USACE / NAVFAC / AFCESA / NASA UFGS-33 52 80 (October 2007 )
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Preparing Activity: NAVFAC
References are in agreement with UMRL dated January 2009
SECTION 33 52 80
LIQUID FUELS PIPELINE COATING SYSTEMS
10/07
NOTE: This guide specification covers the requirements for interior and exterior
coating of aboveground and buried, carbon steel, liquid fuel pipelines. The
exterior coating system for aboveground pipelines is the same as used on the
exterior of fuel tanks, UFGS 09 97 13.27. The exterior coating system for buried
pipelines is either Extruded Polyolefin system or Fusion Bonded Epoxy coating.
An optional Fusion Bonded Epoxy coating is provided for the interior of pipe
to protect aviation fuel from iron contamination.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
Use of electronic communication is encouraged.
Brackets are used in the text to indicate designer choices or locations where
text must be supplied by the designer.
NOTE: This guide specification is intended for coating of new pipe only. For
maintenance coating of existing buried pipe, a coating inspection, or coating
condition survey (CCS), as described in UFGS 09 97 13.27 EXTERIOR COATING OF
STEEL STRUCTURES, should be accomplished prior to designing the coating project.
Without a competent inspection, there is no reliable way to determine the type
or condition of the existing coating system. Without knowing the existing conditions,
proper (effective and financially supportable) surface preparation or coating
system selection cannot be made.
NOTE: this specification ist he result of much experience and expertise pf SSPC
certified Protective Coatings Specialists.
A specifier, in adapting this specification to a project, should not alter the
products and proceses specified herein without thorough knowledge of the need
for the changes and the implicatons of those changes.
Prior to changing or altering the products or processes specified herein, it
is recommended that the specifier consult with the NAVFAC Paints and Coatings
Subject Matter Expert at Naval Facilities Engineering Service Center.
NOTE: The metric standard for measuring coating thickness is microns (25.4
microns=1 mil - use nominal 25 microns=1 mil).
PART 1 GENERAL
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Do not use the Reference Wizard's Check Reference feature
to update the issue dates, as this document is specific to the standards listed.
This guide specification will be updated when the standards are updated.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[AMERICAN WATER WORKS ASSOCIATION (AWWA)AWWA C203(2002) Coal-Tar Protective Coatings and Linings for Steel Water Pipelines - Enamel and Tape - Hot-AppliedAWWA C209(2006) Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections and Fitting for Steel Water PipeAWWA C210(2007) Standard for Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water PipelinesAWWA C213(2007) Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water PipelinesAWWA C215(2004) Extruded Polyolefin Coatings for the Exterior of Steel Water PipelinesAWWA C216(2007) Heat-Shrinkable Cross-Linked Polyolefin Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water PipelinesAWWA C217(2004) Petrolatum and Petroleum Wax Tape Coatings for the Exterior of Connections and Fittings for Steel Water Pipelines][ASTM INTERNATIONAL (ASTM)ASTM D 3276(2007) Painting Inspectors (Metal Substrates)][INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)ISO 9001(2008) Quality Management Systems- Requirements][NACE INTERNATIONAL (NACE)NACE RP0402(2002) Field-Applied Fusion-Bonded Epoxy (FBE) Pipe Coating Systems for Girth Weld Joints: Application, Performance, and Quality Control][THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)SSPC PA 1(2000; E 2004) Shop, Field, and Maintenance PaintingSSPC QP 1(1998; E 2004) Standard Procedure for Evaluating Painting Contractors (Field Application to Complex Industrial Structures)SSPC QP 3(2006; E 2007) Standard Procedure for Evaluating Qualifications of Shop Painting ApplicatorsSSPC QP 5(1999; E 2004) Standard Procedure for Evaluating the Quality of Coating and Lining Inspection CompaniesSSPC QS 1(2004) Standard Procedure for Evaluating a Contractor's Advanced Quality Management SystemSSPC SP 10(2007) Near-White Blast CleaningSSPC SP COM(2004) Surface Preparation Commentary for Steel and Concrete SubstratesSSPC VIS 1(2002; E 2004) Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning][U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)29 CFR 1910.1000Air Contaminants29 CFR 1910.134Respiratory Protection]1.2 SYSTEM DESCRIPTION
This section specifies the requirements for[ interior and] exterior coating of aboveground and buried, carbon
steel, liquid fuel pipelines. The exterior coating system for aboveground pipelines is specified with the same
requirements as the exterior coating system for the exterior of fuel tanks, UFGS 09 97 13.27 EXTERIOR COATING
OF STEEL STRUCTURES. The exterior coating system for buried pipelines is either extruded polyolefin system or
fusion bonded epoxy coating.[ Fusion bonded epoxy coating is specified for the interior of aviation fuel pipe
to protect fuel from iron contamination.]
