Special Provision To Specal Specification Marine Structures

2004 Specifications CSJ 6172-05-001
SPECIAL PROVISION
TO
SPECIAL SPECIFICATION
7349--002
Marine Structures
For this project, Special Specification Item 7349, “Marine Structures,” is hereby amended with
respect to the clauses cited below, and no other clauses or requirements of this Item are waived
or changed hereby.
Article 3. Attached Sections is voided and replaced by the following:
Section Description
(1) 09970 Thermal Sprayed Aluminum (TSA) Coatings

(2) 09980 Epoxy Coatings
(3) 09990 Nonskid Surface Coating
(4) 13000 Transfer Span System
(5) 13020 Transfer Span Machinery Assemblies
Article 5. Payment. The first sentence is voided and replaced by the following:
The work performed and materials furnished in accordance with this Item and measured as
provided under “Measurement” will be paid for at the unit price bid for “Marine Structures” of
the type specified.
1-47 7349--002
09-08
SECTION 09970
THERMAL SPRAYED ALUMINUM (TSA) COATINGS
PART 1 GENERAL
1.1 DESCRIPTION
A. This item shall govern for the application of thermal sprayed aluminum (TSA)
coatings for steel piling and structural steel associated with wingwalls, inner
dolphins, intermediate dolphins, outer dolphins, transfer spans, and the
Bolivar north breakwater.
1.2 REFERENCES
A. The following is a list of standards which may be referenced in this section:
1. American Welding Society (AWS):

a. C2.18, Guide for the Protection of Steel with Thermal Sprayed
Coatings of Aluminum, Zinc and their Alloys and Composites.
b. C2.25, Specification for thermal Spray – Solid and Composite
Wire and Ceramic Rods.
2. ASTM International (ASTM):
a. C633, Standard Test Method for Adhesion or Cohesion Strength
of Thermal Spray Coatings.
b. D4417, Field Measurement of Surface Profile of Blast Cleaned
Steel.
c. D4541, Standard Test Method for Pull-Off Strength of Coatings
Using Portable Adhesion Testers
3. ISO: 209-1, Wrought Aluminum and Aluminum Alloys – Chemical
Composition and forms of products – Part 1, Chemical Composition.
4. MIL-W-6712C: Wire, Metallizing.
5. Occupational Safety and Health Act (OSHA).
6. The Society for Protective Coatings (SSPC):
a. SP 1, Solvent Cleaning.
b. SP 2, Hand Tool Cleaning.
c. SP 3, Power Tool Cleaning.
d. SP 5, Joint Surface Preparation Standard White Metal Blast
Cleaning.
e. SP 7, Joint Surface Preparation Standard Brush-Off Blast
Cleaning.
f. SP 11, Power Tool Cleaning to Bare Metal.
g. PA 1, Shop, Field, and Maintenance Painting.
h. PA 2, Measurement of Dry Coating Thickness with Magnetic
Gages.
i. PA 3, Guide to Safety in Paint Applications.
1.3 DEFINITIONS
A. Terms used in this section:
2-47 7349--002
09-08
1. Coverage: Total minimum dry film thickness in mils or square feet per
gallon.
2. MDFT: Minimum Dry Film Thickness, mils.
3. MDFTPC: Minimum Dry Film Thickness Per Coat, mils.
4. Mil: Thousandth of an inch.
5. PSDS: Paint System Data Sheet.
6. SP: Surface Preparation.
7. TSA: Thermal Spray Aluminum.
1.4 SUBMITTALS
A. Shop Drawings:
1. Data Sheets:
a. For each component of the TSA coating system, furnish a System
Component Data Sheet (SCDS), Material Safety Data Sheet
(MSDS), the manufacturer's technical data sheets, and colors
available (where applicable) for each product used in the system.
The SCDS form is appended to the end of this section.
b. Technical and performance information that demonstrate
compliance with Specification.
c. Certificates of compliance for each batch of thermal spray coating
material.
d. Furnish copies of TSA coating system submittals to the coating
applicator.
e. Indiscriminate submittal of manufacturer's literature only is not
acceptable.
2. Detailed chemical and gradation analysis for each proposed abrasive
material.
B. Samples: Provide qualification procedure test coupons and reference panel.
1. Reference Panel: Unless otherwise specified.
C. Quality Control Submittals:
1. Applicator’s quality control procedures and qualification test results.

2. Thermal spray equipment operators qualification.
3. Applicator’s Qualification: List of references substantiating experience.
4. TSA applicator's written instructions and special details for shop and
field application of TSA and sealer to steel substrates.
5. TSA applicator’s written verification that submitted material is suitable
for the intended use.
1.5 QUALITY ASSURANCE

A. Qualifications:
1. TSA Applicator: Minimum 2 years’ experience in application of

specified products.
3-47 7349--002
09-08
2. TSA applicators who currently meet the required Quality Assurance
requirements include the following companies:
a. Sermatech Dynamic
7615 Fairview
Houston, TX 77041
(713) 849-9474
b. National Thermospray, Inc.
PO Box 1752
Cypress, TX 77410
(281) 373-0609
c. F .W. Gartner
PO Box 231305
Houston, TX 77223
(713) 225-0010
B. Regulatory Requirements:
1. Meet federal, state, and local requirements limiting the emission of

airborne toxic contaminants and volatile organic compounds.
2. Perform surface preparation, TSA and sealer application in accordance
with recommendations of the following:
a. Sealer manufacturer's instructions.
b. SSPC PA 3, Guide to Safety in Paint Applications.
c. Federal, state, and local agencies having jurisdiction.
1.6 INITIAL COATING QUALIFICATION PROCEDURE

A. Quality Control Procedure: Prepare a written quality control procedure for
thermal spray aluminum and sealing. The quality control procedure shall
include, but not be limited to, the following:
1. Visual inspection and acceptance criteria.

2. Surface profile measurements of abrasive blasted steel.
3. Coating thickness measurements.
4. Adhesion test requirements.
5. Nonconformance processing.
6. Requirements for bend test coupons and production test panels.
7. Coating repair procedures.
8. Reports required.
B. Qualification Procedure Approval: Prior to beginning any work, prepare

qualification test coupons in accordance with the quality control plan and as
described below.
C. Procedure Qualification:
1. The thermal spray aluminum coating application procedure shall be

qualified by coating five carbon or low alloy steel qualification test
coupons and three 1-inch diameter test cylinders, using the same
materials, techniques, equipment, and methods to be used for thermal
4-47 7349--002
09-08
spray coating in production. Test coupons shall be 2 inches by 6 inches
by 0.050 inch thick.
2. Secure test coupons to structural steel component with similar
dimensions to that which will be coated in production. The structural
component and coupon shall be thermal spray aluminum coated using
the same coating parameters in the proposed procedure. The test
application may be witnessed and inspected by the Engineer to verify
that the thermal spray process will be consistent with production
techniques.
3. Cross-Sectional Analysis: One of the coated test coupons shall be made
of similar material to the structural components to be coated and shall
be sealed with the epoxy sealer as specified herein. After the coupon has
been sealed and the sealer has cured, the test coupon shall be sectioned
through the thermal spray aluminum coating in at least two locations
and examined at a minimum of 50 times magnification to ensure
penetration of the sealer coatings into the thermal sprayed aluminum
coating. The examined cross section shall have less than or equal to
25 percent porosity and the maximum dimension of any void shall be
less than or equal to 50 percent of the thermal spray aluminum
thickness.
4. Bend Test: Two of the aluminum coated test coupons shall be bent 180
degrees around a 0.5-inch diameter mandrel. No cracking or only minor
cracking shall be observed, as illustrated in Figure C1 or AWS C2.18.
Cracking that results in disbonding or delamination, or thermal sprayed
aluminum coatings that can be removed with a knife blade, shall be
cause for rejection. All discrepancies must be corrected and the bond
test repeated, successfully, before the procedure is qualified.
5. Adhesion Test: An adhesion test, consisting of a minimum of three
separate pulls, shall be made using the 1-inch diameter test cylinders as
used for ASTM C633. The adhesion test cylinders shall be glued to bare
blast cleaned cylinders, then removed using a pull-test rig similar to that
used for ASTM C633 testing. The adhesion values for each pull shall be
2,000 psi, minimum.
6. If any of the qualification tests do not meet the criteria stated, the
process shall be adjusted to correct the defective parameters, and the test
sample procedure shall be repeated. No production work shall begin
before the application procedure is qualified.
7. The remaining two aluminum coated steel test coupons shall be
identified with the applications name and procedure and submitted to
the Engineer.
D. Reference Panel:
1. After the application procedure has been qualified, but before thermal
spray aluminum production coating work is started, prepare a
2-square-foot sample with the thermal sprayed aluminum and specified
sealer on a 3/16-inch thick steel panel as indicated below.
a. Abrasive to white metal as specified herein.
b. Mask one quarter of the steel plate and apply thermal spray
aluminum coating to three quarters of the sample. Use the
5-47 7349--002
09-08
specified thermal spray aluminum coating material and the actual
equipment that will be used on the project. Apply the thermal
spray aluminum coating with the techniques that will be used on
the project.
c. Apply the specified sealer to two thirds of the thermal sprayed
aluminum coated steel sample.
d. Measure and record the sample blast profile and depth, coating
and sealer thickness, and adhesion.
2. Preserve and maintain the reference panel in a dry, protected
environment to provide a project reference.
E. Thermal Spray Operator Qualification:
1. Manual, Shop or Field Application: To qualify as a thermal spray

aluminum application operator, the operator shall set up the manual
thermal spray equipment and spray test three test coupons and three test
cylinders as described in “Procedure Qualification” as specified herein.
These test samples shall be subjected to and pass the tests described in
the “Procedure Qualification.” Acceptable criteria shall be the same a
those stated for the “Procedure Qualification” tests.
2. Automatic: Each automatic thermal spray operator shall have
successfully completed the manual operator qualification specified
herein. The operator shall also successfully complete the following:
a. Operator shall demonstrate knowledge of the automated spray
system parameters required to apply the thermal spray aluminum
coatings in accordance with the requirements specified herein.
The operator shall identify machine setup parameters, verify
correct adjustment of the parameters, demonstrate operation of the
machine, and correct execution of documentation.
b. The operator shall be requalified if the operator has not thermal
sprayed aluminum to the approved procedure for a period of
6 months.
1.7 DELIVERY, STORAGE, AND HANDLING

