Thank you for downloading this file. If you would like further information on water jetting visit the Lydia Frenzel Conference Series . The Advisory Council is a nonprofit, privately funded membership organization that provides a forum for dialogue and the dissemination of information pertaining to the economic and social effects of technological development throughout the world. The Council solicits and makes available pertinent information from both private and public sources, seeks expression of points of view from all who may wish to contribute, advances consensus opinions and selected issues of standards and standards organizations, develops networking to match speaking and information resources with the needs and demands of the community, and promotes specific seminars and symposia. A Primary Mission of the Council is to promote effective means of surface preparation in the maintenance industry using water and water/abrasive blasting techniques. This mission is viewed as important because the conservation of resources, particularly the public infrastructure, has a significant and long lasting economic impact on the well-being of every citizen. The Advisory Council is a sponsor of the Lydia Frenzel Conference Series.
Transcript
Thank you for downloading this file. If you would like further information on water jetting visit the Lydia Frenzel Conference Series. The Advisory Council is a nonprofit, privately funded membership organization that provides a forum for dialogue and the dissemination of information pertaining to the economic and social effects of technological development throughout the world.
The Council solicits and makes available pertinent information from both private and public sources, seeks expression of points of view from all who may wish to contribute, advances consensus opinions and selected issues of standards and standards organizations, develops networking to match speaking and information resources with the needs and demands of the community, and promotes specific seminars and symposia.
A Primary Mission of the Council is to promote effective means of surface preparation in the maintenance industry using water and water/abrasive blasting techniques.
This mission is viewed as important because the conservation of resources, particularly the public infrastructure, has a significant and long lasting economic impact on the well-being of every citizen.
The Advisory Council is a sponsor of the Lydia Frenzel Conference Series.
HEAD DECK PPI, May 17, 2002 1 REV 02
PPI NBR: 63400- 001 (REV 02) DATE: May 17, 2002
PRESERVATION PROCESS INSTRUCTION (PPI) for RENOVATE / REPAIR / HEAD (DECK)
Surface Preparation Method of Power Tool Cleaning
HEAD DECK PPI, May 17, 2002 2 REV 02
1. SCOPE: 1.1 Cleaning, Surface Preparation and Painting Requirements for Head Deck 1.2 If the PPI checkpoint criteria are met, the following table provides service life expectancy for the
listed systems: Coating System Life Expectancy:
Surface Preparation Method System Life Expectancy
SSPC-SP-11 Ceramic Deck Tile System 10 years 2. REFERENCES: 2.a. Systems and Specifications, Steel Structures Painting Council, Volume 2 2.b. SSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages 2.c. MSDS and manufacturer’s ASTM F 718 sheets, Shipbuilders and Marine Paints and Coating Product /
Procedure Data Sheet for Coating System Being Applied.
Prime Coat: ------------------------------------------- EURONAVY ES 301 K Topcoat: ----------------------------------------------- Approved Coating System to match existing Topcoat Tile System: ------------------------------------------ Approved Materials IAW NSTM 634, Section 3, NAVSEA APPROVED MATERIALS LISTS Membrane--------------------------------------------- EPMAR EKY-2102 or DEX-O-TEX ELASTAGUARD Concrete----------------------------------------------- DEX-O-TEX A-70 or DEX-O-TEX A-70 (VLW) 2.d. ASTM D 4417, Method C, Standard Test Methods for Field Measurement of Surface Profile of Blast
Cleaned Steel 2.e. OSHA 29 CFR 1915 Subparts C and Z 2.f. SSPC-VIS-3 Visual Standard For Power and Hand Tool Cleaned Steel 2.g. Naval Ships’ Technical Manual Chapter 631 3. APPENDICES:
APPENDICES
APPENDIX TITLE
1 QA INSPECTION FORM - ENVIRONMENTAL READINGS 2 QA INSPECTION FORM - SURFACE SOLUBLE SALT CONDUCTIVITY LOG 3 QA INSPECTION FORM – SURFACE PROFILE LOG 4 QA INSPECTION FORM – DRY FILM THICKNESS MEASUREMENTS 5 CHECKPOINTS & MILESTONES COMPLETION LOG 6 CERTIFIED COATING INSPECTOR’S CHECKPOINT SIGN OFF LOG 7 PAINT APPLICATION EQUIPMENT & PAINT CONSUMPTION LOG 8 SURFACE CONDUCTIVITY TESTING PROCEDURE
4. REQUIREMENTS: 4.1 SAFETY: Accomplish the safety precautions as specified in NSTM 634, Section 1.4, OSHA 29 CFR 1915
Subparts C and Z (Ref. 2.e), and the Job Order during surface preparation and the application of marine coatings.
HEAD DECK PPI, May 17, 2002 3 REV 02
4.2 WORK NOTICE: The contractor shall post the notice at the ship’s quarterdeck or other designated location for each job or separate area at least four hours, but not more than 24 hours, prior to the start of work. The notice shall contain the following information: ship’s name and hull number, work item number, compartment or frame number, identification of hazard, date and time of work process and identification of engineering and work practice controls. Deliver notification of work planned for a weekend or Monday following that weekend to the Commanding Officer’s representative not later than 0900 on the Friday immediately preceding that weekend. Deliver notification of work planned on a federal holiday and on the day following the federal holiday to the Commanding Officer’s representative not later than 0900 on the last working day preceding the federal holiday.
