MEDIUM DURABILITY MEDIUM DURABILITY

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1 PPI NBR: M (REV 00) DATE: May 27, 2004 MEDIUM DURABILITY PRESERVATION PROCESS INSTRUCTION (PPI) for WELL DECK OVERHEAD to be used in conjunction with CORE PPI with a Surface Preparation Method of Abrasive Blasting MEDIUM DURABILITY WELL DECK OVERHEAD PPI 1

2 1. SCOPE: 1.1 Cleaning, Surface Preparation and Painting Requirements for Well Deck Overhead. 1.2 RISK STATEMENT: Risk for installation. If proper surface preparation and application procedures are not adhered to, coating system failure can occur within 3-6 months Risk for curing. If overcoat window timeframes are not adhered to, coating system failure is possible within the first 6-9 months of application If the PPI checkpoint criteria are met, the following table provides service life expectancy for the listed systems: Coating System Life Expectancy: Specific Coat System Life Expectancy Primer, Stripe, Topcoat F150/F154 Type IV 2-3 years Finish Coat (For areas to be painted that will be subject to direct ultra violet rays) International Interlac One Niles N7229C LSA Ameron Amercoat 7229C LSA 2-3 years 2. REFERENCES: (IN ADDITION TO THE ELEMENTS CONTAINED IN THE CORE PPI, ADD THE FOLLOWING SUPPLEMENTAL ELEMENT) 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. Well Deck Overhead QPL-24441, MIL-PRF-24635, Niles N7229C LSA, International Interlac 1 LSA/Anti-Stain, Ameron Amercoat 7229C LSA 3. APPENDICES: (REFER TO CORE PPI EXCEPT FOR APPENDICES 5, 6, 7 & 10) 4. REQUIREMENTS: (THE FOLLOWING ELEMENTS AUGMENT THE CORE PPI) 4.8 ENVIRONMENTAL CONDITIONS: For zones being worked, maintain and continuously monitor environmental conditions (air temperature, % relative humidity, and dew point) throughout coating system installation (i.e., from beginning of surface preparation through final inspection. This includes periods in which no work is being accomplished.) IAW Ref. 2.c and NSTM 631, Section 6, 7, and 8. Highest and lowest surface temperatures will be taken and recorded immediately prior to application of each coat of a coating system. Record highest and lowest surface temperature measurements in Appendix 1. Maintain four (4) to six (6) air changes per hour during the dehumidification of the zone. Sufficient ventilation must be maintained throughout the application process in order not to exceed Lower Explosive Limit (LEL) specified in the manufacturer s MSDS A dust collector is required during the abrasive blasting process, the dust collector shall run a slight negative pressure to contain dust generated during abrasive blasting in a zone. However, the negative pressure shall not overdraw dehumidified air from the zone to the extent that the relative humidity cannot be maintained. Allowances shall also be made for the positive air displacement of abrasive blasting nozzles (each blast nozzle generates between 500 and 750 CFM of air into the space) and the negative pressure created by vacuum machines All ventilation ducting must be arranged to provide maximum efficiency, circulating processed air throughout the zone. WELL DECK OVERHEAD PPI 2

3 4.14 STAGING: ACCESS / CONFIGURATION / CONTAINMENT: ACCESS TO THE SURFACE: There are alternative points in the project in which the degreasing and water washing may be accomplished: 1. From a man lift (JLG) prior to the assembly of staging. 2. After the staging has been assembled, prior to the installation of the containment bulkheads, flameretardant PVC fabric covering, plywood containment bulkheads or any other aspect of the containment is setup (see Figures 1 & 2). Containment will tend to act as water containment, raising humidity and causing water damage during abrasive blasting Select the method best suited for accessing the well deck overhead surfaces, however; only one method shall be used. Each method impacts the schedule at different points in the sequence STAGING CONFIGURATION: Staging shall be erected using pole type staging from the ship s well deck, see (E) in Fig. 1. To ensure adequate working space, provide a 6-7 foot clearance between the underside of the ship s deck and the top deck platform of the pole staging, see (C) in Fig All staging shall be assembled and configured to ensure safe access to all surfaces being re-preserved within the scope of the project The distance between staging, or staging appendages and re-preservation surfaces shall be a minimum of 12 inches and a maximum of 24 inches from surfaces. Special attention must be made to ensure the aluminum staging or staging poles do not block or limit access to re-preservation surfaces All staging shall be assembled in a manner that complete cleaning of the staging is possible STAGING REMOVAL: Before removing staging, the contractor performing the coating application shall inform the TYCOM/NAVSEA authorized representative of any safety regulations limiting access to area(s) needing touch up coating after the staging is removed from the space All surfaces requiring staging for access must be fully coated (including touch up in way of mechanical damage, burn damage, etc.) and have passed all applicable checkpoints prior to staging removal in the zone ABRASIVE BLASTING GRIT AND DUST CONTAINMENT: Grit and dust containment is required during abrasive blasting. The containment area shall be defined by the work area created by accomplishing step Grit and dust containment shall be achieved two ways: 1. By laying flame retardant Poly Vinyl Chloride (PVC) fabric on a solid aluminum staging deck platform deck assembled on erected pole staging, see (B) in Figure 1; and affixing the PVC covering to all perimeter boundaries, creating a containment seal, see (D) in Figure 1. NOTE: The PVC fabric shall be flame-retardant, laminated, scrim-reinforced PVC with the following properties: Minimum weight of 10 oz. per square yard (available from oz. per square yard) Must pass a self-extinguishing flame test such as Fed Std 5903 Color may vary except yellow, no yellow fabric shall be used for containment purposes 2. By assembling temporary plywood containment bulkheads, creating four containment zones, see (A) in Figure 1. WELL DECK OVERHEAD PPI 3

