prior to all paint related checkpoints. Dry shall be defined as fingernail hard. 7.5 OUT OF SPECIFICATION DRY FILM THICKNESS: Failure to meet minimum dry film thickness requirements will result in application of an additional coat or coats of paint in deficient areas before the coat can pass the DFT checkpoints. 7.6 Excessive dry film thickness in a coat or cumulative coats shall be determined IAW the coating table appendix found in the individual PPIs. If excessive DFT is determined, the Responsible Implementing Authority shall be contacted on how to proceed. 7.7 CHECKPOINT (Paint Storage): Accomplish a visual inspection of paint storage facilities 24 hours prior to paint being mixed to verify that the storage temperature complies within the minimum and maximum range allowed IAW Ref. 2.c. The paint storage temperature shall be monitored and recorded once per shift for 24 hours prior to the paint being used. Record measured temperatures in Appendix PAINT APPLICATION: The use of single or plural component spray equipment is acceptable for application of paint coats specified below. 7.9 When applying prime, stripe, intermediate and topcoat, each must be of a contrasting color MIXING: If single or plural component spray equipment is used, mix primer, stripe, intermediate and topcoat IAW NSTM 631, and Ref. 2.c Monitor environmental conditions throughout painting operations to ensure they meet requirements as specified in paragraphs 4.8 and 4.9. Record measurements in Appendix REPAIRS: Repairs Made To Paint Within Manufacturer's Overcoating Time Period: Surfaces in which mechanical damage extends into the substrate shall be prepared to SSPC-SP-11 Power Tool Cleaning. The power tool prepared surface shall be feathered into the surrounding intact paint, creating a smooth transition Surfaces in which the mechanical damage does not extend into the substrate shall be solvent wiped to clean Hand brush, or in larger areas airless spray the coating system in accordance with manufacturer s ASTM F 718 sheets, Ref. 2.c Repairs Made To Paint Beyond The Manufacturer's Overcoating Time Period: CORE PPI, August 16,

12 Surfaces in which mechanical damage extends into the substrate shall be prepared to SSPC-SP-11 Power Tool Cleaning. The power tool prepared surface shall be feathered into the surrounding intact paint, creating a smooth transition The painted surfaces surrounding the Power Tool Cleaned surface that have exceeded the over coating time period must be roughened to provide a surface profile Painted surfaces in which the mechanical damage does not extend into the substrate must have the surrounding painted surface roughened to provide a surface profile. NOTE: NOTE: NO PAINT SHALL BE APPLIED TO A PAINTED SURFACE THAT HAS EXCEEDED THE OVERCOAT PERIOD WITHOUT THE PROPER REACTIVATING PROCEDURES BEING FOLLOWED. PAINT ONLY REACTIVATED PAINT SURFACES Hand brush or in larger areas airless spray the coating system in accordance with manufacturer s ASTM F 718 sheets, Ref. 2.c Allow for proper drying time as per the manufacturer's instructions after the application of each coat (including damaged touch-up areas) Recoating Beyond Manufacturer's Overcoating Period: If overcoat period is exceeded, (see manufacturer s ASTM F 718 sheets, Ref. 2.c for maximum and minimum overcoating times), the following method shall be followed: 1. Clean affected surface with an approved cleaner. 2. Roughen surface with 60 or 80 grit sandpaper to profile the painted surface. 8. PRIMER COAT APPLICATION: 8.1 Apply prime coat specified in the coating table appendix found in individual PPIs IAW Table , lll (Painting). During application, immediately brush out any runs, drips, sags or puddles. 8.2 CHECKPOINT (Prime Coat): Verify prime coat is applied IAW Table , IV (Cure/Post Cure) (Holiday Inspection): Accomplish a visual holiday inspection of prime coat (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b 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 In order to pass the checkpoint, Appendices 1, 4, 5 and 7 shall be up to date and submitted to QA. QA will update Appendix STRIPE COAT APPLICATION (if applicable): 9.1 Check for evidence of Amine Bloom such as discoloration of paint coating or clear oily film. If evidence of Amine Bloom is present, perform low-pressure water wash or wipe surfaces clean using ethanol/water mixture. 9.2 Apply stripe coat specified in the coating table appendix found in individual PPIs with typical paint equipment IAW Table , lll (Painting). Stripe coat by brush in areas not accessible by paint spray equipment. During application, immediately brush out any runs, drips, sags or puddles. CORE PPI, August 16,