4.3 QUALITY ASSURANCE REQUIREMENTS: 4.3.1 REQUIREMENTS FOR COATED AREAS. Coating systems shall be applied by certified painters.
Checkpoints and final inspections shall be signed off by certified coating inspectors. 4.3.2 PAINTER CERTIFICATION. The implementing contractor shall maintain a certification program for painters
working on the project. The program shall include minimum training requirements and provide for adequate records verifying the completion and currency of training for each painter involved in surface preparation and application of the coating. Documentation shall be maintained verifying that only certified painters are used for preservation work. Training shall include all paint application techniques and procedures appropriate to the surface preparation and coating materials used.
4.3.3 COATING INSPECTOR CERTIFICATION: Documentation shall be maintained verifying that only certified
paint inspectors are used for inspecting preservation work. Training shall include all techniques and procedures appropriate to inspecting the surface preparation and coating application being used. These techniques and procedures include determining the acceptability of surface preparation prior to commencement of paint application; determining the degree of compliance with painting procedures appropriate to the surface preparation and coating materials being used; and determining the acceptability
�������� of finished products IAW established standardized acceptance criteria. At a minimum, coating �������� inspectors shall be certified and maintain certification to the National Association of Corrosion
���� Engineers (NACE) Session I, or the NAVSEA Basic Paint Inspector Course (NBPI). 4.3.4 COATING INSPECTOR RESPONSIBILITIES: Coating inspectors are responsible for providing reasonable
confidence that material storage, surface preparation, paint and tile system application and curing are accomplished IAW the manufacturer’s requirements. These responsibilities require the coating inspector to: inspect material storage facilities; ensure all inspection equipment requiring calibration certification is certified under organization metrology calibration programs; perform in-process inspections of surface preparation, painting and verify successful completion of checkpoints in the application process; and inspect and accept or reject final paint systems.
4.3.4.1 Responsible Government Representative certified coating inspector shall verify checkpoints and sign all
applicable Appendices. 4.3.4.2 Implementing Contractor shall perform all in-process inspections and checkpoints. 4.3.4.3 The Responsible Government Representative shall be present for and verify all in-process inspections /
checkpoints. 4.3.4.4 Implementing Contractor shall participate in a joint Ship’s Force and SUPSHIP personnel safety brief, when
directed by the SUPERVISOR, prior to the start of recommended PCP.
HEAD DECK PPI, May 17, 2002 4 REV 02
4.3.5 IN-PROCESS INSPECTIONS: Responsible Government Representative certified coating inspector shall be given prior notice and shall perform an inspection of each coated area when the following checkpoints are reached: process control procedure, pre-surface preparation & cleaning, contamination containment and masking, surface preparation, paint storage area, prime coat, topcoat of paint applied, free flow test, positive drain test and area ready for final inspection. The inspector is required to examine all data maintained by the paint foremen concerning environmental conditions, surface cleanliness, surface profile and paint thickness. Data shall be verified, depending on the checkpoint in question, including surface cleanliness, surface profile, dry film thickness and workmanship. Environmental data, such as temperatures, relative humidity and dew point need only be verified if the inspector is doubtful of the recorded values. Deficiencies in personnel training, certification, record maintenance, equipment maintenance or any matter that is not IAW good painting practice shall be recorded. The coating inspector shall verify the successful completion of each checkpoint and sign and date the applicable spaces on Appendix 6.
4.3.6 DEVIATIONS: All surface preparation, coating and tile system applications shall be IAW delineated guidance
herein. Any deviation will require NAVSEA approval and Contracting Officer (or representative) sign-off. 4.3.7 A TYCOM / NAVSEA authorized representative will provide QA oversight of this process. Implementing
Contractor shall provide the Government QA inspector a minimum of four (4) hour notification of all checkpoints prior to accomplishing the checkpoint is MANDATORY.
4.3.8 DEVELOP AND ACCOMPLISH PROCESS CONTROL PROCEDURE (PCP): Submit two legible copies of
each PCP not later than seven working days prior to start of the process required by the procedure to the SUPERVISOR. The procedure shall contain the following minimum information:
-Contractor’s name and address, -Process title, number, and date developed, Description of process, including critical factors which have direct bearing on the process quality and safety, -Qualification requirements for the personnel performing the work, -Inspection and documentation forms, -Acceptance and rejection criteria for checkpoints, -The method utilized to ensure personnel accomplishing the procedure have direct knowledge of the requirements prior to beginning work. A copy of the procedure shall be at the work site during the performance of work, -Develop PCP matrix to include the entire job process with start dates, surface preparation dates, coating application dates, etc. -Weekly, update matrix as needed based on schedule changes, until completion / closure of each space or job item. -The method utilized to control the procedure, -Identification of hazardous materials which will be used in the process or hazardous waste that will be generated by the accomplishment of the process and the methodology, which will be utilized to minimize the quantity of these materials which will require control and disposal, -Approval signature and title of the contractor’s representative and the date of submission, 4.3.9 CHECKPOINT (PCP): Provide to responsible QA representative for review and comment on the PCP five
(5) days prior to commencement of this process. 4.4 RECORD KEEPING: 4.4.1 RECORD KEEPING DURING SURFACE PREPARATION / PAINT & TILE SYSTEM APPLICATION: A
permanent record of environmental conditions, surface preparation, paint and tile application operations shall be maintained. Data shall be entered on Appendices 1 – 5. Environmental information on Appendix 1 shall be updated every 4 hours, posted at the job site and an updated copy provided to the coating inspector at each checkpoint for review. The record shall include dates and times of surface preparations, painting and tile operations, air temperatures, surface temperature, relative humidity and dew point. Enter on Appendix 3 the TESTEX PRESS-O-FILM tapes used to measure surface profile.