4 Figure SEALING CONTAINMENT BULKHEADS: The containment zone shall be sufficient to ensure abrasive blasting grit and dust cannot escape from the zone during abrasive blasting. Sealing shall be accomplished by the use of flame-retardant PVC covering the staging. Additionally all openings will require sealing. Since the seal is intended for containment of dust created by abrasive blasting a tight seal is required. In most cases this will be achieved by using a combination of wood blanks, compressible foam and silicone sealant as shown in Figure 2. Figure 2 WELL DECK OVERHEAD PPI 4

5 4.15 ZONE SEQUENCING OF WORK PROCESS: The work area created by the staging (see (C), Figure 1) shall be divided into 4 zones. Containment bulkheads shall be constructed using wood framing covered with plywood (see (A) Figure 1). The containment bulkhead for each zone shall be sealed sufficiently to contain abrasive blasting dust and grit within the zone during abrasive blasting. During the process the containment bulkheads are moved from the initial installation location just enough to expose the surface under the containment bulkhead (footprint, see Figure 3). To minimize re-blasting in a zone it is important to minimize the footprint surface area of the containment bulkheads. Therefore, abrasive blasting will extend to surfaces directly adjacent to the containment bulkhead itself. Under these abrasive-blasting conditions, to maintain containment within the zone, targeted actions will be required to ensure the perimeter edges of the containment bulkheads are capable of withstanding close proximity abrasive blasting Take control of well deck overheads paint zones per the Event Schedule and restrict entry to urgent cases only, as determined by the Ship Superintendent. The paint zones shall be defined by use of curtains, ropes, signs, etc. Whenever possible, take advantage of existing barriers to establish zones Identify well deck overheads to be prepared or painted in the Ship's Plan of the Day meetings. SHIP S FWD WELL DECK OVERHEAD RE-PRESERVATION PROCESS SEQUENCE Erect Staging & Containment Common to Zones 1 4, (E) in Fig. 1 ZONE 1 Third in Sequence PHASE 3: Install Fwd plywood bulkhead in this zone simultaneous to painting in Zone 2 & abrasive blasting in Zone 4. PHASE 4: Abrasive blast & clean this zone simultaneous to painting in Zone 4. PHASE 5: Paint this zone IAW paint system being applied simultaneous to bumping Fwd & Aft plywood bulkheads & abrasive blasting in Zone 3. PHASE 6: Remove Fwd bulkhead in this zone. Accomplish surface preparation on footprint surfaces. Paint IAW paint system being. ZONE 2 First in Sequence PHASE 1: Install Fwd & Aft plywood bulkheads in this zone PHASE 2: Abrasive blast & clean this zone. PHASE 3: Paint this zone IAW paint system being applied simultaneous to abrasive blasting in Zone 4 & Fwd bulkhead installation in Zone 1. PHASE 6: After paint applied in Zone 1 has dried sufficiently bump Fwd plywood bulkhead towards Zone 1. Provide adequate protection of newly painted surfaces in Zone 2, abrasive blast Fwd plywood bulkhead footprint. Paint abrasive blasted footprint surfaces simultaneous with painting in Zone 3. ZONE 3 Fourth in Sequence PHASE 5: Bump Fwd plywood bulkhead towards Zone 2 enough to expose plywood bulkhead footprint (see Figure 3) then bump Aft plywood bulkhead towards Zone 4 enough to expose plywood bulkhead footprint (see Note). Abrasive blast this zone. Accomplish simultaneous to removing Aft bulkhead in Zone 4, surface preparation & painting on footprint surfaces. PHASE 6: Paint this zone IAW paint system being applied in after abrasive blasting Fwd plywood bulkhead footprint in Zone 2. SHIP S AFT ZONE 4 Second in Sequence PHASE 2: Erect Fwd & Aft plywood bulkheads in this zone simultaneous to abrasive blasting in Zone 2. PHASE 3: Abrasive blast & clean this zone simultaneous to painting in Zone 2 & Fwd bulkhead installation in Zone 1. PHASE 4: Paint this zone IAW paint system being applied simultaneous to abrasive blasting in Zone 1. PHASE 5: Remove Aft bulkhead in this zone. Accomplish surface preparation on footprint surfaces. Paint IAW paint system being applied. WELL DECK OVERHEAD PPI 5