13 9.3 CHECKPOINT (Stripe Coat): Verify stripe coat is applied IAW Table , IV (Cure/Post Cure) (Holiday Inspection): Accomplish a visual holiday inspection of stripe coat (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b 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 In order to pass the checkpoint, Appendices 1, 4, 5 and 7 shall be up to date and submitted to QA. QA will update Appendix INTERMEDIATE COAT APPLICATION (if applicable): 10.1 Check for evidence of Amine Bloom such as discoloration of paint coating or clear oily film. If evidence of Amine Bloom is present, perform low-pressure water wash or wipe surfaces clean using ethanol/water mixture Apply intermediate coat specified in the coating table appendix found in individual PPIs IAW Table , lll (Painting). During application, immediately brush out any runs, drips, sags or puddles CHECKPOINT (Intermediate Coat): Verify intermediate coat is applied IAW Table , IV (Cure/Post Cure) (Holiday Inspection): Accomplish a visual holiday inspection of intermediate coat (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b 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 In order to pass the checkpoint, Appendices 1, 4, 5 and 7 shall be up to date and submitted to QA. QA will update Appendix nd STRIPE COAT APPLICATION (if applicable): 11.1 Check for evidence of Amine Bloom such as discoloration of paint coating or clear oily film. If evidence of Amine Bloom is present, perform low-pressure water wash or wipe surfaces clean using ethanol/water mixture Apply 2nd stripe coat specified in the coating table appendix found in individual PPIs with typical paint equipment IAW Table , lll (Painting). Stripe coat by brush in areas not accessible by paint spray equipment. During application, immediately brush out any runs, drips, sags or puddles CHECKPOINT (2nd Stripe Coat): Verify stripe coat is applied IAW Table , IV (Cure/Post Cure) (Holiday Inspection): Accomplish a visual holiday inspection of 2 nd stripe coat (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b 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 In order to pass the checkpoint, Appendices 1, 4, 5 and 7 shall be up to date and submitted to QA. QA will update Appendix 6. CORE PPI, August 16,

14 12. TOPCOAT APPLICATION: NOTE: REMOVABLE SHIP COMPONENTS AND EQUIPMENT TOPCOATED WITH EPOXY PAINTS, SUCH AS SIGMA EDGEGUARD, SHOULD NOT BE STORED IN LOCATIONS SUBJECT TO DIRECT UV EXPOSURE. FAILURE TO PREVENT SUCH EXPOSURE COULD RESULT IN SIGNIFICANT COLOR CHANGE Check for evidence of Amine Bloom such as discoloration of paint coating or clear oily film. If evidence of Amine Bloom is present, perform low-pressure water wash or wipe surfaces clean using ethanol/water mixture Apply topcoat specified in the coating table appendix found in individual PPIs IAW Table , lll (Painting). During application, immediately brush out any runs, drips, sags or puddles CHECKPOINT (Topcoat): Verify topcoat is applied IAW Table , IV (Cure/Post Cure) (Holiday Inspection): Accomplish a visual holiday inspection of topcoat (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b 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 In order to pass the checkpoint, Appendices 1, 4, 5 and 7 shall be up to date and submitted to QA. QA will update Appendix FINAL INSPECTION: 13.1 CHECKPOINT (Finished Painted Surfaces): Accomplish IAW Table , IV (Cure/Post Cure) (Dry Film Thickness): Accomplish final dry film thickness measurements IAW Ref. 2.b Coating imperfections found, which may cause premature coating failure, shall be corrected before the paint system is accepted using appropriate touch-up procedures specified in paragraph Slight imperfections in the coating system are allowable, as long as they are not below minimum mils, and will not result in premature failure of the coating in the immediate vicinity of the imperfection. Such slight imperfections should be left intact, as trying to correct them could result in damage to the surrounding coating system 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 will update Appendix 6. All test inspections noting unsatisfactory conditions shall be corrected. CORE PPI, August 16,

15 APPENDIX 1 QA INSPECTION FORM - ENVIRONMENTAL READINGS SHIP: DATE: LOCATION: 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 Time Enter Activity Paint Facility, Surface Preparation, Prime, Stripe, Intermediate, Tack, Top Coat, etc. Measurement Location Highest & Lowest Surface Temp. ( F) Wet Bulb ( F) Dry Bulb ( F) % RH Dew Point ( F) Each Entry Shall be Signed by Trade Monitor, Foreman or Certified Paint Inspector CORE PPI, August 16,

16 APPENDIX 2 QA INSPECTION FORM - SURFACE SOLUBLE SALT CONDUCTIVITY LOG SHIP: DATE: LOCATION: 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 TEST LOCATIONS CONDUCTIVITY (Microsiemens / Centimeter) CORE PPI, August 16,

17 APPENDIX 3 QA INSPECTION FORM - SURFACE PROFILE LOG SHIP: DATE: LOCATION: 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 Average Place TESTEX PRESS-O-FILM In Spaces Below, Retain As Permanent QA Record Mils Abrasive Manufacturer: (if applicable) Type: (if applicable) Mesh Size: (if applicable) Abrasive Blast QPL and Revision # (if applicable) CORE PPI, August 16,