A. Shipping:
1. Where precoated items are to be shipped to the site, protect TSA coating
from damage. Batten coated items to prevent abrasion.
2. Shop coated surfaces shall be protected during shipment and handling
by suitable provisions including padding, blocking, and use of canvas or
nylon slings.
B. Storage:
1. Protect metallizing wire spools from corrosion and environmental

deterioration.
2. Store sealer products in a protected area that is heated or cooled to
maintain temperatures within the range recommended by the sealer
manufacturer.
6-47 7349--002
09-08
PART 2 MATERIALS
2.1 MANUFACTURERS
A. Nationally recognized manufacturers who are regularly engaged in the
production of such materials for essentially identical service conditions.
B. Minimum of 3 years’ verifiable experience in manufacture of specified

product.
2.2 ABRASIVE MATERIALS

A. Select abrasive type and size to produce surface profile specified herein.
B. Blasting abrasives shall be clean, dry, sharp, and angular and shall be free of
clay, slat, oil, and other foreign matter.
2.3 THERMAL SPRAY COATING MATERIAL

A. Conforming to the requirements of MIL-W-6712 or ISO 209-1, Type A1 99.5.
Provide certificates of compliance for each batch of material supplied.
B. Individual wire spools shall be clearly and permanently labeled to indicate

manufacturer’s name, material type, lot number, net weight, wire diameter,
and date of manufacturer.
C. TSA applicator shall sample, store, and retain a sample of wire from each
batch for a period of 12 months following substantial completion of the
project.
2.4 SEALER MATERIALS

A. Two component, converted epoxy, Carboline 893 or approved equal.
B. Thinners, Cleaners, Driers, and Other Additives: As recommended by the

sealer manufacturer.
C. Mixing:
1. Prepare using each component as packaged by sealer manufacturer.

2. No partial batches will be permitted.
3. Do not use multiple-component sealers that have been mixed beyond
their pot life.
4. Mix only components specified and furnished by sealer manufacturer.
5. Do not intermix additional components for reasons of color or
otherwise, even within the same generic type of sealer.
D. Color:
1. Gray.
2. Formulate sealer with colorants free of lead or lead compounds.
7-47 7349--002
09-08
2.5 THERMAL SPRAY EQUIPMENT
A. Each type and model of thermal spray equipment shall be qualified in
accordance with this section. The equipment shall be capable of maintaining
current and voltage output, wire feed rates, atomized air pressure, and flow
volumes at set values without deviating by 5 percent during a 15-minute
period. The wire feed mechanism shall be designed for automatic alignment.
The equipment shall be capable of continuous start and stop operation for a
minimum of 15 cycles of 10 seconds on and 5 seconds off, without fusing,
sputtering, or deposition of nodules. The equipment shall be capable of
uniform spray application when operating continuously for a 20-minute period
without sputter, pop, or stopping.
PART 3 EXECUTION
3.1 General
A. Provide Engineer minimum 7 days' advance notice to start of field surface
preparation work and coating application work.
B. Perform the Work only in presence of Engineer, unless Engineer grants prior
approval to perform the Work in Engineer’s absence.
C. Schedule inspection with Engineer in advance for cleaned surfaces and all
coats prior to succeeding coat.
3.2 PROTECTION OF ITEMS NOT TO BE PAINTED

A. Remove, mask, or otherwise protect hardware, machined surfaces, couplings,
shafts, bearings, nameplates on machinery, and other surfaces not specified
elsewhere to be coated.
B. Protect working parts of mechanical and electrical equipment from damage

during surface preparation and painting process.
3.3 ENVIRONMENTAL CONTROLS

A. General:
1. Contractor shall provide heating, cooling, or dehumidification

equipment as required to meet the surface preparation and coating
application environmental requirements as specified.
2. Products shall comply with federal, state, and local requirements
limiting the emission of volatile organic compounds and worker
exposure.
3. Comply with applicable federal, state, and local, air pollution and
environmental control regulations for surface preparation, blast
cleaning, disposition of spent aggregate and debris, and application of
metal and solvent-based coatings.
8-47 7349--002
09-08
4. Do not perform abrasive blast cleaning whenever the relative humidity
exceeds 85 percent, whenever surface temperature is less than
5 degrees F above the dew point of the ambient air.
5. Do not apply coating when:
a. In dust or smoke-laden atmosphere, blowing dust or debris, damp
or humid weather, or under conditions that could cause icing on
the metal surface.
b. When it expected that surface temperatures would drop below
5 degrees above dew point within 4 hours after application of
coating.
6. Where weather conditions or project requirements dictate, TSA
applicator shall provide and operate heaters and/or dehumidification
equipment to allow surfaces be abrasive blasted and coated as specified
and in accordance with the manufacturers coating application
recommendations.
7. Work activities can be restricted by the Engineer until adequate
temperature and humidity controls are in place and functioning within
the environmental limits specified.
3.4 SURFACE PREPARATION

A. Metal Surface Preparation:
1. General: Compressed air for cleaning and blasting operations shall be

clean and dry.
2. Where indicated, meet requirements of SSPC Specifications
summarized below:
a. SP1, Solvent Cleaning: Removal of all visible oil, grease, soil,
drawing and cutting compounds, and other soluble contaminants
by cleaning with solvent.
b. SP5, White Metal Blast Cleaning: Removal of all visible oil,
grease, dust, dirt, mill scale, rust, coatings, oxides, corrosion
products, and other foreign matter by blast cleaning.
3. The words “solvent cleaning,” “hand tool cleaning,” “wire brushing,”
and “blast cleaning,” or similar words of equal intent in these
Specifications or in paint manufacturer's specification refer to the
applicable SSPC Specification.
4. Round or chamfer sharp edges and grind smooth burrs, jagged edges,
and surface defects.
5. Welds and Adjacent Areas:
a. Prepare such that there is:
1) No undercutting or reverse ridges on weld bead.
2) No weld spatter on or adjacent to weld or any area to be
painted.
3) No sharp peaks or ridges along weld bead.
b. Grind embedded pieces of electrode or wire flush with adjacent
surface of weld bead.
6. Preblast Cleaning Requirements:
a. Remove oil, grease, welding fluxes, and other surface
contaminants prior to blast cleaning.
9-47 7349--002
09-08
b. Cleaning Methods: Steam, open flame, hot water, or cold water
with appropriate detergent additives followed with clean water
rinsing.
c. Clean small isolated areas as above or solvent clean with suitable
solvent and clean cloth.
7. Blast Cleaning Requirements:
a. Type of Equipment and Speed of Travel: Design to obtain
specified degree of cleanliness and anchor profile. Minimum
surface preparation is as specified herein and takes precedence
over coating manufacturer's recommendations.
b. Use only dry blast cleaning methods.
c. Do not reuse abrasive, except for designed recyclable systems. If
recycled abrasives are used in conjunction with a recyclable
abrasive blast system, maintain abrasive particle size distribution
such that a consistent blast profile is obtained.
d. Meet applicable federal, state, and local air pollution and
environmental control regulations for blast cleaning, confined
space entry (if required), and disposition of spent aggregate and
debris.
8. Post-Blast Cleaning and Other Cleaning Requirements:
a. Clean surfaces of dust and residual particles from cleaning
operations by dry (no oil or water vapor) air blast cleaning or
other method prior to painting. Vacuum clean enclosed areas and
other areas where dust settling is a problem and wipe with a tack
cloth.
b. Coat and seal surfaces the same day they are blasted. Reblast
surfaces that have started to rust before they are painted.
3.5 SURFACE CLEANING

A. Solvent Cleaning:
1. Consists of removal of foreign matter such as oil, grease, soil, drawing

and cutting compounds, and any other surface contaminants by using
solvents, emulsions, cleaning compounds, steam cleaning, or similar
materials and methods which involve a solvent or cleaning action.
2. Meets requirements of SSPC SP 1.
3.6 APPLICATION
A. General:
1. For coatings subject to immersion, obtain full cure for completed

system. Consult coatings manufacturer's written instructions for these
requirements. Do not immerse coating until completion of curing cycle.
2. Apply coating and sealer in accordance with these Specifications, the
applicator’s approved procedures, and special details.
3. Coat units or surfaces to be bolted together or joined closely to
structures or to one another prior to assembly or installation.
4. Keep TSA sealer materials sealed when not in use.
10-47 7349--002
09-08
B. Metallizing Application:
1. Shop and field apply thermal spray aluminum coatings as specified

herein and as shown on the Drawings.
2. Metallizing methods which employ metal wire feed stock with oxygen-
fuel gas flame spray or electric-arc spray that produce coatings in
conformance with requirements of this specification are acceptable.
3. Set up and operate metallizing equipment in accordance with the
equipment manufacturer’s directions and in the same manner used to
prepare the sample.
4. Preheat surfaces to be coated, as required. Arc spray application does
not require preheating of the substrate.
5. Metallizing equipment shall be operated by qualified applicators in
accordance with these specifications and the equipment manufacturer’s
recommendations.
6. Mask or otherwise protect surfaces that are not intended to be coated.
7. Spray guns used to apply thermal sprayed aluminum coatings shall be
held approximately perpendicular to the surface to be coated and at a
distance required to deposit an even, continuous film of uniform
thickness. Gun distance from the work-piece shall not exceed 8 inches.
8. Coating passes shall overlap a minimum of 40 percent.
9. Thermal spray coatings shall not be applied closer than 1 inch to any
surface that will be welded after the coating is applied.
10. Give particular attention to edges, angles, flanges, and other similar
areas, where insufficient film thicknesses are likely to be present, and
ensure proper millage in these areas.
C. Coating System Check:
1. Manual or Field Application:

a. For each structure or component to be coated, a production test
panel shall be blast-cleaned and thermal spray aluminum coated at
the same time and in an identical manner to the structure or
component being coated. The test panel shall be carbon steel, at
least 36 inches square, and the same nominal thickness as the
structure or component being coated.
b. Production test panels shall be labeled in such a way as to
permanently identify the test sample and the companion structure
or component.
c. Provide one production test panel per 10 components and per
operator.
d. Perform three adhesion tests on each production panel in
accordance with ASTM D4541. Adhesion shall be 1,000 psi,
minimum.
e. If any adhesion values are less than 1,000 psi, three tests shall be
made at random on the structure or component. If the production
panel represents multiple structures or components, three tests
shall be made on each component coated by that operator since
that operators last successful production test panel or component.
All three adhesion test values shall be 1,000 psi, minimum. If the
11-47 7349--002
09-08
adhesion value does not meet the specified value, the structure or
component shall be completely blast cleaned and recoated as
specified herein.
1) Dollies for adhesion testing shall be glued to the coating
surface and permitted to cure a minimum of 12 hours.
2) Repair coating damaged by the adhesion tests in accordance
with the coating applicator’s standard, written instructions.
f. Production test panels shall be retained for a period of 1 year after
delivery of the structure or component and shall be available for
inspection by the Engineer.
2. Automated Application:
a. Perform a system check at the start of each production run. The
system check shall be performed before thermal spray application
to components and after any change to the machine setup
parameters. The system check shall consist of thermal spray
aluminum application one carbon steel test coupon, 2 inches by
6 inches by 0.050 inch thick, and one 1-inch diameter test
cylinder. The coupon and test cylinder shall be fixed to the length
of production component so that they are approximately the same
distance from the guns as the production component. The test
coupons shall then be coated using the same methods and
parameters as the production component.
b. The coupon and cylinder shall be removed from the production
component and tested. The coupon shall be bent to 180 degrees
around a 0.5-inch mandrel in two places. After bending, the
coupon shall be free of significant cracking that exposes the steel
substrate, and shall conform to the requirements of bend test
coupons described in ANSI/AWS C2.18. Small hairline cracks or
“alligatoring” of the coating in the vicinity of the bend are
permissible.
c. An adhesion test shall be made on the 1-inch diameter test
cylinder as used for ASTM C633. The adhesion test cylinder shall
be glued to another test cylinder of bare substrate that has been
abraded by blasting. The test cylinder will then be removed using
a pull-test rig similar to that used for ASTM C633. The adhesion
value shall be 2,000 psi, minimum.
d. If the coupon or cylinder does not meet the specified criteria, the
process shall be corrected and testing repeated until the operator
can demonstrate that the thermal spray coating can be applied to
meet the test requirements.
e. If the coupon and cylinder tests indicate that the process does not
meet the specified requirements, any component that had been
coated after the coupon and cylinders were prepared shall be
tested. Three adhesion tests shall be made at random on each
structure or component that was coated subsequent to application
of coating to and testing of the test coupon or cylinder. Adhesion
tests shall be made in accordance with ASTM D4251, and all
three adhesion values shall be 1,000 psi, minimum. If the adhesion
value does not meet the specified value, the structure or
12-47 7349--002
09-08
component shall be completely blast cleaned and recoated as
specified herein
1) Dollies for adhesion testing shall be glued to the coating
surface and permitted to cure a minimum of 12 hours.
2) Repair coating damaged by the adhesion tests in accordance
with the coating applicator’s standard, written instructions.
D. Sealer Application:
1. Apply sealer within 24 hours of the thermal spray aluminum coating is

application. Sealer coat shall not be applied to any surfaces with any
visible signs of rust or thermal spray aluminum coating degradation.
2. Apply sealer in strict accordance with the manufacturer’s written
directions.
3. Do not use sealer materials that have exceeded the manufacturer’s
expiration date, as marked on the container.
4. Sealer materials may be thinned in accordance with the manufacturer’s
written instructions. Provide a letter from the coating manufacturer
indicating that additional thinning is acceptable for thermal spray
aluminum sealing purposes.
5. Apply a stripe coat of sealer to edges, corners, welds, brackets, and
other irregular surfaces prior to application of a full sealer coat. Stripe
coating shall consist of one coat of sealer, brush applied, to the
thickness specified.
6. Brush out runs and sags.
3.7 INSPECTION AND TESTING

A. General: Applicator shall conduct quality control inspection and testing of the
coating system in accordance with these specifications and the applicator’s
approved quality procedure qualifications. The frequency of testing and
inspections shall be determined by the applicator.
B. Abrasive Blast Cleaned Surfaces:
1. Abrasive Blast Air Cleanliness: At the beginning of each work shift,

check compressed air cleanliness in accordance with ASTM D4285.
The compressed air source shall not be used if there is any oil or water
contamination present.
2. Abrasive Cleanliness: At the beginning of each work shift and at four
hour intervals, the cleanliness of the abrasive shall be checked as
described below.
a. Fill a small, clean, clear glass bottle half full of abrasive mix.
b. Fill the remainder of the bottle with distilled or deionized water.
c. Stir the contents; cap and shake the bottle.
d. Examine the water for the presence of an oil sheen. If any oil
sheen is present, discontinue use of the media and equipment until
the source of the contamination is identified and corrected.
13-47 7349--002
09-08
e. Examine the water for the presence of dust particles. If excessive
fine particles are present, recycling screens shall be adjusted and
the abrasive recycled prior to continued use.
3. Anchor Profile Measurements:
a. Measure the anchor profile on representative samples of the
component using replica tape. One anchor profile measurements
shall be made for each 500 square feet of surface area. Perform a
minimum of one anchor profile measurement on each component.
b. Anchor profile measurements shall be randomly spaced.
c. Spot measure anchor profile at weldments and flame-cut edges.
d. Areas not meeting the specified anchor profile shall be re-blasted.
4. Cleanliness of Prepared Surfaces:
a. Visually inspect cleaned, prepared surfaces to verify that no oil,
grease, dust, moisture, or other contaminants are on the surface
prior to application of the thermal spray aluminum coating.
b. Use clear adhesive tape to determine the presence of dust. Place a
piece of clear tape on the surface and inspect the removed tape for
the presence of adherent particles. Perform one tape test for each
500 square feet of prepared and cleaned surface.
c. Reclean surfaces that are found to be contaminated.
C. Thermal Spray Aluminum Coated Surfaces:
1. Visual Inspection: Thermal spray aluminum coated surfaces shall be

free from lumps, coarse areas, loosely adherent particles, blisters,
cracks, chips, or pits. The coating shall have a uniform appearance with
no discoloration.
2. Adhesion Testing: Perform adhesion tests as specified in Coating
System Check, this section.
3. Film Thickness Measurements:
a. Perform with properly calibrated instruments.
b. Perform film thickness measurements in accordance with SSPC
PA-2, with the exception that the absolute minimum film
thickness shall be 7 mils.
c. Mark areas of deficient coating thickness. Areas of deficient
coating thickness shall be repaired prior to application of the
sealer.
D. Sealed Surfaces:
1. The sealed coating shall be free from blisters, cracks, holidays, sags,
excessive runs, drips, or sags, and other visual defects. Each coat shall
have a uniform appearance.
2. Inspect sealed areas at with a 30 power magnifier to verify that there are
no voids or missed areas in coverage. Check each component at a
minimum of three random locations.
3. Prepare surfaces and reseal areas that have evidence of improper
application or insufficient coverage.
3.8 COATING REPAIRS

14-47 7349--002
09-08
A. Defective work shall be identified. No subsequent coating shall be performed
until the cause of the defective work is identified and rectified.
B. For areas with damaged sealer, clean to remove contamination and prepare
surfaces as recommended by the applicator. Feather edges of adjacent sealer,
as required.
C. For areas where the thermal spray aluminum coating is damaged to the
substrate, the coating shall be completed removed in the damaged area by
abrasive blast cleaning and the full coating system replaced in that area and
overlap intact coating as recommended in the applicator’s quality control
procedures. Feather edges of adjacent, intact coating. Overlap sealer onto
existing coatings around the repaired area.
D. Retest all coating repairs to verify that the repairs meet the requirements of
this specification.
3.9 PROTECTIVE COATING SYSTEM

A. System No. TSA. Use this coating system for steel piling and structural steel
associated with the following structures and as indicated on the plans:
1. Wingwalls.
2. Inner and Intermediate Dolphins.
3. Outer Dolphins.
4. Bolivar North Breakwater.
5. Transfer Spans.
Surface Prep. Material Thickness

SP1, Solvent Cleaning Thermal Spray 1 coat, 7 mils minimum,
Aluminum 14 mils maximum
SP5, White Blast Cleaning
Anchor Profile: 3 mils Epoxy Sealer 1 coat, 1.5 MDFT
minimum, 5 mils maximum
3.10 MANUFACTURER'S SERVICES

A. The coating manufacturer's representative shall be present at site as follows:
1. On first day of application of any coating system.

2. A minimum of two additional site inspection visits, each for a minimum
of 4 hours, in order to provide Manufacturer's Certificate of Proper
Installation.
3. As required to resolve field problems attributable to or associated with
manufacturer’s product.
4. To verify full cure of coating prior to coated surfaces being placed into
immersion service.
15-47 7349--002
09-08
3.11 SUPPLEMENTS
A. The supplement listed below, following “END OF SECTION,” are a part of
this Specification:
1. Data Sheet: Example Coating System Data Sheet (CSDS).
PART 4 MEASUREMENT AND PAYMENT
4.1 MEASUREMENT AND PAYMENT

A. The work performed, materials furnished and all labor, tools, equipment and
incidentals necessary to complete the work under this Item will not be
measured or paid for directly, but will be considered subsidiary to the various
bid items of the contract.
END OF SECTION
176866A.SEA
16-47 7349--002
09-08
COATING SYSTEM DATA SHEET
Complete and attach manufacturer's Technical Data Sheet to this CSDS for each coating
system.
Paint System Number (from Spec.):
Paint System Title (from Spec.):
Coating Supplier:
Representative:
Surface Preparation:
Product Name/Number
Coating Material (Generic) (Proprietary) Min. Coats, Coverage
Provide sealer’s manufacturer’s recommendations for the following parameters at

temperature (F)/relative humidity:
Temperature/RH 50/50 70/30 90/25
Induction Time
Pot Life
Shelf Life
Drying Time
Curing Time
Min. Recoat Time
Max. Recoat Time
Provide manufacturer’s recommendations for the following:
Mixing Ratio:
Maximum Permissible Thinning:
Ambient Temperature Limitations: min.: max.:
Surface Temperature Limitations: min.: max.:
Surface Profile Requirements: min.: max.:
Attach additional sheets detailing manufacturer’s recommended storage requirements and

holiday testing procedures.
17-47 7349-XXX
08-08
SECTION 09980
EPOXY COATINGS
PART 1 GENERAL
1.1 DESCRIPTION
A. This work consists of all labor, materials, equipment, and supervision
necessary to provide coatings as specified herein, complete.
B. This work includes, but is not limited to, cleaning and epoxy coating portions
of exposed structural steel, concrete encased steel, and specific surfaces of
steel pipe piling and sheet piling, as indicated on the plans.
1.2 REFERENCES
A. The following is a list of standards which may be referenced in this section:
1. International Organization for Standardization: 8502-6, extraction of