HEAD DECK PPI, May 17, 2002 5 REV 02
4.4.2 REVIEW OF RECORDS FOR FINAL COATING EVALUATION: A certified paint inspector authorized to represent NAVSEA shall review the Appendices of each area to ensure adequate quality control of the surface preparation, painting and tile system application process. Records shall include all the test and inspection data required by this PPI. Failure to produce such records, or records which indicate that surface preparation, painting and tile system installation were not done IAW governing specifications/instructions, will be grounds for rejection.
4.4.3 Ensure process control documentation provides a record of the data required to control and determine satisfactory completion of the process. 4.4.4 Submit updated or changed PCP procedures to the SUPERVISOR at least three working days prior to implementation. 4.5 TEMPORARY SERVICES: The project will require temporary services such as, but not limited to, lighting,
compressed air, ventilation, portable head, fresh water, electrical services, and crane service. Ensure all equipment is IAW safety requirements delineated in this instruction.
4.5.1 Record and restore existing painted labels, compartment designations, hull markings, and other painted
information which will be removed or covered during cleaning and painting operations. 4.6 FORWARDING APPENDICES AND RETENTION OF RECORDS: After the project is completed, forward
two copies of the completed Appendix forms to the TYCOM, Supervisor of Shipbuilding and Implementing Authority. Records shall be maintained by the Supervisor for a period of 3 years.
4.7 LOG OF EQUIPMENT & MATERIAL USED: Record equipment information and material used in Appendix 7.
Compare materials used, to paint and tile materials specified in work order or contract. 4.8 ENVIRONMENTAL CONDITIONS: Maintain environmental conditions IAW Ref. 2.c and NSTM 634. Record
measurements in Appendix 1. 4.8.1 Maximum Relative Humidity requirement of 85% is to be maintained from surface preparation operations
through the final curing of the topcoat. 4.8.2 The application of Euronavy ES 301 is exempt from relative humidity and dew point requirements since it
may be applied on damp surfaces. 4.8.3 If environmental conditions are not provided or are unclear, contact Responsible Implementing Authority for
resolution. 4.9 TEMPERATURES TO BE MAINTAINED FOR PAINT/TILE SYSTEMS: Ensure temperatures are within
acceptable limits as specified IAW Ref. 2.c and NSTM 634. If inconsistencies in temperatures exist, NSTM 634 will supersede Ref. 2.c. If temperatures are not provided or are unclear, contact Responsible Implementing Authority for resolution. Material should be conditioned in compartment for 24 hours prior to use or location that maintains the temperature recommended by the manufacturer.
4.10 CONTAMINATION CONTAINMENT AND MASKING FOR SURFACE PREPARATION, PAINTING AND
TILE SYSTEM OPERATIONS: The following requirements shall be observed, in addition to the specific requirements of the Job Order, for maintaining cleanliness of the ship, ship’s equipment, components, and spaces for the duration of the availability.
4.10.1 Prevent contamination and surface damage of the ship’s equipment, components, and spaces during
contamination-producing operations. 4.10.1.1 Plug, blank, wrap, cover, seal, and mask equipment, components, cables, wire ways, and openings using
fire retardant/ water repellent materials, and prevent entry of contaminants to machinery, electrical equipment, electronic equipment, valves, vents not in use, and other openings.
HEAD DECK PPI, May 17, 2002 6 REV 02
4.10.1.2 Install covering as needed, conforming to A-A-55308 and/or fire retardant plywood. 4.10.1.3 Install fire retardant industrial filter material on the intake of supply and exhaust end of ventilation systems
which will be in use. 4.10.1.4 Remove existing and install new filter or clean the filter material when airflow is restricted. 4.10.1.5 All protective measures are to be in place prior to start of any contamination-producing operations and shall
remain in place until the contamination-producing operations are complete. 4.10.1.6 Install double curtain baffles at the entrances of each access door where airborne contamination could
occur during contamination-producing operations. Install a dirt-collecting mat on the deck directly inside each door. The SUPERVISOR will select a maximum of four doors. Tag out doors not designated for access.
4.10.1.7 Temporary coverings shall not be removed during contamination-producing operations without permission
of the SUPERVISOR. 4.10.2 PROTECTIVE COVERING: Inspect the integrity of the protective covering at the beginning of each shift in
which contamination-producing operations will be accomplished. Ensure that equipment and machinery have not been infiltrated by contaminants. Notify the SUPERVISOR immediately by verbal means, followed on the next workday in writing, if contamination or surface damage has occurred. Reseal to prevent further entry of contaminants or surface damage.
4.10.3 Maintain cleanliness of the work site free from accumulation of industrial debris caused by contractor and /
or subcontractor employees on a continuous basis throughout the availability. Workspaces include those areas immediately under and adjacent, and those areas where service lines are run in the vicinity of the work site.