1.3 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Submittals are for Contractor Quality Control approval only. The following shall be submitted in accordance
with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
External Pipe Coating
[Internal Pipe Coating]
Field-Applied External Pipe Coating
SD-06 Test Reports
Qualification Testing of Shop-Applied External Pipe Coating
[Acceptance Testing of Shop-Applied Internal Pipe Coating]
Qualification Testing of Field-Applied External Pipe Coating
Inspection Report Forms
Daily Inspection Reports
SD-07 Certificates
Contract Errors, Omissions, and Other Discrepancies
Corrective Action Procedures
Coating Work Plan
Qualifications of Certified Industrial Hygienist (CIH)
Qualifications of Pipe Coating Shop
Qualifications of Certified Protective Coatings Specialist (PCS)
Qualifications of Coating Inspection Company for Field Coating
Qualifications of Coating Inspector for Field Coating
Qualifications Of Individuals Performing Abrasive Blasting for Field Coating
Qualifications of Individuals Performing Coating Application for Field Coating
Qualifications of Individuals Performing Coating Application for Field Coating
Qualifications of Individuals Operating Plural Component Equipment (Pump Tenders) for Field
Coating
Qualifications of Coating Contractors
SD-11 Closeout Submittals
Inspection Logbook
1.4 QUALITY ASSURANCE
1.4.1 Contract Errors, Omissions, and Other Discrepancies
Submit all errors, omissions, and other discrepancies in contract documents to the Contracting Officer within
30 days of contract award for all work covered in this Section, other than the work that will not be uncovered
until a later date. All such discrepancies shall be addressed and resolved, and the Coating Work Plan modified,
prior to beginning the Initial and Follow-Up phases of work. Discrepancies that become apparent only after work
is uncovered shall be identified at the earliest discoverable time and submitted for resolution. Schedule time
(Float) should be built into the project schedule at those points where old work is to be uncovered or where
access is not available during the first 30 days after award, to allow for resolution of contract discrepancies.
1.4.2 Corrective Action (CA)
CA shall be included in the Quality Control Plan.
1.4.2.1 Corrective Action Procedures
Develop procedures for determining the root cause of each non-compliance, developing a plan to eliminate the
root cause so that the non-compliance does not recur, and following up to ensure that the root cause was eliminated.
Develop Corrective Action Request (CAR) forms for initiating CA, and for tracking and documenting each step.
1.4.2.2 Implement Corrective Action
The Contractor shall take action to identify and eliminate the root cause of each non-compliance so as to prevent
recurrence. These procedures shall apply to non-compliance in the work, and to non-compliance in the QC System.
Corrective actions shall be appropriate to the effects of the non-compliance encountered. Each CAR shall be serialized,
tracked in a Log to completion and acceptance by the Contracting Officer, and retained in project records. The
Corrective Action Log, showing status of each CAR, shall be submitted to the Contracting Officer monthly. A
CAR may be initiated by either the Contractor or the Contracting Officer. The Contracting Officer must approve
each CAR at the root cause identification stage, the plan for elimination stage, and the close out stage after
verification that the root cause has been eliminated.
1.4.3 Coating Work Plan
Provide procedures for reviewing contract documents immediately after award to identify errors, omissions, and
discrepancies so that any such issues can be resolved prior to project planning and development of detailed procedures.
Provide procedures for verification of key processes during Initial Phase to ensure that contract requirements
can be met. Key processes shall include surface preparation, coating application and curing, inspection, and
documentation, and any other process that might adversely impact orderly progression of work.