soluble contaminants for Analysis - the Bresle Method.
2. National Association of Corrosion Engineers (NACE): Manual for
Painter Safety.
3. Occupational Safety and Health Act (OSHA).
4. The Society for Protective Coatings (SSPC):
a. PA 1, Shop, Field, and Maintenance Painting
b. PA 2, Measurement of Dry Coating Thickness with Magnetic
Gauges.
c. PA Guide 3, A Guide to Safety in Paint Application.
d. SP1, Solvent Cleaning.
e. SP 2, Hand Tool Cleaning.
f. SP 3, Power Tool Cleaning.
g. SP 5, Joint Surface Preparation Standard, White Metal Blast
Cleaning.
h. SP 7, Joint Surface Preparation Standard, Brush-Off Blast
Cleaning.
i. SP 10, Joint Surface Preparation Standard, Near-White Blast
Cleaning.
1.3 DEFINITIONS
A. Terms used in this section:
1. Coverage: Total minimum dry film thickness in mils, or square feet per
gallon.
2. MDFT: Minimum Dry Film Thickness.
3. MDFTPC: Minimum Dry Film Thickness Per Coat.
4. Mil: Thousandth of an inch.
5. PSDS: Paint System Data Sheet.
6. SP: Surface Preparation.
18-47 7349-XXX
08-08
7. VOC: Volatile Organic Compounds
1.4 SUBMITTALS
A. Shop Drawings:
1. Data Sheets:
a. For each paint and/or protective coating system, furnish a Paint
System Data Sheet (PSDS), the manufacturer's Technical Data
Sheets, and paint colors available (where applicable) for each
product used in the paint system. The PSDS form is appended to
the end of this section.
b. Submit required information on a system-by-system basis.
c. Furnish copies of paint system submittals to the coating
applicator.
d. Indiscriminate submittal of manufacturer's literature only is not
acceptable.
2. Detailed chemical and gradation analysis for each proposed abrasive
material.
B. Quality Control Submittals:
1. Applicator’s Experience: List of references substantiating experience.

2. If the field applied coatings differ from the epoxy sealer applied to
thermal spray aluminum coatings, provide both coating manufacturers’
written confirmation that the materials are compatible.
3. Manufacturer's written instructions and special details for applying each
type of paint.
4. Submit procedures for field repair of damaged coating and field
application of coatings.
5. Coating Applicator’s Quality Control Plan for bulkhead wall system
coatings with letter of approval from the coating manufacturer.
6. Submit Coating Application Quality Control Test Data if requested by
the Engineer.
7. Manufacturers' Certificate of Proper Installation.

A. Qualifications:
1. Applicator: Minimum 5 years’ experience in application of specified

products.
B. Regulatory Requirements:
1. Meet federal, state, and local requirements limiting the emission of

volatile organic compounds.
2. Perform surface preparation and painting in accordance with
recommendations of the following:
a. Paint manufacturer's instructions.
b. SSPC-PA Guide No. 3, Guide to Safety in Paint Applications.
19-47 7349-XXX
08-08
c. Federal, state, and local agencies having jurisdiction.
C. Applicator’s Quality Control Program:
1. Quality control tests shall be conducted in accordance with the test

equipment manufacturer’s recommended procedures with accurately
calibrated test equipment.
2. Quality control test frequency shall be in accordance with the coating
manufacturer’s recommended quality control program parameters and
these specifications.
3. The minimum testing parameters shall include:
a. Environmental conditions, including, but not limited to, date and
time, weather conditions, precipitation, ambient temperature,
relative humidity, and dew point.
b. Steel temperature at time of surface preparation.
c. Surface chloride tests.
d. Visual observations of prepared surface.
e. Anchor pattern of prepared steel using Surface Profile Comparator
Reference Disks and 10 power magnifier, Testex Press-O-Film, or
approved equal.
f. Wet film coating thickness.
g. Dry film coating thickness.
h. Results of final coating inspection.
i. Record and number of coating repairs.
4. Quality control test data shall be recorded on forms approved by the
Engineer and be readily accessible to either the coating manufacturer or
Engineer, if requested.
1.6 DELIVERY, STORAGE, AND HANDLING

A. Store products in a protected area that is heated or cooled to maintain
temperatures within the range recommended by paint manufacturer.
B. Shipping:
1. Where precoated items are to be shipped to the site, protect coating from
damage. Batten coated items to prevent abrasion.
2. Use nonmetallic or padded slings and straps in handling.
3. Items with excessive coating damage as determined by the Engineer
will be rejected.
1.7 ENVIRONMENTAL REQUIREMENTS

A. Do not apply paint in temperatures outside of manufacturer's recommended
maximum or minimum allowable, or in dust, smoke-laden atmosphere, damp
or humid weather.
B. Do not perform abrasive blast cleaning whenever relative humidity exceeds

85 percent, or whenever surface temperature is less than 5 degrees F above
dew point of ambient air.
20-47 7349-XXX
08-08
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Coatings Manufacturers:
1. Ameron Protective Coatings, Brea, CA.

2. Carboline Coatings Co., St. Louis, MO.
3. ICI Devoe, Louisville, KY.
4. International Coatings, Houston, TX.
2.2 MATERIALS
A. General:
1. Product Verification: Provide letter from coating manufacturer stating

that the proposed materials are compatible and suitable for the intended
exposure.
2. Material Quality: Manufacturer's highest quality products and suitable
for intended service.
3. Materials Including Primer and Finish Coats: Produced by same
manufacturer.
4. Thinners, Cleaners, Driers, and Other Additives: As recommended by
manufacturer of the particular coating.
B. Products are listed below according to their approximate order of appearance

in the systems:
1. High Solids Epoxy Coating: Two-component, high-solids, low VOC,

epoxy coating that will continue to cure when immersed in water;
capable of 14 to 20 mils dry film thickness in one coat application;
suitable for application to marine structural steel components that will
be exposed to atmosphere, tidal zone, immersion and mud; International
Coatings Interzone 954, or approved equal.
2.3 MIXING
A. Multiple Component Coatings:
1. Prepare using the contents of the container for each component as

packaged by paint manufacturer.
2. No partial batches will be permitted.
3. Do not use multiple component coatings that have been mixed beyond
their pot life.
4. Furnish small quantity kits for touchup painting and for painting other
small areas.
5. Mix only components specified and furnished by paint manufacturer.
6. Do not intermix additional components for reasons of color or
otherwise, even within the same generic type of coating.
B. Colors: Formulate paints with colorants free of lead and lead compounds.
21-47 7349-XXX
08-08
PART 3 EXECUTION
3.1 GENERAL
A. All coatings on the breakwater sheet piles shall be shop applied. No field
coating of the sheet piling, with the exception of coating repairs, shall be
allowed.
3.2 EXAMINATION
A. Surface Preparation Verifications:
1. Inspect and provide substrate surfaces prepared in accordance with these

Specifications and the printed directions and recommendations of paint
manufacturer whose product is to be applied. The more stringent
requirements shall apply.
2. Provide Engineer minimum 7 days' advance notice to start of shop or
field surface preparation work and coating application work.
3. Perform such work only in presence of Engineer, unless Engineer grants
prior approval to perform such work in Engineer’s absence.
B. Schedule inspection with Engineer in advance for cleaned surfaces and all
coats prior to succeeding coat.
3.3 PREPARATION
A. Shop Blast Cleaning: Notify Engineer at least 7 days prior to start of shop
blast cleaning to allow for inspection of the work during surface preparation
and shop application of paints.
B. Field Abrasive Blasting: Perform blasting for items and equipment where
specified and as required to restore damaged surfaces previously shop or field
blasted and primed.
C. Protection of Items not to be Painted:
1. Protect all surfaces adjacent to, or downwind of Work area from

overspray. Contractor shall be responsible for any damages resulting
from overspray.
2. Take all necessary precautions to prevent any materials from entering
the water.
3. Remove, mask, or otherwise protect hardware and other surfaces not
intended to be painted.
4. Provide drop cloths to prevent paint materials from falling on or marring
adjacent surfaces.
5. Protect working parts of mechanical and electrical equipment from
damage during surface preparation and painting process.
22-47 7349-XXX
08-08
3.4 PREPARATION OF SURFACES
A. Metal Surfaces:
1. Where indicated, meet requirements of the following SSPC

Specifications:
a. Solvent Cleaning: SP 1.
b. Hand Tool Cleaning: SP 2.
c. Power Tool Cleaning: SP 3.
d. White Metal Blast Cleaning: SP 5.
e. Brush-Off Blast Cleaning: SP 7.
f. Near-White Blast Cleaning: SP 10.
2. The words “solvent cleaning,” “hand tool cleaning,” “wire brushing,”
and “blast cleaning,” or similar words of equal intent in these
Specifications or in paint manufacturer's specifications refer to the
applicable SSPC Specifications.
3. Where OSHA or EPA regulations preclude standard abrasive blast
cleaning, wet or vacu-blast methods may be required. Coating
manufacturers' recommendations for wet blast additives and first coat
application shall apply.
4. Hand tool clean areas that cannot be cleaned by power tool cleaning.
5. Round or chamfer sharp edges and grind smooth burrs, jagged edges,
and surface defects.
6. Welds and Adjacent Areas:
a. Prepare such that there is:
1) No undercutting or reverse ridges on weld bead.
2) No weld spatter on or adjacent to weld or any other area to
be painted.
3) No sharp peaks or ridges along weld bead.
b. Grind embedded pieces of electrode or wire flush with adjacent
surface of weld bead.
7. Preblast Cleaning Requirements:
a. Remove oil, grease, welding fluxes, salts, and other surface
contaminants prior to blast cleaning.
b. Test steel surfaces for chloride contamination as described in IOS
8502-6. Perform a minimum of one test per each five pilings.
Surface chlorides must be below the coating manufacturer’s
recommendations. Clean surfaces in accordance with the coating
manufacturer’s recommendations for those surfaces that exceed
the surface contamination levels specified by the coating
manufacturer.
c. Cleaning Methods: Steam, open flame, hot water, or cold water
with appropriate detergent additives followed with clean water
rinsing.
d. Clean small isolated areas as above or solvent clean with suitable
solvents and clean cloths.
8. Blast Cleaning Requirements:
a. Type of Equipment and Speed of Travel: Design to obtain
specified degree of cleanliness. Minimum surface preparation is as
23-47 7349-XXX
08-08
specified herein and takes precedence over coating manufacturer's
recommendations.
b. Select type and size of abrasive to produce a surface profile that
meets coating manufacturer's recommendations for particular
coating to be used.
c. Use only dry blast cleaning methods.
d. Do not reuse abrasive, except for designed recyclable systems.
e. Meet applicable federal, state, and local air pollution and
environmental control regulations for blast cleaning, confined
space entry (if required), and disposition of spent aggregate and
debris.
9. Post-Blast Cleaning and Other Cleaning Requirements:
a. Clean surfaces of dust and residual particles from cleaning
operations by dry (no oil or water vapor) air blast cleaning or
other method prior to painting. Vacuum clean enclosed areas and
other areas where dust settling is a problem and wipe with a tack
cloth.
b. Paint surfaces the same day they are blasted. Reblast surfaces that
have started to rust before they are painted.
3.5 SURFACE CLEANING METHODS