4.10.3.1 Area cleaning shall be accomplished no later than at the end of each shift, on a daily basis and prior to any
checkpoints. 4.10.3.2 Remove and dispose of industrial debris from the ship on a daily basis. 4.10.4 Accomplish an initial walk-through of all locations aboard ship where contractor responsible work will take
place, to observe cleanliness conditions. The inspection shall be made jointly with the SUPERVISOR and the ship’s Commanding Officer’s representative, and shall take place prior to the commencement of any work by the contractor.
4.10.4.1 Submit four legible copies of a written report of any unclean sites/spaces to the SUPERVISOR and
Commanding Officer of the ship within 72 hours after completion of the inspection. 4.10.5 Accomplish a cleanliness inspection on a daily basis whenever work is in progress. The inspection shall be
made jointly with the SUPERVISOR and the designated representative of the ship’s Commanding Officer. During inspection the responsible party shall be assigned. A written report of any unclean work sites/spaces shall be prepared by the contractor and copies distributed to the SUPERVISOR and Commanding Officer of the ship within four hours after completion of the inspection. The inspection report shall list the responsible activity (contractor, ship, etc.) for each unclean site/area. Unclean sites/areas determined as contractor responsible shall be immediately cleaned.
4.10.5.1 Inspections and reporting shall be accomplished during the daily fire prevention and housekeeping
inspections. 4.10.6 COVERING REMOVAL: Remove protective covering upon completion of contamination-producing
operations and inspect for presence of contamination or surface damage. Notify the SUPERVISOR immediately by verbal means, followed on the next workday in writing, if contamination or surface damage has occurred, prior to removal of the contamination and repair of damage.
HEAD DECK PPI, May 17, 2002 7 REV 02
4.10.7 Remove from the ship and dispose of debris and foreign matter generated because of work being accomplished on this ship and from work being accomplished on other naval and private ships. Comply with the requirements of federal, state, and local laws, codes, regulations, and ordinances or as specified elsewhere in the Job Order.
4.11 ISOLATION, BLANKING AND TAGGING REQUIREMENTS: Notify the Commanding Officer’s
representative in writing of equipment, systems, circuits, components, piping, and valves that require isolation to accomplish work in the Work Item before any work is started on each individual Work Item so that tag-outs can be accomplished as required by ship’s instructions.
4.11.1 After ship’s force install tags; verify use of sufficient tags to prevent operation of equipment, systems,
circuits, components, piping, or valves from all stations that could exercise control. 4.11.2 A contractor’s representative shall print name, badge number, identify company, and sign on a ship’s tag-out
record sheet and tags after installation, indicating repair activity satisfaction with the completeness of the tag-out and alerting personnel removing tags that contractor concurrence is required.
4.12 Post warning signs and barriers and install temporary positive means to prevent closure or movement of
component that create a safety hazard. 4.13 Do not disturb, modify, remove, energize, or operate any switch, fitting, valve, or other equipment affixed
with a ship’s isolation or DANGER tag. 4.13.1 Do not remove or relocate ship’s isolation or DANGER tags. 4.13.2 Notify the Commanding Officer’s representative immediately when the contractor’s work is complete and
the system, piping, or circuit is ready for activation to accomplish removal of tags. 4.13.3 The contractor’s representative shall sign the ship’s tag-out log sheet to show concurrence in tag removal
and clearance before removal. 4.13.4 Verify removal and clearance of all isolation or DANGER tags in accordance with ship’s instruction before
the equipment is operationally tested or operated. 5. PRE-SURFACE PREPARATION: 5.1 Remove deck strainer plates and retain for reinstallation as applicable. Provide adequate protection to deck
drains(s) opening to prevent contamination. Log and provide identification tags for removed strainer plates. 5.2 STRUCTURAL INSPECTION: Prior to commencement of work, the government will provide an authorized
representative to conduct a structural inspection for the entire area to be prepared. Heavily rusted or corroded area, damaged metal and holes in the structure or piping shall be documented and provided to ship’s force and Responsible Contracting Authority to determine if further structural evaluation or NDT is warranted and for possible repair before surface preparation.
5.3 PRE-SURFACE CONDITIONING WHEN USING NON-EDGE RETENTIVE COATINGS: Before surface
preparation the Responsible Implementing Authority shall have all welds, protrusions, projections and spikes ground smooth; pits in the welds shall be ground out; all weld splatter shall be removed; radius all edges, flanges, angles, pipe hangers to a minimum radius of 3mm. Radius of edges is not required when using approved edge retentive coatings, all other requirements apply.
5.4 DEGREASE / FRESH WATER WASH DOWN: Prior to surface preparation, remove all surface contaminants
such as grease and oil (hydrocarbons), loose rust, chlorides and all other contaminates. Where required, perform spot degreasing on affected areas with solvent cleaning compound (MIL-C-22230) followed by freshwater rinsing. Use vacuum to remove standing water followed by an adequate period of time to allow the surface to dry prior to surface preparation. SSPC-SP-1 requirements shall be met. Oily wastes and chemicals shall be disposed of per local and State instructions.
HEAD DECK PPI, May 17, 2002 8 REV 02
5.5 Remove existing deck covering and underlay using power tools, including pneumatic air chisels. Care shall be taken as to prevent damage to existing deck plating. Gouges and cuts into the plating shall be reported immediately to the Responsible Implementing Authority.