Provide procedures for all phases of coating operations, including planned work, rework, repair, inspection,
and documentation. Address mobilization and setup, surface preparation, coating application, coating initial
cure, tracking and correction of non-compliant work, and demobilization. Coordinate work processes with health
and safety plans and confined space entry plans. For each process, provide procedures that include appropriate
work instructions, material and equipment requirements, personnel qualifications, controls, and process verification
procedures. Provide procedures for inspecting work to verify and document compliance with contract requirements,
including inspection forms and checklists, and acceptance and rejection criteria.
Provide procedures for correcting non-compliant work. Detailed procedures are required in advance to avoid delays
in meeting overcoat windows as well as to avoid delays in production. Provide procedures for repairing defects
in the coating film, such as runs, drips, sags, holidays, overspray, as well as how to handle correct coating
thickness non-compliance, any other areas of repair or rework that might be adversely affected by delays in preparing
and approving new procedures.
If a procedure is based on a proposed or approved request for deviation, the deviation shall be referenced.
Changes to procedures shall be noted by submittal number and date approved, clearly delineating old requirements
and new requirements, so that the records provide a continuous log of requirements and procedures.
1.4.4 Qualifications
The qualifications specified in this paragraph must be met throughout the duration of this contract. No work
that is subject to specified qualifications shall be provided by personnel or corporate entities unless all specified
qualifications are met.
1.4.4.1 Qualifications of Certified Industrial Hygienist (CIH)
Submit name, address, telephone number, FAX number, and e-mail address of the independent third party CIH. Submit
documentation that hygienist is certified by the American Board of Industrial Hygiene in comprehensive practice,
including certification number and date of certification/recertification. Provide evidence of experience with
hazards involved in industrial coating application work.
1.4.4.2 Qualifications of Certified Protective Coatings Specialist (PCS)
Submit name, address, telephone number, FAX number, and e-mail address of the independent third party PCS. Submit
documentation that specialist is certified by SSPC: The Society for Protective Coatings (SSPC) as a PCS, including
certification number and date of certification/recertification. If the PCS is employed by the same coating inspection
company to which the coating inspector is employed, this does not violate the independent third-party requirements.
The PCS shall not be the designated coating inspector.
1.4.4.3 Qualifications of Coating Inspection Company for Field Coating
Submit documentation that the selected coating inspection company is certified by SSPC to the requirements of
SSPC QP 5 prior to contract award. The coating inspection company must remain so certified for the duration
of the project.
1.4.4.4 Qualifications of Coating Inspector for Field Coating
Submit documentation that each coating inspector is employed, and qualified to SSPC QP 5, Level III, by the selected
coating inspection company.
1.4.4.5 Qualifications Of Individuals Performing Abrasive Blasting for Field Coating
All individuals performing abrasive blasting shall be certified by SSPC to the SSPC C-7 Dry Abrasive Blaster
Qualification Program, and shall remain certified during the entire period of coating application. Submit name,
address, telephone number, and evidence of certification of each person that will be performing abrasive blasting.
This requirement applies to all manual abrasive blasting performed in shop and field locations. This requirement
does not apply to automated abrasive blasting perfromed in the shop.
1.4.4.6 Qualifications of Individuals Performing Coating Application for Field Coating
All individuals performing coating application shall be certified by SSPC to either the SSPC C-12 Marine/Industrial
Airless Spray Program or to the SSPC C-15 Plural Component Spray Program; Spray Painter Category, and shall remain
certified during the entire period of coating application. Submit name, address, telephone number, and evidence
of certification of each person that will be performing coating application by any method.
1.4.4.7 Qualifications of Individuals Operating Plural Component Equipment (Pump Tenders) for Field Coating
All individuals operating plural component equipment shall be certified by SSPC to the SSPC C-15 Plural Component
Spray Program; Equipment Operator Category, and shall remain certified during the entire period of coating application.
Submit name, address, telephone number, and evidence of certification of each person that will be operating plural
component equipment.