A. Brushoff Blast Cleaning:
1. Equipment, procedure, and degree of cleaning shall meet requirements

of SSPC-SP 7, Brushoff Blast Cleaning.
2. Abrasive: Either wet or dry blasting sand, grit, or nut shell.
3. Select various surface preparation parameters such as size and hardness
of abrasive, nozzle size, air pressure, and nozzle distance from surface
such that surface is cleaned without pitting, chipping, or other damage.
4. Verify parameter selection by blast cleaning a trial area that will not be
exposed to view.
5. Engineer will approve acceptable trial blast cleaned area and will use
area as a representative sample of surface preparation.
6. Repair or replace surfaces damaged by blast cleaning.
B. Solvent Cleaning:
1. Consists of removal of foreign matter such as oil, grease, soil, drawing

and cutting compounds, and any other surface contaminants by using
solvents, emulsions, cleaning compounds, steam cleaning, or similar
materials and methods which involve a solvent or cleaning action.
2. Meets requirements of SSPC-SP 1.
3.6 APPLICATION
A. General:
1. The intention of these Specifications is for new, exterior, exposed and

submerged metal surfaces to be painted, as indicated on the plans.
24-47 7349-XXX
08-08
2. For coatings subject to immersion, obtain full cure for completed
system. Consult coatings manufacturer's written instructions for these
requirements. Do not immerse coating for any purpose until completion
of curing cycle.
3. Apply coatings in accordance with these Specifications and the paint
manufacturers' printed recommendations and special details. The more
stringent requirements shall apply.
4. For Multiple Coat Systems:
a. Allow sufficient time between coats to assure thorough drying of
previously applied paint.
b. Alternate color to provide a visual reference that the required
number of coats have been applied.
c. Vacuum clean surfaces free of loose particles. Use tack cloth just
prior to applying next coat.
5. Coat units or surfaces to be bolted together or joined closely to
structures or to one another prior to assembly or installation.
6. Keep paint materials sealed when not in use.
7. Field painting shall be by brush, roller, or spray.
B. Shop Finished Surfaces: Schedule inspection with Engineer before shop

coated items delivered to site.
C. Film Thickness:
1. Number of Coats: Minimum required without regard to coating

thickness. Additional coats may be required to obtain minimum required
paint thickness, depending on method of application, differences in
manufacturers' products, and atmospheric conditions.
2. Maximum film build per coat shall not exceed coating manufacturer's
recommendations.
3. Film Thickness Measurements:
a. Perform with properly calibrated instruments.
b. Recoat and repair as necessary for compliance with the
Specifications.
c. All coats are subject to inspection by Engineer and coating
manufacturer's representative.
4. Give particular attention to edges, angles, flanges, and other similar
areas, where insufficient film thicknesses are likely to be present, and
ensure proper millage in these areas.
5. Thickness Testing:
a. After repaired and recoated areas have dried sufficiently, final
tests will be conducted by the Engineer.
b. Measure coating thickness specified in mils with a magnetic type
dry film thickness gauge.
c. Check each coat for correct millage. Do not make measurement
before a minimum of 8 hours after application of coating.
D. Unsatisfactory Application:
25-47 7349-XXX
08-08
1. If item has an improper finish color, or insufficient film thickness, clean
surface and topcoat with specified paint material to obtain specified
color and coverage. Obtain specific surface preparation information
from coating manufacturer.
2. Hand or power sand visible areas of chipped, peeled, or abraded paint,
and feather the edges. Follow with repair coat.
3. Evidence of runs, bridges, shiners, laps, or other imperfections is cause
for rejection.
4. Repair defects in accordance with written recommendations of coating
manufacturer and these specifications.
5. Leave staging up until Engineer has inspected surface or coating.
Replace staging removed prior to approval by Engineer.
3.7 FIELD QUALITY CONTROL

A. Testing Gauges: Provide a magnetic type dry film thickness gauge to test
coating thickness specified in mils, as manufactured by Nordson Corp.,
Anaheim, CA, Mikrotest.
3.8 MANUFACTURERS’ SERVICES

A. Provide manufacturer's representative at site in accordance with
Section 01640, MANUFACTURERS' SERVICES, for installation assistance,
inspection, and certification of installation.
B. The paint manufacturer shall provide a technical representative to make a

minimum of four person-day visits; one to observe surface preparation and
application of the shop coating, one to observe surface preparation and
application of the field coating, and two to verify that field repairs are made in
accordance with the manufacturer’s directions and these specifications.
Additional site visits may be required at other intervals during surface
preparation and coating application for product application quality assurance
and resolution of field problems attributed to, or associated with,
manufacturer’s products furnished under this project.
3.9 CLEANUP
A. Place cloths and waste that might constitute a fire hazard in closed metal
containers or destroy at the end of each day.
B. Upon completion of the Work, remove staging, scaffolding, and containers

from the site or destroy in a legal manner.
C. Completely remove paint spots, oil, or stains upon adjacent surfaces and
floors and leave entire job clean.
3.10 PROTECTIVE COATINGS SYSTEMS

A. Sheet and Pipe Pile Surfaces Exposed to Mud: Where indicated on plans, this
system shall be used on steel sheet and pipe piling that is exposed to mud. See
26-47 7349-XXX
08-08
plans for vertical limits of epoxy coating. Coat both sides of sheet piling, and
extend epoxy coating 1/2 to 1 inch into pile interlocks.
Surface Prep. Paint Material Min. Coats, Cover

Abrasive Blast, or Centrifugal High Solids Epoxy 1 coat, 16 MDFT
Wheel Blast (SP-10) Coating
B. Coating System Repair, Epoxy Coated Surfaces of Sheet and Pipe Piles
Exposed to Mud: Use this system to repair minor epoxy coating damage
(scrapes, abrasions, scratches) during shipment and handling.

Power Tool Clean (SP-3), Manufacturer’s Recommended Primer
Feathering Edges, and in
High Solids Epoxy 1 coat, 16 MDFT
Accordance with the
Manufacturer’s Directions
C. Exposed and Concrete Encased Metals with Thermal Spray Aluminum

Coating: Use this system on the following surfaces:
1. Exposed metal surfaces of thermal spray aluminum coated surfaces, as

indicated on the plans.
2. Thermal spray aluminum coated surfaces that are in contact with or
embedded in concrete.

Solvent Clean (SP-1) followed High Solids Epoxy 1 coat, 16 MDFT
by Epoxy Manufacturer’s Coating
Recommendations

(See PSDS form attached)

END OF SECTION
176866A.SEA
27-47 7349-XXX
08-08
PAINT SYSTEM DATA SHEET
Complete and attach manufacturer’s Technical Data Sheet to this PSDS for each coating
system.
Paint System Number (from Spec.):
Paint System Title (from Spec.):
Coating Supplier:
Representative:
Surface Preparation:
Product Name/Number
Paint Material (Generic) (Proprietary) Min. Coats, Coverage
Provide manufacturer’s recommendations for the following parameters at temperature

(F)/relative humidity:
Temperature/RH 50/50 70/30 90/25
Induction Time
Pot Life
Shelf Life
Drying Time
Curing Time
Min. Recoat Time
Max. Recoat Time
Provide manufacturer’s recommendations for the following:
Mixing Ratio:
Maximum Permissible Thinning:
28-47 7349-XXX
08-08
Ambient Temperature Limitations: min.: max.:
Surface Temperature Limitations: min.: max.:
Surface Profile Requirements: min.: max.:
Attach additional sheets detailing manufacturer’s recommended storage requirements and

holiday testing procedures.
29-47 7349-XXX
08-08
SECTION 09990
NONSKID SURFACE COATING
PART 1 GENERAL
1.1 DESCRIPTION
A. This work shall consist of applying a nonskid surface treatment, and shall be
used on the following:
1. The top surface of the transfer span checkered plate decking, including
decking for wing assemblies.
1.2 DEFINITIONS
A. MMA: Methyl methacrylate.
1.3 SUBMITTALS
A. The Contractor shall prepare and submit the design mix for methyl
methacrylate concrete, including samples of all components for each lot, and
deliver to the Engineer. The Contractor shall obtain approval prior to ordering
any materials for application of methyl methacrylate concrete.
B. The Contractor shall submit each of the following to the Engineer for
approval:
1. The Request for Approval of Aggregate Material Source.