18 APPENDIX 4 QA INSPECTION FORM - DRY FILM THICKNESS MEASUREMENTS SHIP: DATE: LOCATION: 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, FOR NUMBER OF MEASUREMENTS TO BE TAKEN SEE NOTES BELOW. Indicate Coating System Seq. Indicate Type 1 or 2 DFT Gage Being Used: Gage Manufacturer: Serial Number of Gage Being Used: Date Last Calibrated: Current Calibration Due Date: 1 Prime Coat: Top Coat: Stripe Coat: Other: Intermediate Coat: Other: Stripe Coat: Other: DFT (mils) Approximate Avg. of 3 Gage Location Readings Spot Measurement Spot Measurement 5 5 Average Average DFT (mils) Avg. of 3 Gage Readings Approximate Location DFT (mils) Approximate Avg. of 3 Gage Location Readings Spot Measurement Spot Measurement 5 5 Average Average DFT (mils) Avg. of 3 Gage Readings Approximate Location DFT (mils) Approximate Avg. of 3 Gage Location Readings Spot Measurement Spot Measurement DFT (mils) Avg. of 3 Gage Readings Approximate Location 5 5 Average Average Required Number of Measurements for Conformance to a Thickness Specification: 1. Make five (5) separate spot measurements (average of the gage readings, see SSPC-PA 2, section 4.1.2) spaced randomly over each 10 m 2 (100 ft 2 ) area to be measured. The five spot measurements shall be made for each 10 m 2 (100 ft 2 ) of area as follows: a. For structures not exceeding 30 m 2 (300 ft 2 ) in area, each 10 m 2 (100 ft 2 ) area shall be measured. b. For structures not exceeding 100 m 2 (1,000 ft 2 ) in area, three 10 m 2 (100 ft 2 ) areas shall be randomly selected and measured. c. For structures exceeding 100 m 2 (1,000 ft 2 ) in area, the first 100 m 2 (1,000 ft 2 ) shall be measured as stated in 1.b. and for each additional 100 m 2 (1,000 ft 2 ) of area or increment thereof, one 10 m 2 (100 ft 2 ) area shall be randomly selected and measured. d. If the dry film thickness for any 10 m 2 (100 ft 2 ) area is not in compliance with the requirements of SSPC-PA 2, sections and 5.2.2, then additional measurements must be made to isolate the non-conforming area. CORE PPI, August 16,

19 APPENDIX 5 CHECKPOINT & MILESTONE COMPLETION LOG SHIP: DATE: LOCATION: 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 Process Control Procedure (PCP) Demonstrated Date Pre-Surface Preparation and Cleaning Begins Date of Pre-Surface Preparation and Cleaning Checkpoint --Date of Visual and UV Light Inspection Check --Date of Structural and Pre-Surface Conditioning (ensuring de-burring and grinding) Check --Date of Contamination Containment and Masking Check Date Surface Preparation Begins 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 paint application Check Date Paint Storage Area Inspected Date Prime Coat is Applied Date of Prime Coat Checkpoint Date Stripe Coat Applied (if applicable) Date of Stripe Coat Checkpoint (if applicable) Date Intermediate Coat Applied (if applicable) Date of Intermediate Coat Checkpoint (if applicable) Date Stripe Coat Applied (if applicable) Date of Stripe Coat Checkpoint (if applicable) Date Top Coat Applied Date of Top Coat Checkpoint Date Finished Painted Surfaces Checkpoint ACTIVITY TIME DATE CORE PPI, August 16,

20 APPENDIX 6 CERTIFIED COATING INSPECTOR S CHECKPOINT SIGN OFF LOG Must Be Signed By Certified Coating Inspector To Pass Checkpoints SHIP: DATE: LOCATION: 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 Process Control Procedure Demonstrated Inspected and Accepted: Certified Inspector (Print): Certified Inspector (Signature): Pre-Surface Preparation and Cleaning Inspected and Accepted: Certified Inspector (Print): Certified Inspector (Signature): Surface Preparation Inspected and Accepted: Certified Inspector (Print): Certified Inspector (Signature): Paint Storage Area Inspected and Accepted: Certified Inspector (Print): Certified Inspector (Signature): Prime Coat Inspected and Accepted: Certified Inspector (Print): Certified Inspector (Signature): Stripe Coat Inspected and Accepted: (if applicable): Certified Inspector (Print): Certified Inspector (Signature): Intermediate Coat Inspected and Accepted (if applicable): Certified Inspector (Print): Certified Inspector (Signature): Stripe Coat Inspected and Accepted: (if applicable): Certified Inspector (Print): Certified Inspector (Signature): Top Coat Inspected and Accepted: Certified Inspector (Print): Certified Inspector (Signature): Finished Painted Surfaces Inspected and Accepted: Certified Inspector (Print): Certified Inspector (Signature): Date: Time: Date: Time: Date: Time: Date: Time: Date: Time: Date: Time: Date: Time: Date: Time: Date: Time: Date: Time: CORE PPI, August 16,

21 APPENDIX 7 PAINT APPLICATION EQUIPMENT AND PAINT CONSUMPTION LOG SHIP: DATE: LOCATION: 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 Stripe Coat Intermediate Coat Stripe Coat Top Coat Airless Paint Hose Size Airless Paint Hose Length Airless Tip Orifice Diameter / Fan Width Airless Pump Used & Model Airless Pump Ratio If plural component: Fixed or Variable If Using Inline Heater Temperature in Fº (Fahrenheit) Plural Airless Conventional Airless Temperature Setting At Heater Temperature At Tip Product Applied Product Manufacturer Expiration Date Color Applied Product VOC Base Portion Batch (Part A) Hardener Portion Batch (Part B) Gallons Used per Coat Square Feet Painted CORE PPI, August 16,

22 CORE PPI, August 16, APPENDIX 8