1.4.4.8 Qualifications of Pipe Coating Shop
NOTE: Solicitations requiring certification for prequalification should point
out the existence and location of the certification requirement on the PROJECT
INFORMATION FORM. This requirement must be pointed out in the solicitation
documents for the "prior to contract award" requirement to be enforceable.
Certification is a special responsibility requirement pursuant to FAR 9.104-2.
This is analogous to requiring bidders to have a specified level of experience
or expertise and GAO has sustained these types of special requirements.
Each shop that applies coatings to pipe shall be certified to either ISO 9001 or SSPC QP 3, Class A prior to
contract award.
1.4.4.9 Qualifications of Coating Contractors for Field Coating
NOTE: If project involves removal of paint containing hazardous materials,
add requirement for SSPC QP-2 certification in section of specification where
the hazardous paint removal is specified, generally UFGS 02 83 13.00 20 or 02
82 33.13 20.
All Contractors and Subcontractors that perform surface preparation or coating application shall be certified
to either ISO 9001 or SSPC QP 1 and SSPC QS 1 prior to contract award.
1.4.5 Protective Coating Specialist (PCS)
NOTE: Specifier of this section shall ensure coordination with the related
"QC Specialist" specification in Section 01 45 02 NAVFAC QUALITY CONTROL. Provide
the required data to complete the "QC Specialist" specifications of that Section
01 45 02.
The PCS shall be considered a QC Specialist and shall report to the QC Manager, as specified in Section
01 45 02 NAVFAC QUALITY CONTROL. The PCS shall approve all submittals prior to submission to the QC Manager
for approval or submission to the government for approval.
1.4.6 Pre-Application Meeting For Field Coating
After approval of submittals but prior to the initiation of coating work, Contractor representatives, including
at a minimum, project superintendent and QC manager, paint foreman, coating inspector, and PCS shall have a pre-application
coating preparatory meeting. This meeting shall be in addition to the pre-construction conference. Specific
items addressed shall include: corrective action requirements and procedures, coating work plan, safety plan,
coordination with other Sections, inspection standards, inspection requirements and tools, test procedures, environmental
control system, safety plan, and test logs. Notify Contracting Officer at least ten days prior to meeting.
1.5 DELIVERY AND STORAGE
Ship, store, and handle materials in accordance with SSPC PA 1, applicable standards, and as modified in this
Section. Maintain temperature in storage spaces between 5 and 24 degrees C 40 and 75 degrees F, and air temperature
more than 3 degrees C 5 degrees F above the dew-point at all times. Inspect materials for damage and return
non-compliant materials to manufacturer. Remove materials with expired shelf life from government property immediately
and notify the Contracting Officer. Expired materials may be returned to manufacturer, tested, and if compliant,
issued a shelf life extension.
1.6 COATING HAZARDS
NOTE: This specification Section should be used with UFGS 01 35 29 SAFETY AND
OCCUPATIONAL HEALTH REQUIREMENTS.
Ensure that employees are trained in all aspects of the safety plan. Specified coatings may have potential health
hazards if ingested or improperly handled. The coating manufacturer's written safety precautions shall be followed
throughout mixing, application, and curing of the coatings. During tank cleaning, cleanup, surface preparation,
and paint application phases, ensure that employees are protected from toxic and hazardous chemical agents which
exceed concentrations in 29 CFR 1910.1000. Comply with respiratory protection requirements in 29 CFR 1910.134
. The CIH shall approve work procedures and personal protective equipment.
1.7 JOB SITE REFERENCES - SHOP
Make available to the Contracting Officer a copy of each standard to which the shop will be applying coating
under this Section.
1.8 JOB SITE REFERENCES - FIELD
NOTE: Include any other references that might be added during design.
Make available to the Contracting Officer at least one copy each of AWWA C203, AWWA C209, AWWA C210, AWWA C215
, AWWA C216, AWWA C217, ISO 9001, SSPC PA 1, SSPC QP 1, SSPC QP 3, SSPC QS 1, SSPC SP COM, SSPC SP 10, and an
SSPC Certified Contractor Evaluation Form at the job site.