2. The design mix report for Methyl Methacrylate Overlay.
3. A table showing the expected cure time in minutes at the corresponding
temperatures between 40 degrees F and 90 degrees F in 10-degree
increments of the concrete overlay.
4. Certification that key personnel to be used in the application of the
overlay material have experience in the application of this type of
material.
C. Samples of the mixed resin prior to placement excluding any aggregate shall
be taken at the initial application of the overlay, and again at the midpoint and
end of each application. These samples shall be placed in straight-sided plastic
8-ounce (minimum) sealed containers. The containers shall be labeled with
the date, time, and location where taken.
D. The samples shall be retained and submitted for analysis. These samples shall
be used to verify the final mix ratio of the MMA placed on the surface. If a
laboratory analysis determines these samples vary from the approved mix
ratio, then these overlay sections shall be subject to rejection.
E. The Contractor shall allow 3 weeks for approval after submitting these
samples.
30-47 7349-XXX
08-08
1.4 DELIVERY, STORAGE AND HANDLING OF MATERIALS
A. All materials shall be delivered unopened in their original containers bearing
the manufacturer’s label. This label shall specify date of manufacture, batch
number, trade name brand, quantity and mixing ratio.
B. Sufficient material to perform the entire methyl methacrylate concrete overlay

application shall be in storage at the site prior to field preparation.
C. The material shall be stored to prevent damage by the elements and to ensure
the preservation of their quality and fitness for the work. The storage space
shall be kept clean and dry and shall contain a high-low thermometer. The
temperatures of the storage space shall not fall below nor rise above that
recommended by the manufacturer. Every precaution shall be taken to avoid
contact with the flame. The containers shall be stored in a manner that will not
allow leakage or spillage from one material to contact other containers.
D. Stored materials shall be inspected prior to use, and shall meet the
requirements of these Specifications at the time of use.
E. Any material that is rejected because of failure to meet the required tests or
that has been damaged so as to cause rejection shall be immediately replaced
by the Contractor at no additional cost to the State.
F. Each shipment of methyl methacrylate concrete resin shall be accompanied by

Material Safety Data Sheets (MSDS) and a Certificate of Compliance
certifying that the materials conform to the requirements of these Special
Provisions.
G. Appropriate impermeable protective garments shall be used by all workers

who may contact the resins to prevent skin contact. If skin contact occurs the
resins shall be immediately washed off. Clothing that becomes saturated with
resins shall be removed immediately.
PART 2 PRODUCTS
2.1 MATERIALS
A. Overlay material shall be methyl methacrylate (MMA) concrete resurfacing
material.
B. Methyl Methacrylate (MMA) Concrete Overlay:
1. Methyl methacrylate overlay shall be composed of the following three

components:
a. Flexible methyl methacrylate.
b. Methyl methacrylate base hardener.
c. Aggregate.
2. The methyl methacrylate shall be one of the following:
a. DEGADUR, manufactured by Degussa Corp. , 2 Turner Place ,
Piscataway, New Jersey 08855 , Phone; (800) 477-4545
31-47 7349-XXX
08-08
b. R66, manufactured by Silikal , 173 Interstate Lane , Waterbury,
Connecticut 06705 , Phone: (203) 754-8373
c. Cryl-A-Flex system, manufactured by Duraflex , 95 Goodwin
Street , East Hartford, Connecticut 06108 , Phone: (800) 253-3539
C. Aggregate: Aggregate shall be from an approved pit site. The aggregate shall
be 100 percent fractured, thoroughly washed, and kiln dried. The fracture
requirements shall be at least one mechanically fractured face and will apply
to material retained on US Sieve No. 10.
Aggregate Grading/US Sieve # % Retained

6 0 - 30
10 65 - 90
20 10 - 30
20 minus 0-3
PART 3 EXECUTION
3.1 CONSTRUCTION REQUIREMENTS
A. The Contractor shall arrange to have the material supplier furnish technical
service relating to application of material and health and safety training for
personnel who are to handle the methyl methacrylate concrete. This shall
include a technical service representative on site for the first applications.
3.2 EQUIPMENT FOR SURFACE PREPARATION

A. All equipment for preparing and cleaning the surfaces and mixing and
applying the overlay shall be in strict accordance with manufacturer
requirements and approved by the Engineer prior to commencement of work.
B. Prior to placing the methyl methacrylate overlay, the surface shall be cleaned
to remove contaminants. Surfaces shall be clean, free of dust, and dry for
proper bonding of the methyl methacrylate concrete. Automatic shot blast
cleaning shall be used for this purpose. The unit shall be equipped with its
own dust collector and shall recycle the abrasives.
C. The unit shall be composed of a blasting unit and vacuum unit, both self-
propelled. All contaminants shall be picked up and stored in the vacuum.
3.3 SURFACE PREPARATION

A. Surfaces shall be prepared by removing all material that may act as a bond
breaker between the surface and the overlay. Provide a suitable grit/shot
abrasive mixture that provides the manufacturer’s recommended anchor
profile.
32-47 7349-XXX
08-08
B. Those surfaces that are not accessible for cleaning by the shot blasting unit
shall be blast cleaned using conventional methods, subject to prior approval of
the Engineer.
C. The Contractor shall take all necessary precautions to ensure that no dust or
debris leaves the work area and that all passengers and crew are protected
from rebound and dust during the blast cleaning process. All necessary
precautions shall be taken to prevent any materials from entering the water.
3.4 MIXING COMPONENTS

A. The base and hardener shall be combined according to the manufacturer’s
written instructions in an approved mixer, with blades that wipe the inside of
the mixer clean. These components shall be mixed thoroughly and applied
immediately. A slow motion mixing device shall be used to prevent air
entrapment in the mix.
B. The MMA overlay shall not be proportioned by a continuous volume

machine.
C. The methyl methacrylate concrete shall use the aggregate described under
“Aggregate Grading No. 10” for filler adjustment as recommended by the
manufacturer.
3.5 PRE-OVERLAY PREPARATION

A. The MMA overlay placement shall not begin if rain is expected within
24 hours. If the surface is wet it shall be allowed to dry for 24 hours prior to
the overlay applications. The overlay shall not be placed when temperature of
the surface is less than 45 degrees F or greater than 90 degrees F.
B. If in the opinion of the Engineer the surface has become soiled or

contaminated prior to the application of the concrete overlay, the surface shall
be cleaned again to the satisfaction of the Engineer, at no additional cost to the
State.
3.6 PLACEMENT OF METHYL METHACRYLATE (MMA)

A. Immediately prior to applying the prime coat, the surface shall be swept clean
by compressed air to remove accumulated dust and any other loose material.
Following the cleaning operation MMA primer shall be applied to the surface.
The MMA primer shall be applied using paint rollers or brooms at an
application rate of 60 square feet per gallon and a sufficient rate to achieve a
uniform layer of primer without puddles or dried areas. The MMA primer
cure time shall be as specified by the manufacturer.
B. Apply primer the same day that the surfaces are shot blasted. The area to
receive the prime coat shall be surface dry prior to applying the prime coat.
C. The prime resin shall be applied in a manner to ensure complete coverage of

the areas.
33-47 7349-XXX
08-08
D. If the prime surface becomes contaminated, the contaminated areas shall be
cleaned by abrasive blasting in accordance with the manufacturer’s directions
and re-primed.
E. Apply the primer to one 12-inch by 12-inch random test area to verify that the
primer dries properly before application to the full surface. If the primer does
not dry properly within 30 minutes, obtain specific instructions from the
MMA manufacturer and reapply a test patch to verify that corrective actions
provide a cured primer.
F. After the MMA primer has cured, the MMA shall be applied using squeegees
or trowels at the application rate specified by the manufacturer to obtain a
1/8-inch thickness above the metal surface.
G. Aggregate shall be broadcast on the freshly placed MMA system so that the
entire surface is covered to excess and in the manner that will not create
waves (wrinkles) or an uneven overlay surface. The aggregate shall be
embedded by a roller or other approved method prior.
H. Prior to completion, a low viscosity sealer tie coat comprised of the same
polymer that was used in the overlay shall be spray applied to the exposed
aggregate. The sealer tie coat shall be applied at an application rate specified
by the manufacturer.
I. The Contractor shall provide adequate dams to contain the overlay material.
J. Trowel the MMA to feather the edges of the material along the sides of the
decking plate.
3.7 FINISHED OVERLAY SURFACE

A. The finished overlay surface thickness shall be 1/8-inch minimum.
3.8 REPAIR OF SURFACE DEFECTS

A. The repair method for surface defects of the overlay shall be identical to the
original application of the overlay, and shall be in accordance with the MMA
manufacturer’s written instructions.
3.9 CURING
A. The methyl methacrylate overlay including sealer tie coat shall be allowed to
cure sufficiently before subjecting it to loads of any nature that may damage
the overlay. The Contractor shall inform the Engineer of the expected cure
time based upon the ambient and surface temperatures at the time of the
application.
B. Actual degrees of cure and stability for loads on the actual methyl
methacrylate overlay shall be determined by the manufacturer and be
approved by the Engineer. The manufacturer shall determine, prior to bid, that
34-47 7349-XXX
08-08
its system will cure in sufficient time to satisfy the requirements for
operations.
3.10 CHECKING FOR BOND

A. After the requirements for curing have been met, the entire overlaid surface
shall be sounded by the Contractor, in a manner approved by and in the
presence of the Engineer to ensure total bond of the methyl methacrylate
concrete to the structural surfaces. Methyl methacrylate concrete in unbonded
areas shall be removed and replaced with methyl methacrylate concrete by the
Contractor, at no expense to the State.

END OF SECTION
176866A.SEA
35-47 7349-XXX
08-08
SECTION 13000
TRANSFER SPAN SYSTEM
PART 1 GENERAL
1.1 SCOPE OF WORK
A. This work consists of removing, installing, testing and commissioning the
Transfer Span Assembly and all of its associated subsystems at Galveston
Slip 2 and 3 and Bolivar Slip 3. Specific tasks associated with this work
include but are not limited to:
1. Preparing the existing transfer span systems for removal.

2. Removing the existing transfer span assembly and torque tube.
3. Transferring components that are to be reused from the existing transfer
span assemblies to the new transfer span assemblies.
4. Installing the new transfer span assemblies and torque tubes.
5. Performing required modifications to the electrical control system of
each transfer span.
6. Performing and documenting the final span balance for each system.
7. Testing and commissioning the complete Transfer Span System.
1.2 SUBMITTALS
A. Before delivering materials, setting equipment or performing any
testing/commissioning of the system, the Contractor shall submit to the
Engineer six (6) copies of the following for review and approval:
1. Mill Certifications and test reports for all raw materials.