6 * Footprint is the surface that was covered by the plywood containment bulkhead when initially installed (see figure 3). Zone 3 Note: If Fwd plywood bulkhead is bumped first, the paint applied in Zone 4 should be dry enough when the Aft plywood bulkhead is bumped. If not, the appropriate additional time will be required. Figure PRE-SURFACE PREPARATION: (THE FOLLOWING ELEMENT AUGMENTS THE CORE PPI) 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 3,000-5,000 PSI 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. 6. SURFACE PREPARATION: (REFER TO CORE PPI AND AUGMENT IT WITH THE FOLLOWING CORRELATE ELEMENTS) 6.2 USE ABRASIVE BLASTING FOR SURFACE PREPARATION WIRE SPRAY ALUMINUM (WSA): Wire spray aluminum is often encountered on well deck overheads. If wire spray aluminum is found, there will often be loose edges where the layer of the wire spray aluminum has delaminated away from the carbon steel substrate (see Top, Fig 4). Surfaces with wire spray aluminum shall also be abrasive blasted with close attention to loose (not tightly adherent) edges at the carbon steel to wire spray aluminum interface. When loose edges are abrasive blasted, work into the edge of wire spray aluminum layer continuing to blast the edge until a tight, void free, transition between the carbon steel substrate and the layer of wire spray aluminum has been achieved (see Bottom, Fig. 4). 6.3 Not Applicable to this PPI. WELL DECK OVERHEAD PPI 6

7 Figure PAINTING REQUIREMENTS: (REFER TO CORE PPI AND ADD THE FOLLOWING CORRELATE/SUPPLEMENTAL ELEMENTS) 7.1 WET FILM MEASUREMENTS: During application of the MIL-DTL-24441, MIL-PRF-24635, International Interlac 1 LSA/Anti-Stain, Niles N7229C LSA, and Ameron Amercoat 7229C coating systems, 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. Record WFT measurements in Appendix Receipt inspection of MIL-PRF paint material is to be completed in accordance with section of the CORE PPI. NOTE: WET AND DRY FILM MEASUREMENTS WILL BE TAKEN DURING THE APPLICATION PROCESS OF THE MIL-DTL-24441, MIL-PRF-24635, INTERNATIONAL INTERLAC 1 LSA/ANTI-STAIN, NILES N7229C LSA, AND AMERON AMERCOAT 7229C COATING SYSTEMS. 8. PRIMER COAT APPLICATION: (REFER TO CORE PPI) 9. STRIPE COAT APPLICATION: (REFER TO CORE PPI) 10. Not Applicable to this PPI 11. Not Applicable to this PPI 12. TOP COAT APPLICATION: (REFER TO CORE PPI) NOTE: IF AREA PAINTED WILL BE SUBJECT TO DIRECT ULTRA VIOLET RAYS, USE THE FOLLOWING PROCEDURE; OTHERWISE PROCEED TO FINAL INSPECTION. COMPLETION OF STEP 13, (TACK COAT APPLICATION) IS NOT REQUIRED IF TOP COAT IS STILL TACKY WHEN APPLYING FINISH COAT. WELL DECK OVERHEAD PPI 7

8 13. TACK COAT APPLICATION: 13.1 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 a contrasting color tack coat at 1-2 mils DFT over the topcoat with a MIL-PRF coating. During application, immediately brush out any runs, drips, sags or puddles WET FILM MEASUREMENTS: During application of the MIL-DTL coating system, 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. Record WFT measurements in Appendix 9. NOTE: WET AND DRY FILM MEASUREMENTS WILL BE TAKEN DURING THE APPLICATION PROCESS OF THE MIL-DTL coating system CHECKPOINT (Tack coat): Verify tack coat is applied IAW Table , IV (Cure/Post Cure) 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, 5 and 7-shall be up to date and submitted to QA. QA will update Appendix FINISH COAT APPLICATION: 14.1 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 a finish coat at 2-3 mils DFT with International Interlac 1 LSA/Anti-Stain or Niles N7229C LSA or Ameron Amercoat 7229C LSA or MIL-PRF During application, immediately brush out any runs, drips, sags or puddles CHECKPOINT (Finish Coat): Verify finish coat is applied IAW Table , IV (Cure/Post Cure) (Holiday Inspection): Accomplish a visual holiday inspection of finish 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 FINAL INSPECTION: (REFER TO THE ELEMENTS CONTAINED IN SECTION 13 OF THE CORE PPI) WELL DECK OVERHEAD PPI 8