PART 2 PRODUCTS
2.1 SHOP-APPLIED COATING FOR BURIED PIPING
2.1.1 External Pipe Coating
NOTE: Use first option (AWWA C215 Extruded Polyolefin Coating (2-Layer Polyolefin))
for normal situations, or second option (AWWA C213 Fusion Bonded Epoxy (FBE))where
fuel contaminated soil is anticipated.
AWWA C215 2-Layer Polyolefin lists minimum thickness of coating system according
to pipe diameter:
Pipe diameter Minimum coating thickness
--------------------- ----------------------------
up to 2 in (50 mm) 31 mils (789 micrometers (um))
3-6 in (75-150 mm) 39 mils (991 um)
8-16 in (200-400 mm) 45 mils (1143 um)
18-36 in (450-900 mm) 49 mils (1245 um)
> 36 in (950 mm) 69 mils (1753 um)
AWWA C213 FBE requires minimum and maximum thickness of 12 mils and 16 mils,
respectively, for both interior and exterior coatings.
[2-Layer Extruded Polyolefin Coating Over Soft Adhesive: AWWA C215 ][Fusion-Bonded Epoxy Coating: AWWA C213,
minimum 15 mils375 microns, maximum 20 mils500 microns]
[2.1.2 Internal Pipe Coating (Lining)
NOTE: Delete requirement for lining where not required to protect aviation
fuel.
Fusion-Bonded Epoxy Coating: AWWA C213, minimum 15 mils375 microns, maximum 20 mils500 microns, and certification
from the coating manufacturer that the coating is suitable for immersion service in aviation fuel.
]2.2 SOURCE QUALITY CONTROL
2.2.1 Test Requirements
Qualification testing of coating materials and coating system performance requirements shall be based on laboratory
testing of identical materials used in production, tested within the last two years. All required and optional
tests shall be performed. Acceptance of each batch of production coating materials may be based on laboratory
testing or manufacturer's certificate of conformity.
NOTE: Include first bracketed text if AWWA C215 2-Layer Polyolefin coating
is specified. Include second bracketed text if AWWA C213 FBE is specified,
either interior or exterior, or both.
[Acceptance testing of Extruded Polyolefin coated pipe shall be based on all required production verification
testing required by AWWA C215. ][Acceptance testing of Fusion Bonded Epoxy coated pipe shall be based on all
required and optional production verification testing required by AWWA C213. Perform optional production verification
testing described in paragraph OPTIONAL COATING PERFORMANCE TESTING OF COATED PIPE of AWWA C213, including cross-section
porosity, interface porosity, thermal analysis (DSC), permanent strain (bendability), and interfacial contamination.
Perform production verification testing on a minimum of one pipe joint in the first half hour of production each
day, and on a minimum of one pipe joint in the last half hour of production each day. Perform additional testing
as required to segregate any non-compliant material. Testing may be performed using qualified in-house personnel
and facilities, or by independent laboratory. Submit results of tests as proof of compliance. ]Document compliance
with the approved Coating Work Plan.
2.2.2 Coating Inspector for Shop Coating
The coating inspector shall be the shop Quality Manager or appropriate designee. The coating inspector shall
be considered a QC Specialist and shall report to the prime Contractor's QC Manager, as specified in Section
01 45 02 NAVFAC QUALITY CONTROL. The Coating Inspector shall be present during all pre-preparation testing,
surface preparation, coating application, initial cure of the coating system, and during all coating repair work
required of the shop. The Coating Inspector shall provide complete documentation of conditions and occurrences
on the job site, and be aware of conditions and occurrences that are potentially detrimental to the coating system.
2.2.3 Shop Inspection
2.2.3.1 Inspection Requirements
Provide all tools and instruments required to perform the required testing, as well as any tools or instruments
that the inspector considers necessary to perform the required inspections and tests. Document each inspection
and test, including required hold points and other required inspections and tests, as well as those inspections
and tests deemed prudent from on-site evaluation to document a particular process or condition, as follows:
a. Location or area;
b. Purpose (required or special);
c. Method;
d. Criteria for evaluation;
e. Results;
f. Determination of compliance;
g. List of required rework;
h. Observations.