2. Transfer Span Installation, Alignment and Fit Check Plan as required by
this specification.
3. Final Span Balancing Plan as required by this specification.
4. Shop drawings of the field installed interconnecting wiring and
conduits, including the location and size off all junction boxes, conduits,
conduit supports and conduit lengths.
B. The drawings and submittals shall be submitted on suitable size sheets that are
completely clear and legible.
C. The Contractor shall be responsible for the completeness of the drawings and
other information. The Contractor shall clearly indicate any deviations from
the plans on the submittals.
D. The review and approval of drawings and other information shall conform
with the design concept and shall be understood to be an acceptance of the
character and sufficiency of the details and not a check of detailed dimensions
or other key data.
36-47 7349-XXX
08-08
A. The Contractor shall provide a manufacturer’s certificate of quality that the
actual valves, supports, flanges and pipe material etc. supplied conforms to the
test reports, supplemental test documentation and certifications that were
submitted.
B. The Owner Certified Welding Inspector shall perform Quality Assurance

inspections of the Contractor’s welding.
1.4 COORDINATION
A. The Contractor shall coordinate the submittal of drawings and other
information in a timely manner to allow sufficient time for review and
approval by the Engineer (21 calendar days) and time for fabrication and
delivery of the material so as to not delay completion of the construction
within the established schedule for completion of the project.
B. The Engineer shall have ten (10) working days to review and comment on all
submittals.
PART 2 PRODUCTS
2.1 GENERAL
A. All materials shall generally be provided as specified on the plans.
B. Wherever a material, article, device product or fixture is identified by a

manufacturers name, or by a manufacturers name and either partial or
complete catalog part number, such specification shall be deemed to be used
for the purposes of facilitating a description of the material or process desired,
establishing a standard of quality, and stating a preference for a specific
manufacturer. This procedure is not to be construed as eliminating from
competition other products of equal or better quality by the same or other
manufacturers where such products are fully suitable in the design,
functionality and physical interchangeability, and shall be followed by the
words “or approved equal”. The decision as to equality shall be made solely
by the Engineer.
C. Wherever a material, article, device product or fixture is identified by a

generic term or trade name, such specification shall be deemed to be used for
the purposes of describing the device or process desired, not establishing a
standard of quality or stating a preference for a specific manufacturer, and
shall be understood to be followed by the words “or equal”.
2.2 FIELD INSTALLED ELECTRICAL WIRING, CONDUIT AND

JUNCTION BOXES
A. Field installed, interconnecting wiring and conduits shall generally be
fabricated, installed and supported per the plans.
37-47 7349-XXX
08-08
B. All raw materials, wires, cables conduit, junction boxes and other components
shall be supplied as described in the plans.
C. Unless otherwise noted, the Contractor may propose the use of equivalent
materials or components in place of those indicated on the plans per
Article 2.1 above.
D. If alternate materials or components are proposed, the Contractor shall take

full responsibility for coordination of any revisions required to any other
portion of the transfer span system or its subcomponents required to
accommodate the proposed substitutions. Any required design revisions shall
be identified and a design solution shall be identified in writing and shall be
submitted along with the shop drawings for the proposed substitution.
PART 3 EXECUTION
3.1 GENERAL
A. All equipment and interconnecting wiring shall be installed and connected per
the plans.
B. The location of junction boxes for the interconnecting electrical wiring are
critical both for construction of the system and for future maintenance of the
facility. The Contractor shall not significantly modify the location of these
items.
C. The routing and support of electrical conduits is provided to illustrate the

quality and workmanship that is required by the Engineer. The Contractor’s
installation may deviate from the “as designed” routing and support
configurations shown on the plans as long as the proposed installation is of
comparable quality and workmanship and provides equivalent or better
accessibility for ongoing maintenance and repairs.
3.2 INSTALLATION, ALIGNMENT AND FIT CHECK OF THE

TRANSFER SPAN ASSEMBLY
A. Correct installation and alignment of the Transfer Span Machinery Assembly
is absolutely critical to the operation of this system.
B. The Transfer Span Assembly shall be installed, aligned and fit checked
against the ferries in accordance with the plans.
C. The Contractor shall prepare a detailed Transfer Span Installation, Alignment

and Fit Check Plan as required by this specification.
D. This plan shall as a minimum identify:
1. The procedure for shoring the counter weight system and removing the
existing transfer span assemblies and torque tubes.
2. The procedure to transfer the reused components from the existing
transfer span assemblies to the new transfer span assemblies.
38-47 7349-XXX
08-08
3. The procedure for transporting the Transfer Span Machinery Assembly
from the staging area to the site for installation.
4. The equipment and methods that will be used to set the transfer span
assembly onto the existing pintals.
5. The methodology and equipment that will be employed to complete a
fit-check of the installed and aligned Transfer Span Machinery
Assembly as described in the documents.
6. The acceptance criteria for the alignment and fit check as described in
the plans along with a box for recording the actual field data observed.
7. Signature boxes beside each acceptance criteria to accept the initials of
the individual supervising the installation/check and the
installation/check witness.
E. The Engineer shall witness the installation, alignment and fit check of the
Transfer Span Assembly.
3.3 INTERCONNECTING ELECTRICAL WIRING, CONDUIT AND

JUNCTION BOXES
A. Interconnecting wiring and conduit system shall generally be installed per the
plans.
B. The Contractor may deviate from the indicated routing and support details as
long as he/she can demonstrate that his/her plan are equivalent in quality,
workmanship and accessibility for future maintenance. These changes shall be
thoroughly documented in the shop drawings and must be explicitly approved
by the Engineer.
C. The Contractor shall provide detailed shop drawings showing the routing of
each conduit; all support locations, the type of support hardware employed,
conduit and junction boxes utilized and other relevant data.
3.4 FINAL SPAN BALANCING

A. The span balance of the Transfer Span Machinery shall be adjusted after the
new transfer span assembly and torque tube have been installed at each slip in
accordance with the plans.
B. Span balancing shall be completed after all new components have been
installed.
C. The Contractor shall perform a final check of the span balance per the
requirements of the plans.
D. The Contractor shall prepare and submit a Final Span Balancing Plan that
details the equipment and methodology that will be employed to complete the
final span balancing.
E. The Engineer shall witness the final span balancing of the Transfer Span
Assembly.
39-47 7349-XXX
08-08
3.5 FIELD FUNCTIONAL TESTING
A. The performance and functionality of the Transfer Span System shall be
checked and adjusted as necessary in accordance with the plans.
B. The purpose of this testing is to insure that all of the set points for the limit
switches and other control devices are correct and that all operator control
devices are providing the functionality as designed. The test shall demonstrate
the full range of motion of the Transfer Span System and shall record the time
required to traverse from one extreme ramp limit to the opposite extreme.
C. The Contractor shall perform Field Functional Test of the system per the
requirements of the plans.
D. The Contractor shall prepare and submit a Field Functional Test Plan that
details the equipment and methodology that will be employed to complete this
testing.
E. The Engineer shall witness the field functional test of the Transfer Span
Machinery Assembly.
3.6 COMMISSIONING
A. The completed Transfer Span System shall be commissioned in accordance
with the requirements of the plans.
B. The purpose of commissioning is to operate and observe the system over a

longer period of time in order to identify any operational issues with the
equipment that are not evident during the functional testing.
C. The Contractor shall prepare and submit a Commissioning Plan that details
the equipment and methodology that will be employed to commission the
completed system.
3.7 CLEANING
A. Prior to final inspection, the Contractor shall thoroughly clean and inspect all
work that they have installed.
B. Any damage to protective coatings or decorative surfaces shall be repaired or

touched up.
3.8 INSPECTION
A. After the Contractor has completed cleaning the installed equipment per the
above section, the Contractor shall make a final inspection of the installation
to insure all work meets the requirements established in the plans.
40-47 7349-XXX
08-08
B. Once the Contractor believes the system is complete and that it fully meets the
requirements established by the plans, they shall notify the Engineer and
schedule a Final Inspection.
C. During the Final Inspection, the Contractor shall prepare and maintain a
formal punch list identifying any discrepancies that are identified by the
Inspection and shall submit copies of this punch list to the Engineer.
3.9 ACCEPTANCE
A. Final acceptance of the Work shall be contingent on the Contractor
demonstrating the following:
1. Final Inspection has been completed and the punch list generated has
been fully addressed.
2. Field functional testing is complete and has been certified by the
Engineer.
3. Commissioning is complete and has been certified by the Engineer.

END OF SECTION
176866A.SEA
41-47 7349-XXX
08-08
SECTION 13020
TRANSFER SPAN ASSEMBLIES AND MISCELLANEOUS ITEMS
PART 1 GENERAL
1.1 SCOPE OF WORK
A. This work consists of fabricating, assembling and shop testing three (3) new
transfer span systems that will be installed in Slips 2 and 3 at the Galveston
Terminal and in Slip 3 at the Bolivar Terminal. This work also includes
fabricating three new torque tube assemblies, finger assemblies and other
miscellaneous items required to support the new transfer span assemblies.
Specific tasks associated with this work include but are not limited to:
1. Fabricating, machining and coating the new transfer span assembly for
each slip.
2. Fabricating, machining and coating the new torque tube assembly for
each slip.
3. Fabricating, machining and coating the finger assemblies and other
miscellaneous components required to complete the system
4. Pre-assembling each of the span structures off-site in order to insure
proper fit and function of all components.
5. Performing a shop demonstration to insure that the new transfer spans
will deform to follow the vessel deck.
6. Disassembling (if required) the transfer span assemblies and
transporting them to the staging area at the site.
7. Re-assembling the span at site if disassembly was required for transport
to the site.
1.2 SYSTEM DESCRIPTION

A. Each transfer span assembly consists of a fabricated bridge seat girder, eight
fabricated longitudinal girders, a fabricated lift girder, steel bridge grating,
aluminum guard rails and various other smaller structures used to position and
support the main structural members
B. One complete transfer span assembly along with a torque tube, fingers and
other miscellaneous components is to be installed at each of the new slips
(Galveston Slips 2 and 3 and Bolivar Slip 3).
1.3 SUBMITTALS
A. Before delivering materials, fabricating components or performing any shop
testing/commissioning of the system, the Contractor shall submit to the
Engineer six (6) copies of the following for review and approval:
1. Shop drawings of all fabricated components.

2. Mill certifications and test reports for all raw materials.
3. Welding submittals which shall include:
42-47 7349-XXX
08-08
a. All weld processes, including pre-qualified and Contractor-
proposed welding procedure specifications (including weld rod
data).
b. Detailed welding drawings including proposed inspection plans
and repair procedures.
c. Welder qualifications and certifications.
d. Qualifications and certification of the AWS certified welding
inspector who shall witness all welding of the diesel fuel line.
e. Welding inspection/testing results to the Engineer for approval.
B. Prior to inspection and acceptance as described below, the Contractor shall

submit to the Engineer four (4) complete copies of the following documents
for review and approval:
1. As-built plans.
2. Welding QA/QC Reports
C. The drawings and submittals shall be submitted on suitable size sheets that are
completely clear and legible.
D. The Contractor shall be responsible for the completeness of the drawings and
other information. The Contractor shall clearly indicate any deviations from
the plans on the submittals.
E. The review and approval of drawings and other information shall conform
with the design concept and shall be understood to be an acceptance of the
character and sufficiency of the details and not a check of detailed dimensions
or other key data.