9 APPENDIX 1: QA INSPECTION FORM ENVIRONMENTAL READING APPENDIX 2: QA INSPECTION FORM SURFACE SOLUBLE SALT CONDUCTIVITY LOG APPENDIX 3: QA INSPECTION FORM SURFACE PROFILE LOG APPENDIX 4: QA INSPECTION FORM DRY FILM THICKNESS MEASUREMENTS APPENDIX 5: CHECKPOINTS & MILESTONES COMPLETION LOG APPENDIX 6: CERTIFIED COATING INSPECTOR S CHECKPOINT SIGN OFF LOG APPENDIX 7: PAINT APPLICATION EQUIPMENT & PAINT CONSUMPTION LOG APPENDIX 8: SURFACE CONDUCTIVITY TESTING PROCEDURE APPENDIX 9: WET FILM THICKNESS MEASUREMENTS APPENDIX 10: COATING SYSTEM (S) (REFER TO CORE PPI) (REFER TO CORE PPI) (REFER TO CORE PPI) (REFER TO CORE PPI) (REFER TO THIS PPI) (REFER TO THIS PPI) (REFER TO THIS PPI) (REFER TO CORE PPI) (REFER TO CORE PPI) (REFER TO THIS PPI) WELL DECK OVERHEAD PPI 9

10 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 or Water-Break Inspection Check --Date of Structural and Pre-Surface Conditioning (ensuring de-burring and grinding) Check --Date of Contamination Containment and Masking Check 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 Paint Mixing Inspected --Date of Shelf Life Check --Date of Temperature Check --Date of Mixing Check Date Prime Coat is Applied Date of Prime Coat Checkpoint Date Stripe Coat Applied Date of Stripe Coat Checkpoint Date Top Coat Applied Date of Top Coat Checkpoint Date Tack Coat Applied (if applicable) Date of Tack Coat Checkpoint (if applicable) Date Finish Coat Applied (if applicable) Date of Finish Coat Checkpoint (if applicable) Date Finished Painted Surfaces Checkpoint ACTIVITY TIME DATE WELL DECK OVERHEAD PPI 10

11 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: Inspector #: Certification Expiration Pre-Surface Preparation and Cleaning Inspected and Accepted: Inspector #: Certification Expiration Surface Preparation Inspected and Accepted: Inspector #: Certification Expiration Paint Storage Area Inspected and Accepted: Inspector #: Certification Expiration Paint Mixing Inspected and Accepted: Inspector #: Certification Expiration Prime Coat Inspected and Accepted: Inspector #: Certification Expiration Stripe Coat Inspected and Accepted: Inspector #: Certification Expiration Top Coat Inspected and Accepted: Inspector #: Certification Expiration WELL DECK OVERHEAD PPI 11

12 APPENDIX 6 (Continued) 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 Tack Coat (If Applicable) Inspected and Accepted: Inspector #: Certification Expiration Finish Coat (If Applicable) Inspected and Accepted: Inspector #: Certification Expiration Finished Painted Surfaces Inspected and Accepted: Inspector #: Certification Expiration WELL DECK OVERHEAD PPI 12

13 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 Top Coat Tack Coat Finish Coat Airless Paint Hose Size Airless Paint Hose Length Airless Tip Orifice Diameter / Fan Width Airless Pump Used & Model Plural Airless Conventional Airless Airless Pump Ratio If plural component: Fixed or Variable If Using Inline Heater Temperature in Fº (Fahrenheit) 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 WELL DECK OVERHEAD PPI 13

14 APPENDIX 10 COATING SYSTEMS Coating Prime Stripe Top Coat System DFT Tack Coat (If Applicable) Finish Coat (If Applicable) (For areas to be painted that will be subject to direct ultra violet rays) F150 Series Type IV 4 6 mils DFT (F-150) 4 6 mils DFT (F-154) 4 6 mils DFT (F-154) 8 12 mils DFT mils DFT with stripe coat 1 2 mils DFT MIL-DTL mils DFT MIL-PRF (LSA Only), Haze Gray # Or 2 3 mils DFT Niles N7229C, LSA Anti-Stain, Haze Gray Or 2 3 mils DFT Interlac 1, LSA Anti-Stain, Haze Gray #45587A Or 2 3 mils DFT Ameron Amercoat 7229C, LSA Anti-Stain, Haze Gray WELL DECK OVERHEAD PPI 14