Collect and record Environmental Conditions as described in ASTM D 3276 on a 24 hour basis, from beginning of
surface preparation through initial curing of coating, as follows:
a. During surface preparation, every two hours or when changes occur;
b. During coating application and the first four days of initial cure, every hour, or when changes occur;
c. Note location, time, and temperature of the highest and lowest surface temperatures each day;
d. Use a non-contact thermometer to locate temperature extremes, then verify with contact thermometers.
Document all equipment used in inspections and testing, including manufacturer, model number, serial number,
last calibration date and future calibration date, and results of on-site calibration performed.
Document Contractors compliance with the approved Coating Work Plan.
2.2.3.2 Inspection Report Forms
Develop project-specific report forms as required to report measurements, test results, and observations being
complete and conforming to contract requirements. This includes all direct requirements of the contract documents
and indirect requirements of referenced documents. Show acceptance criteria with each requirement and indication
of conformity of each inspected item. The data may be in any format, but must be legible and presented so that
entered data can be quickly compared to the appropriate requirement.
2.2.3.3 Daily Inspection Reports
Submit one copy of daily inspection report completed each day when performing work under this Section, to the
Contracting Officer. Note all non-compliance issues, and all issues that were reported for rework in accordance
with QC procedures of Section 01 45 02 NAVFAC QUALITY CONTROL. Each report shall be signed by the coating inspector
and the QC Manager. Submit report within 24 hours of date recorded on the report.
2.2.3.4 Inspection Equipment
All equipment shall be in good condition, operational within its design range, and calibrated as required by
the specified standard for use of each device.
PART 3 EXECUTION
3.1 FIELD EXTERIOR COATING OF ABOVEGROUND PIPING
Coat aboveground piping in accordance with Section 09 97 13.27 EXTERIOR COATING OF STEEL STRUCTURES.
3.2 FIELD REPAIRS TO EXTERNAL COATING OF BURIED PIPING
3.2.1 Field-Applied External Pipe Coating
NOTE: This paragraph must be coordinated with Part 2 Materials. Use the first
option where the shop-applied exterior coating is the AWWA C215 2-Layer Polyolefin
coating, and use the second option when the exterior coating is the AWWA C213 FBE.
While other methods of repairing/girth weld coating of FBE coatings are usable
according to the standard, the options allowed here are limited to those that
will provide satisfactory service in fuel contaminated soil.
Use one or more of the following repair methods, as modified herein, to repair shop applied coatings and coat
external girth welds:
[a. Coal Tar Enamel: AWWA C203, Type II enamel, Type III outerwrap
b. Coal Tar Tape: AWWA C203
c. Cold Applied Tape: AWWA C209
d. Petrolatum or Petroleum Wax Tape Coating: AWWA C217
e. Heat Shrink Sleeve: AWWA C216
][a. Fusion-Bonded Epoxy (FBE) Coating: NACE RP0402, coating material to be same as applied to pipe in
shop
b. Liquid-Epoxy Coating System: AWWA C210
]
3.2.2 Surface Preparation
Prepare girth welds, and repairs to bare steel, to SSPC SP 10 immediately prior to coating application. Verify
that prepared surfaces comply with SSPC VIS 1 at time of coating application. All other surfaces shall be prepared
in accordance with the appropriate coating standard referenced herein.
Block or suspended pipeline at a height that will allow the blast nozzle to be perpendicular to the surface being
blasted, and at the proper standoff distance, at all times.
3.2.3 Soluble Salt Testing
3.2.3.1 Test Kit for Measuring Chloride, Sulfate and Nitrate Ions on Steel and Coated Surfaces
Provide test kits called CHLOR*TEST CSN Salts, as manufactured by CHLOR*RID International Inc. of Chandler, Arizona
(www.chlor-rid.com) or equal. An "equal" test kit shall meet the following requirements:
a. Kit contains all materials, supplies, tools and instructions for field testing and on-site quantitative
evaluation of chloride, sulfate and nitrate ions;
b. Kit extract solution is acidic, factory pre-measured, pre-packaged, and of uniform concentration;
c. Kit components and solutions are mercury free and environmentally friendly;
d. Kit contains new materials and solutions for each test extraction;
e. Extraction test container (vessel, sleeve, cell. etc.) creates a sealed, encapsulated environment
during salt ion extraction;
f. Test extract container is suitable for testing the following steel surfaces: horizontal (up/down configuration),
vertical, flat, curved, smooth, pitted, and rough;
g. All salt ion concentrations are directly measured in micrograms per square centimeter.