5.6 CHECKPOINT (Pre-Surface Preparation Inspection): NOTE: ULTRAVIOLET LIGHTS SHALL NOT BE USED (OR BE REQUIRED) IN MERCURY EXCLUSION AREAS. 5.6.1���� (Visual and Ultraviolet (UV) Light): Conduct a visual inspection to verify all surfaces within the scope of the
project are free of hydrocarbons, and other contaminants such as sea salts, loose rust, mud, and marine �������� growth, which could become imbedded in the surface to be prepared. Inspect surface using a UV light
(approx. 60 Å) to detect hydrocarbons on the surface. The ultraviolet light will not allow the proper detection of hydrocarbons on the surface if the surface being inspected is exposed to day or artificial light. Therefore
�������� for proper UV light hydrocarbon detection, lights must be off for interior spaces, and the inspection must �������� be conducted during darkness for surfaces exposed to sunlight. Take appropriate safety measures to
prevent worker hazards in the darkened space. 5.6.1.1 When hydrocarbons are present, the hydrocarbons will fluoresce as bright green, lime green, or blue/violet on
the surface. 5.6.1.2 To remove detected contaminants or hydrocarbons, accomplish a solvent wipe on affected areas. Follow
SSPC-SP-1 to remove contaminants and hydrocarbons. 5.6.1.3 If contaminants or hydrocarbons are detected on the surface after attempting to solvent spot repair, the
Responsible Implementing Authority shall require the surface be de-greased again as directed in paragraph 5.4. 5.6.2 (Structural and Pre-Surface Conditioning): Verify all surfaces within the scope of the project are IAW
paragraphs 5.1 through 5.3. 5.6.3 (Contamination Containment and Masking): Verify all surfaces within the scope of the project are IAW
paragraphs 4.10 through 4.11. 6. SURFACE PREPARATION: 6.1 Monitor environmental conditions throughout surface preparation operations to ensure they meet
requirements as specified in paragraphs 4.8 and 4.9. Record measurements in Appendix 1. 6.2 POWER TOOL CLEANING: 6.2.1 Accomplish the requirements of SSPC-SP-11 Power Tool Cleaning to Bare Metal to remove all the existing
coating and corrosion products. Perform this requirement to the deck, shower stall and vertical surfaces extending six (6) inch up from the deck. Well-adherent paint that is in pits and depressions below the immediate deck surface is acceptable if removal would require sanding or grinding to eliminate. Surface preparation accomplished using a surface preparation device such as a disk sander or power wire wheel that burnishes, polishes or smoothes the surface is not authorized.
6.2.2 Feather edges of adherent paint in adjacent areas remaining after cleaning. 6.3 SURFACE PROFILE: 6.3.1 Accomplish a surface profile of 1 mil minimum. 6.4 CHECKPOINT (Surface Preparation): Accomplish IAW Table 631-11-1, II (Surface Preparation). The record shall show the extent of the inspection and detailed results. The degree of surface cleanliness
shall be IAW the NACE/SSPC surface preparation standard specified; surface profile, soluble salt measurements, and adequacy of cleanup operations shall be recorded. The inspections shall be conducted to standardized acceptance criteria. Visual aids, such as SSPC-VIS 3, (Visual Standard for Power and
HEAD DECK PPI, May 17, 2002 9 REV 02
Hand Tool Cleaned Steel, SSPC 93-04) (Ref. 2.f) may be used to ensure quality standards are met. Surfaces shall match the pictorial standard F SP 11. Enter data on all applicable Appendices.
6.4.1 (Surface Profile Measurements): Accomplish IAW Ref. 2.d. Record one measurement every 200 ft² randomly dispersed over the entire prepared surface area. Enter on Appendix 3 TESTEX PRESS-O-FILM tapes used to measure surface profile.
6.4.2 (Soluble Salt Measurements Conductivity Testing): Accomplish conductivity tests IAW the method
described in Appendix 8. Use HORIBA B-173 or equivalent NAVSEA approved test equipment. Measurements shall be made randomly over the prepared surface. Take five (5) measurements every 1,000 ft² (90m²). Areas less than 1,000 ft² (90m²) shall have (5) measurements made. For non-immersed applications soluble salts (total ionic) shall not exceed 70µS/cm (microsiemens/cm).
6.4.2.1 If conductivity measurements in an isolated area exceed the respective values, circle area and perform
spot solvent cleaning (Super High Flash Naphtha) followed by retest. 6.4.2.2 For prepared surfaces not practical for the spot cleaning method, water wash with copious amounts of
DEIONIZED water using hand scrub brush. Remove all standing water and dry the affected area. Disk sand using # 36 disk to remove all rust. Perform an SSPC-SP-1 solvent wipe on all sanded areas and retest. Repeat necessary steps until satisfactory levels are obtained.
6.4.3 (Environmental): Verify environmental conditions were monitored and maintained IAW paragraphs 4.8 and 4.9. 6.4.4 (Contamination Containment and Masking): Verify all surfaces within the scope of the project are IAW
paragraph 4.10 prior to the application of paint. Surfaces must be clean and free of debris and dust. 6.4.5 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of
the checkpoint. At rescheduled checkpoint, QA will document satisfactory corrective actions taken to correct the discrepancy.
6.4.6 In order to pass the checkpoint, Appendices 1-3 and 5 shall be up to date and submitted to QA. QA will
update Appendix 6. 7. PAINTING REQUIREMENTS: 7.1 WET FILM MEASUREMENTS: During application, spray applicators shall monitor wet film thickness using
wet film gauges. Random wet film thickness (WFT) measurements shall be taken during the application process to ensure the specified dry film thickness (DFT) is achieved.