A. The Contractor shall provide a manufacturer’s certificate of quality that the
actual bearings, raw materials and other purchased components supplied
conforms to the test reports, supplemental test documentation and
certifications that were submitted.
B. The certified welding inspector shall perform quality assurance inspections of

the Contractor’s welding.
1.5 COORDINATION
A. The Contractor shall coordinate the submittal of drawings and other
information in a timely manner to allow sufficient time for review and
approval by the Engineer and time for fabrication and delivery of the material
so as to not delay completion of the construction within the established
schedule for completion of the project.
B. The Engineer shall have ten (10) working days to review and comment on all
submittals.
43-47 7349-XXX
08-08
PART 2 PRODUCTS
2.1 GENERAL
A. All materials shall be new and shall generally be provided as specified on the
plans.
B. Wherever a material, article, device product or fixture is identified by a

manufacturers name, or by a manufacturers name and either partial or
complete catalog part number, such specification shall be deemed to be used
for the purposes of facilitating a description of the material or process desired,
establishing a standard of quality, and stating a preference for a specific
manufacturer. This procedure is not to be construed as eliminating from
competition other products of equal or better quality by the same or other
manufacturers where such products are fully suitable in the design,
functionality and physical interchangeability, and shall be followed by the
words “or approved equal.” The decision as to equality shall be made solely
by the Engineer.
C. Wherever a material, article, device product or fixture is identified by a

generic term or trade name, such specification shall be deemed to be used for
the purposes of describing the device or process desired, not establishing a
standard of quality or stating a preference for a specific manufacturer, and
shall be understood to be followed by the words “or equal.”
2.2 BEARING SYSTEMS

A. Both custom fabricated and standard self lubricated marine bearings are used
extensively in this design. The plans specify the use of Karon V self lubricated
liners from Kamatics Corporation for these bearings.
B. The Contractor may propose an alternate bearing systems if those systems can
demonstrate equivalent performance and application history. Any
substitutions on the bearing systems must be explicitly approved by the
Engineer in writing.
C. If alternate materials or components are proposed, the Contractor shall take

2.3 SHOP INSTALLED HYDRAULIC PIPE AND HOSES

A. Shop-installed, interconnecting wiring and conduits shall generally be
fabricated, installed, and supported per the plans.
B. All raw materials, wires, cables conduit, junction boxes and other components
shall be supplied as described in the plans.
44-47 7349-XXX
08-08
C. Unless otherwise noted, the Contractor may propose the use of equivalent
materials or components in place of those indicated on the plans per
Article 2.1 above.
D. If alternate materials or components are proposed, the Contractor shall take

PART 3 EXECUTION
3.1 GENERAL
A. All structures, fasteners, grating, guard rails, bearings, pins, and shop-installed
wiring shall be installed and connected per the plans.
B. The shape, size and configuration of all structures, bearings, pins and other
components shown by the plans are critical to the performance of the overall
system. The Contractor shall not significantly alter any parts of this system
without the explicit approval of the Engineer.
3.2 SHOP ASSEMBLY, ALIGNMENT AND FIT CHECK OF

TRANSFER SPAN ASSEMBLY.
A. Each transfer span assembly shall be completely assembled and fit checked
off site at a site chosen by the Contractor prior to shipping to the site.
B. The fit check shall include the installation of the grating, guard rails and finger
assemblies.
C. A demonstration of the structural compliance of the new transfer span

assembly shall be completed off-site at a site chosen by the Contractor using
the first unit completed. This demonstration shall insure that the new transfer
span design will deform in order to follow the vessel deck as the ferry rolls.
The Contractor shall prepare a detailed Transfer Span Assembly Torsional
Flexibility Check Plan. The purpose of this plan is to establish a methodology
for demonstrating the torsional flexibility of the new span and to verify the
overall range of motion for the new structure
D. This plan shall as a minimum identify:
1. The equipment and methods that will be used to carry out the
demonstration and measure the range of motion.
2. The acceptance criteria for the demonstration including the total
torsional deflection that is to be shown along with a box for recording
the actual field data observed.
45-47 7349-XXX
08-08
3. Signature boxes beside each acceptance criteria to accept the initials of
the individual supervising the demonstration and the demonstration
witness.
E. The Engineer shall witness all fit-checks and range of motion tests of the
Transfer Span Assembly.
3.3 INTERCONNECTING ELECTRICAL WIRING, CONDUIT AND

JUNCTION BOXES
A. Interconnecting wiring and conduit system shall generally be installed per the
plans.
B. The Contractor may deviate from the indicated routing and support details as
long as he/she can demonstrate that his/her plan are equivalent in quality,
workmanship and accessibility for future maintenance. These changes shall be
thoroughly documented in the shop drawings and must be explicitly approved
by the Engineer.
C. The Contractor shall provide detailed shop drawings showing the routing of
each conduit; all support locations, the type of support hardware employed,
conduit and junction boxes utilized and other relevant data.
3.4 AS-BUILT DOCUMENTATION

A. The Contractor shall provide the Owner four (4) full sets of as-built plans for
the transfer span system and all of its subcomponents as required by the plans.
B. As a minimum, each as-built drawing set shall consist of a clean copy of the
contract documents with all changes clearly and neatly marked with
permanent red ink.
C. Each sheet shall also be clearly labeled “as-built” using permanent red ink.
D. These as-built drawings shall be submitted to the Engineer for review.
3.5 OPERATION AND MAINTENANCE MANUALS

A. The Contractor shall prepare and submit four (4) complete Operation and
Maintenance Manuals for the Owner’s records.
B. As a minimum these manuals shall:
1. Identify the manufacturer and part or model number of all purchased

components or materials used by the Contractor in this work.
2. Identify all components that require maintenance and provide a
recommended maintenance interval for these components.
3. Provide a check list summarizing the required maintenance and
recommended maintenance intervals.
3.6 CLEANING
46-47 7349-XXX
08-08
A. Prior to final inspection, the Contractor shall thoroughly clean and inspect all
work that they have installed.
B. Any damage to protective coatings or decorative surfaces shall be repaired or

touched up.
3.7 INSPECTION
A. After the Contractor has completed Cleaning the installed equipment per the
above section, the Contractor shall make a final inspection of the installation
to insure all work meets the requirements established on the plans.
B. Once the Contractor believes the system is complete and that it fully meets the
requirements established by the plans, he/she shall notify the Engineer and
schedule a final inspection.
C. During the final inspection, the Contractor shall prepare and maintain a formal
punch list identifying any discrepancies that are identified by the Inspection
and shall submit copies of this punch list to the Engineer.
3.8 ACCEPTANCE
A. Final Acceptance of the work shall be contingent on the Contractor
demonstrating the following:
1. Final inspection has been completed and the punch list generated has
been fully addressed.
2. As-built documentation has been submitted and certified by the
Engineer.

END OF SECTION
176866A.SEA
47-47 7349-XXX
08-08

Special Provision To Specal Specification Marine Structures

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Special Provision To Specal Specification Marine Structures

Uploaded by

Copyright:

Available Formats

2004 Specifications CSJ 6172-05-001

(1) 09970 Thermal Sprayed Aluminum (TSA) Coatings

1. American Welding Society (AWS):

B. Samples: Provide qualification procedure test coupons and reference panel.

1. Reference Panel: Unless otherwise specified.

C. Quality Control Submittals:

1. Applicator’s quality control procedures and qualification test results.

1.5 QUALITY ASSURANCE

1. TSA Applicator: Minimum 2 years’ experience in application of

1. Meet federal, state, and local requirements limiting the emission of

1.6 INITIAL COATING QUALIFICATION PROCEDURE

1. Visual inspection and acceptance criteria.

B. Qualification Procedure Approval: Prior to beginning any work, prepare

1. The thermal spray aluminum coating application procedure shall be

E. Thermal Spray Operator Qualification:

1. Manual, Shop or Field Application: To qualify as a thermal spray

1.7 DELIVERY, STORAGE, AND HANDLING

1. Protect metallizing wire spools from corrosion and environmental

B. Minimum of 3 years’ verifiable experience in manufacture of specified

2.2 ABRASIVE MATERIALS

2.3 THERMAL SPRAY COATING MATERIAL

B. Individual wire spools shall be clearly and permanently labeled to indicate

2.4 SEALER MATERIALS

B. Thinners, Cleaners, Driers, and Other Additives: As recommended by the

1. Prepare using each component as packaged by sealer manufacturer.

3.2 PROTECTION OF ITEMS NOT TO BE PAINTED

B. Protect working parts of mechanical and electrical equipment from damage

3.3 ENVIRONMENTAL CONTROLS

1. Contractor shall provide heating, cooling, or dehumidification

3.4 SURFACE PREPARATION

1. General: Compressed air for cleaning and blasting operations shall be

3.5 SURFACE CLEANING

1. Consists of removal of foreign matter such as oil, grease, soil, drawing

1. For coatings subject to immersion, obtain full cure for completed

1. Shop and field apply thermal spray aluminum coatings as specified

C. Coating System Check:

1. Manual or Field Application:

1. Apply sealer within 24 hours of the thermal spray aluminum coating is

3.7 INSPECTION AND TESTING

B. Abrasive Blast Cleaned Surfaces:

1. Abrasive Blast Air Cleanliness: At the beginning of each work shift,

C. Thermal Spray Aluminum Coated Surfaces:

1. Visual Inspection: Thermal spray aluminum coated surfaces shall be

3.8 COATING REPAIRS

3.9 PROTECTIVE COATING SYSTEM

Surface Prep. Material Thickness

3.10 MANUFACTURER'S SERVICES

1. On first day of application of any coating system.

1. Data Sheet: Example Coating System Data Sheet (CSDS).

PART 4 MEASUREMENT AND PAYMENT

4.1 MEASUREMENT AND PAYMENT

Provide sealer’s manufacturer’s recommendations for the following parameters at

Provide manufacturer’s recommendations for the following:

Maximum Permissible Thinning:

Ambient Temperature Limitations: min.: max.:

Surface Temperature Limitations: min.: max.:

Surface Profile Requirements: min.: max.:

Attach additional sheets detailing manufacturer’s recommended storage requirements and

1. International Organization for Standardization: 8502-6, extraction of

B. Quality Control Submittals:

1. Applicator’s Experience: List of references substantiating experience.

1.5 QUALITY ASSURANCE

1. Applicator: Minimum 5 years’ experience in application of specified