3.2.3.2 Pre-Preparation Testing for Soluble Salts Contamination
Test surfaces for soluble salts, and wash as required, prior to abrasive blasting. Soluble salt testing is also
required in paragraph PRE-APPLICATION TESTING FOR SOLUBLE SALTS CONTAMINATION as a final acceptance test of prepared
surfaces after abrasive blasting, and successful completion of this phase does not negate that requirement.
This phase is recommended since pre-preparation testing and washing are generally more advantageous than attempting
to remove soluble salt contamination after abrasive blasting. Effective removal of soluble salts will require
removal of any barrier to the steel surface, including rust. This procedure may necessitate combinations of
wet abrasive blasting, high pressure water rinsing, and cleaning using a solution of water washing and soluble
salts remover. The soluble salts remover shall be acidic, biodegradable, nontoxic, noncorrosive, and after application,
will not interfere with primer adhesion. Delays between testing and preparation, or testing and coating application,
may allow for the formation of new contamination. Use potable water, or potable water modified with soluble
salt remover, for all washing or wet abrasive blasting. Test methods and equipment used in this phase are selected
at the Contractor's discretion.
3.2.3.3 Pre-Application Testing for Soluble Salts Contamination
Test girth welds and areas to be repaired for chloride contamination using the Test Kit described in paragraph
TEST KIT FOR MEASURING CHLORIDE, SULFATE AND NITRATE IONS ON STEEL AND COATED SURFACES. One or more readings
greater than 3 micrograms per square centimeter of chlorides or 10 micrograms per square centimeter of sulfates
or 5 micrograms per square centimeter of nitrates is evidence of soluble salt contamination. Reject contaminated
surfaces, wash as discussed in paragraph PRE-PREPARATION TESTING FOR SOLUBLE SALTS CONTAMINATION, allow to dry,
and re-test until all required tests show allowable results. Reblast tested and cleaned areas as required.
Label all test tubes and retain for test verification.
3.2.4 Coating Application
Apply coatings in accordance with SSPC PA 1 and as specified herein. Apply coatings to surfaces that meet all
stated surface preparation requirements.
3.2.5 Final Inspection of Pipeline Prior to Burial
Verify that all surfaces of the pipeline are holiday-free at time of placement of backfill over pipe. Use holiday
inspection requirements and acceptance criteria of the standards applicable to the coatings being tested.
3.3 PROJECT IDENTIFICATION
At the completion of the work, affix pertinent coating data on structure at a location that is readily accessible
and visible from the ground. Use either stencils or nameplates. The following list generally describes the
pertinent coating data, but should be modified as required to describe the coating systems.
Date coated/accepted: __________/__________
Project Number: ________________________
Contractor: ___________________________________
Address: ______________________________________
Coating System
Manufacturer: _____________________
Surface Prep: SSPC SP __ Profile: ____
Primer: ____________ Thickness: ____
Intermediate: ____________ Thickness: ____
Topcoat: ____________ Thickness: ____
Total Thickness: ____
3.3.1 Stencils
Use stencils on piping 8 in or larger. Use stencils with 3/4 to one inch Helvetica style letters and acrylic
stencil paint of contrasting color.
3.3.2 Nameplates
NOTE: In a salt water environment, substitute
acceptable non-corroding metal such as, but not
limited to, nickel-copper, 304 stainless steel, or
monel. Aluminum is unacceptable. Nomenclature (or
system identification) should be established by the
designer. Require melamine plastic nameplates for all NAVFAC projects.
Use nameplates for piping smaller than 8 in. Construct plates of [anodized aluminum] [stainless steel] [melamine
plastic, 3 mm 0.125 in thick, UV resistance, black with white center core, matte finish surface and square corners]
[_____]. Install nameplates in prominent locations with nonferrous screws, nonferrous bolts, or permanent adhesive.