7.2 DRY FILM THICKNESS MEASUREMENTS: Accomplish IAW Ref. 2.b, record measurements in Appendix 4. 7.3 RE-COAT PERIODS: Applicator will not exceed manufacturer’s maximum re-coat periods IAW Ref. 2.c. 7.4 DRY PAINT FOR CHECKPOINTS: Paint shall be dry prior to all paint related checkpoints. Dry shall be
defined as fingernail hard. 7.5���� OUT OF SPECIFICATION DRY FILM THICKNESS: Failure to meet minimum dry film thickness
requirements will result in application of an additional coat or coats of paint in deficient areas before the coat can pass the DFT checkpoint.
7.6 CHECKPOINT (Material Storage): Accomplish a visual inspection of material storage facilities 24 hours
prior to material being mixed to verify the storage temperature complies within the minimum and maximum �������� range allowed IAW Ref. 2.c. The material storage temperature shall be monitored and recorded once per �������� shift for 24 hours prior to the material being used. Record measured temperatures in Appendix 1.
7.7 PAINT APPLICATION: The use of brush, rollers, single or plural component spray equipment is acceptable
for application of the paint coat specified below. 7.8 MIXING: If single or plural component spray paint equipment is used mix primer and topcoat IAW Ref. 2.c.
HEAD DECK PPI, May 17, 2002 10 REV 02
7.9 Monitor environmental conditions throughout painting operations to ensure they meet requirements as specified in paragraphs 4.8 and 4.9. Record measurements in Appendix 1.
8. PRIMER COAT APPLICATION: 8.1 Apply prime coat of Euronavy ES 301 K to the dry film thickness of 4-5 mils DFT to prepared surfaces.
During application, immediately brush out any drips or puddles. 8.2. CHECKPOINT (Prime Coat): Verify prime coat is applied IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c. 8.2.1���� (Holiday Inspection): Accomplish a visual holiday inspection of prime coat. 8.2.2 (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b. 8.2.3 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of
the checkpoint. At rescheduled checkpoint, QA will document satisfactory corrective actions taken to correct discrepancy.
8.2.4 In order to pass the checkpoint, Appendices 1, 4, 5 and 7 shall be up to date and submitted to QA. QA will
update Appendix 6. NOTE: IMPLEMENTING AUTHORITY WILL SPECIFY NAVSEA APPROVED MATERIALS TO BE UTILIZED
FOR THE TILE SYSTEM. REFER TO PARAGRAPH 2.C AND NSTM 634 SECTION 3. 9. UNDERLAYMENT SYSTEM: NOTE: APPLY UNDERLAYMENT TO ENTIRE DECK, LEVEL OUT DEPRESSIONS IN THE DECK, SLOPE
DECK TO DRAINS, AND APPLY ON VERTICAL SURFACES UP 4 INCHES FROM DECK. 9.1 BOND COAT: 9.1.1 Mix Bond Coat IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c. 9.1.2 Apply Bond Coat with brush, trowel, or squeegee. Application techniques will vary depending on when
underlayment will be applied. Refer to manufacturer’s ASTM F-718 sheet Ref. 2.c. 9.2 UNDERLAYMENT: NOTE: UNDERLAYMENT MUST BE APPLIED WHILE BOND COAT IS STILL TACKY. 9.2.1 Mix Underlayment IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c. 9.2.2 Apply by trowel over bond coat to fair deck irregularities and produce positive slopes toward drains IAW
manufacturer’s ASTM F-718 sheet, Ref. 2.c. 9.2.3 Curing overnight is recommended prior to application of next coat. 9.2.4 Use low-level lighting to help avoid trowel marks. 9.3 WATERPROOF MEMBRANE: NOTE: APPLY MEMBRANE TO ENTIRE DECK AND ON VERTICAL SURFACES UP 5 INCHES FROM DECK. 9.3.1 Mix Waterproof Membrane IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c. 9.3.2 Apply membrane by brush, roller, squeegee or trowel. Do not allow material to puddle. 9.3.3 If specified by the manufacturer, apply additional coat to applicable areas IAW manufacturer’s ASTM F-718
sheet, Ref. 2.c.
HEAD DECK PPI, May 17, 2002 11 REV 02
NOTE: IMPLEMENTING AUTHORITY WILL SPECIFY NAVSEA APPROVED MATERIALS TO BE UTILIZED FOR THE TILE SYSTEM. REFER TO PARAGRAPH 2.C AND NSTM 634 SECTION 3.
9.4 CONCRETE: 9.4.1 Fabricate and install box units around hard to reach areas, i.e. vent ducting, stuffing tubes, and pipe brackets. 9.4.2 Mix Concrete IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c. 9.4.3 Apply concrete by pouring into boxed area to produce slope towards deck drains. 9.4.4 Remove box units when concrete is cured sufficiently IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c. 9.5 MORTAR: NOTE: THE APPLICATION AND INSTALLATION OF MORTAR AND TILE MAY HAVE TO BE ACCOMPLISHED
IN SECTIONS IF THE AREA IS SO LARGE TO PREVENT LAYING TILES WITHIN MORTAR POTLIFE. NOTE: APPLY MORTAR TO DECK AND ON VERTICAL SURFACES UP 4 INCHES FROM DECK. 9.5.1 Mix an ANSI, A118.3 epoxy mortar IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c. 9.5.2 Apply mortar IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c. Periodically lift a set tile and inspect to ensure
that 100% contact between mortar and tile is achieved and that there is no entrapped air in the mortar. 10. TILE INSTALLATION: 10.1 Tiles are to be installed in accordance with the manufacturer’s recommended instructions of proprietary
materials for installation. 10.2 It is preferable to protect the deck from heavy traffic for 24 hours after installation, and decks must not be
washed for 48 hours. 10.3 Tiles, mortar and deck should be allowed to stabilize to a temperature as close as practicable to room
temperature, but in cases between 64-81o F for a period of 24 hours before, during, and after installation. Tiles must be stored flat.
11. GROUT INSTALLATION: 11.1 Mix an ANSI, A118.3 epoxy grout manufacturer’s ASTM F-718 sheet, Ref. 2.c. 11.2 Apply grout by working it into tile seams to ensure air pockets are eliminated. 11.3 Clean epoxy grout residue from the surface of the tile. 11.4 Protect tile from foot traffic for a minimum of 24 hours. 12. TOPCOAT APPLICATION VERTICAL BULKHEADS: 12.1 Check for evidence of Amine Bloom such as discoloration of paint coating or clear oily film. If evidence of
Amine Bloom is present, perform low-pressure water wash or wipe surfaces clean using ethanol/water mixture. 12.2 Apply topcoat to a DFT of 1.5 – 2 mils, to primed surfaces of type and color to match existing color scheme
of vertical bulkhead. During application, immediately brush out any drips or puddles. 12.3 CHECKPOINT (Topcoat): Verify topcoat is applied IAW manufacturer’s ASTM F-718 sheet, Ref. 2.c and
complies with color match. 12.3.1 (Dry Film Thickness): Accomplish dry film thickness measurements IAW Ref. 2.b.
HEAD DECK PPI, May 17, 2002 12 REV 02
12.3.2 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of the checkpoint. At rescheduled checkpoint, QA will document satisfactory corrective actions taken to correct discrepancy.
12.3.3 In order to pass the checkpoint, Appendices 1, 4, 5 and 7 shall be up to date and submitted to QA. QA will update Appendix 6.
13. CHECKPOINT (Free Flow Test): 13.1 Mechanically clean each deck drain from point of entry to each terminating point, free of foreign matter that
could affect performance or damage system components. 13.2 Isolate each component that may be damaged by cleaning. 13.3 Flush each drain after cleaning with clean, fresh water, until free of debris. Test to ensure drains flow free. 13.4 Reinstall each deck drain strainer plate removed in 5.1. 13.5 Retap each hole for each new fastener. 13.6 Install new fasteners, same type and size as those removed in paragraph 5.1. 13.7 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of
the checkpoint. At rescheduled checkpoint, QA will document satisfactory corrective actions taken to correct discrepancy.
13.8 In order to pass the checkpoint, Appendix 5 shall be up to date and submitted to QA. QA will update
Appendix 6. 14. CHECKPOINT (Positive Drain Test): 14.1 Apply a sufficient amount of clean, fresh water throughout compartment deck surfaces to verify that new
deck covering slopes to drains and water does not stand or puddle on deck. Water shall flow to drains when applied to deck surfaces.
14.2 All tests and inspections noting unsatisfactory conditions shall result in the termination and rescheduling of
the checkpoint. At rescheduled checkpoint, QA will document satisfactory corrective actions taken to correct discrepancy.
14.3 In order to pass the checkpoint, Appendix 5 shall be up to date and submitted to QA. QA will update
Appendix 6. 15. FINAL INSPECTION: 15.1 CHECKPOINT (Finished Painted Surfaces): 15.1.1 (Dry Film Thickness): Accomplish final dry film thickness measurements IAW Ref. 2.b. 15.1.2 Paint and tile system imperfections found, which may cause premature coating failure, shall be corrected
before the tile system is accepted. Slight imperfections in the coating system are allowable, as long as they are not below minimum mils, and will not result in premature failure of the coating in the immediate vicinity of the imperfection. Such slight imperfections should be left intact, as trying to correct them could result in damage to the surrounding coating system.
15.1.3 In order to pass the checkpoint, any Appendices required by the certified coating inspector shall be up to
date or completed and submitted to QA. QA will update Appendix 6. All test inspections noting unsatisfactory conditions shall be corrected.
HEAD DECK PPI, May 17, 2002 13 REV 02
APPENDIX 1
QA INSPECTION FORM - ENVIRONMENTAL READINGS
SHIP: ________________________________________________________ LOCATION: ___________________________________________________ DATE: ________ PRODUCT BEING APPLIED: _________________________________________________________
MAINTAIN SEPARATE LOG FOR EACH AREA / LOCATION, PREPARED OR PAINTED SURFACE,
WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION
QA INSPECTION FORM - DRY FILM THICKNESS MEASUREMENTS
SHIP: ________________________________________________________ LOCATION: ___________________________________________________ DATE: ________ PRODUCT BEING APPLIED: _________________________________________________________
MAINTAIN SEPARATE LOG FOR EACH AREA / LOCATION, PREPARED OR PAINTED SURFACE,
WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION
Indicate Coating System
Seq.