Minimum size of nameplates shall be 25 by 65 mm one by 2.5 in. Lettering shall be the normal block style with
a minimum 6 mm 0.25 in height. Accurately align all lettering on nameplates. [For plastic nameplates, engrave
lettering into the white core.]
3.4 FIELD QUALITY CONTROL
For marking of surfaces, use chalk for marking bare steel, and water based markers for marking coated surfaces,
and remove marks prior to coating. Do not use any wax or grease based markers, or any other markers that leave
a residue or stain.
3.4.1 Coating Inspector
The coating inspector shall be considered a QC Specialist and shall report to the QC Manager, as specified in
Section 01 45 02 NAVFAC QUALITY CONTROL. The Coating Inspector shall be present during all pre-preparation testing,
surface preparation, coating application, initial cure of the coating system, during all coating repair work,
and during completion activities as specified in Section 01 45 02 NAVFAC QUALITY CONTROL. The Coating Inspector
shall provide complete documentation of conditions and occurrences on the job site, and be aware of conditions
and occurrences that are potentially detrimental to the coating system. The requirements for inspection listed
in this Section are in addition to the QC inspection and reporting requirements specified in Section
01 45 02 NAVFAC QUALITY CONTROL.
3.4.2 Field Inspection
3.4.2.1 Inspection Requirements
Perform field inspection in accordance with ASTM D 3276 and the approved Coating Work Plan. Document Contractor's
compliance with the approved Coating Work Plan.
Provide all tools and instruments required to perform the required testing, as well as any tools or instruments
that the inspector considers necessary to perform the required inspections and tests. Document each inspection
and test, including required hold points and other required inspections and tests, as well as those inspections
and tests deemed prudent from on-site evaluation to document a particular process or condition, as follows:
a. Location or area;
b. Purpose (required or special);
c. Method;
d. Criteria for evaluation;
e. Results;
f. Determination of compliance;
g. List of required rework;
h. Observations.
Collect and record Environmental Conditions as described in ASTM D 3276 on a 24 hour basis, as follows:
a. During surface preparation, every two hours or when changes occur;
b. During coating application and the first four days of initial cure, every hour, or when changes occur;
c. Note location, time, and temperature of the highest and lowest surface temperatures each day;
d. Use a non-contact thermometer to locate temperature extremes, then verify with contact thermometers.
Document all equipment used in inspections and testing, including manufacturer, model number, serial number,
last calibration date and future calibration date, and results of on-site calibration performed.
Document Contractors compliance with the approved Coating Work Plan.
3.4.2.2 Inspection Report Forms
Develop project-specific report forms as required to report measurements, test results, and observations being
complete and conforming to contract requirements. This includes all direct requirements of the contract documents
and indirect requirements of referenced documents. Show acceptance criteria with each requirement and indication
of conformity of each inspected item. The data may be in any format, but must be legible and presented so that
entered data can be quickly compared to the appropriate requirement.
3.4.2.3 Daily Inspection Reports
Submit one copy of daily inspection report completed each day when performing work under this Section, to the
Contracting Officer. Note all non-compliance issues, and all issues that were reported for rework in accordance
with QC procedures of Section 01 45 02 NAVFAC QUALITY CONTROL. Each report shall be signed by the coating inspector
and the QC Manager. Submit report within 24 hours of date recorded on the report.
3.4.2.4 Inspection Logbook
A continuous record of all activity related to this Section shall be maintained in an Inspection Logbook on a
daily basis. The logbook shall be hard or spiral bound with consecutively numbered pages, and shall be used
to record all information provided in the Daily Inspection Reports, as well as other pertinent observations and
information. The Coating Inspector's Logbook that is sold by NACE is satisfactory. Submit the original Inspection
Logbook to the Contracting Officer upon completion of the project and prior to final payment.
3.4.2.5 Inspection Equipment
All equipment shall be in good condition, operational within its design range, and calibrated as required by
the specified standard for use of each device.
3.5 FINAL CLEANUP
Following completion of the work, remove debris, equipment, and materials from the site. Remove temporary connections
to Government or Contractor furnished water and electrical services. Restore existing facilities in and around
the work areas to their original condition.