Indicate Type 1 or 2 DFT Gage Being Used: ____ Gage Manufacturer: _________________________________________________ Serial Number of Gage Being Used: ____________________________________ Date Last Calibrated: ____________________ Current Calibration Due Date: ________________
1 Prime Coat: Top Coat: Other: ____________
First 1,000 F², First 100 F² Area. Five Spot Measurements (Spot Measurement
Consists of the Average of Three Gage Readings)
After First 1,000 F², One 100 F² Area Every 1,000 F² Consisting of Five Spot Measurements (Spot Measurement Consists of the Average of Three Gage
Readings)
Spot Measurement
DFT (mils) Avg. of 3 Gage
Readings
Approximate Location
Spot Measurement
DFT (mils) Avg. of 3 Gage
Readings
Approximate Location
1 1 2 2 3 3 4 4 5 5
Average
Average
First 1,000 F², Second 100 F² Area. Five Spot Measurements (Spot Measurement Consists of the Average of Three Gage Readings)
After First 1,000 F², One 100 F² Area Every 1,000 F² Consisting of Five Spot Measurements (Spot Measurement Consists of the Average of Three Gage
Readings)
Spot Measurement
DFT (mils) Avg. of 3 Gage
Readings
Approximate Location
Spot Measurement
DFT (mils) Avg. of 3 Gage
Readings
Approximate Location
1 1 2 2 3 3 4 4 5 5
Average
Average
First 1,000 F², Third 100 F² Area. Five Spot Measurements (Spot Measurement Consists of the Average of Three Gage Readings)
After First 1,000 F², One 100 F² Area Every 1,000 F² Consisting of Five Spot Measurements (Spot Measurement Consists of the Average of Three Gage
Readings)
Spot Measurement
DFT (mils) Avg. of 3 Gage
Readings
Approximate Location
Spot Measurement
DFT (mils) Avg. of 3 Gage
Readings
Approximate Location
1 1 2 2 3 3 4 4 5 5
Average
Average Implementing Contractor (Print): ________________________________________________________ Implementing Contractor (Signature): ____________________________________________________
HEAD DECK PPI, May 17, 2002 17 REV 02
APPENDIX 5
CHECKPOINT & MILESTONE COMPLETION LOG
SHIP: ________________________________________________________ LOCATION: ___________________________________________________ DATE: ________ PRODUCT BEING APPLIED: ________________________________________________________
MAINTAIN SEPARATE LOG FOR EACH AREA / LOCATION, PREPARED OR PAINTED SURFACE,
WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION
ACTIVITY TIME DATE
Date Process Control Procedure (PCP) Demonstrated Implementing Contractor (Print/ Signature): __________________________________________
Date Pre-Surface Preparation and Cleaning Begins Implementing Contractor (Print/ Signature): __________________________________________
Date of Pre-Surface Preparation and Cleaning Checkpoint --Date of Visual and UV Light Inspection Check --Date of Structural and Pre-Surface Conditioning (ensuring de-burring and grinding) Check --Date of Contamination Containment and Masking Check Implementing Contractor (Print/ Signature): __________________________________________
Date Surface Preparation Begins Implementing Contractor (Print/ Signature): __________________________________________
Date of Surface Preparation Checkpoint --Date of Surface Profile Measurement Check --Date of Soluble Salt Measurement Check --Date of Environmental Check --Date of Contamination Containment and Masking Check --Date of Inspection of prepared area (ensuring all areas are properly prepared) Check --Date of Inspection of area cleanliness prior to paint application Check Implementing Contractor (Print/ Signature): __________________________________________
Date Material Storage Area Inspected Implementing Contractor (Print/ Signature): __________________________________________
Date Prime Coat is Applied Implementing Contractor (Print/ Signature): __________________________________________
Date of Prime Coat Checkpoint Implementing Contractor (Print/ Signature): __________________________________________
Date Top Coat Applied Implementing Contractor (Print/ Signature): __________________________________________
Date of Top Coat Checkpoint Implementing Contractor (Print/ Signature): __________________________________________
Date of Free Flow Test Implementing Contractor (Print/ Signature): __________________________________________
Date of Positive Drain Test Implementing Contractor (Print/ Signature): __________________________________________
Date Finished Painted Surfaces Checkpoint Implementing Contractor (Print/ Signature): __________________________________________
HEAD DECK PPI, May 17, 2002 18 REV 02
APPENDIX 6
CERTIFIED COATING INSPECTOR’S CHECKPOINT SIGN OFF LOG
Must Be Signed By Certified Coating Inspector To Pass Checkpoints
SHIP: ________________________________________________________ LOCATION: ___________________________________________________ DATE: ________ PRODUCT BEING APPLIED: _________________________________________________________
MAINTAIN SEPARATE LOG FOR EACH AREA / LOCATION, PREPARED OR PAINTED SURFACE,
WHEN AN AREA IS DIVIDED INTO SEPARATE SECTIONS MAINTAIN A SEPARATE LOG FOR EACH SECTION
Process Control Procedure Demonstrated Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________
Date: ___________ Time: ___________
Pre-Surface Preparation and Cleaning Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________
Material Storage Area Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________
Date: ___________ Time: ___________
Prime Coat Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________
Date: ___________ Time: ___________
Top Coat Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________
Date: ___________ Time: ___________
Free Flow Test Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________
Date: ___________ Time: ___________
Positive Drain Test Inspected and Accepted: Certified Inspector (Print): _________________________________________ Certified Inspector (Signature): _____________________________________
