SECTION 05080

SECTION 05 05 13 (Masterformat 2004)

SHOP APPLIED COATINGS FOR METAL

 

PART 1    GENERAL

1.01         SECTION INCLUDES

NTS: The following can be edited by deleting those processes not applicable to the project.

A.       This Section specifies factory-applied metal coatings as listed below:

1.     Hot-dip galvanizing - Duragalv®

2.     Hot-dip galvanizing and factory-applied primer - Primergalv®

3.     Hot-dip galvanizing and factory-applied architectural finish - Colorgalv®

4.     Hot-dip galvanizing and factory-applied ultra-durable architectural finish. Colorgalv 10®

5.     High Performance thermosetting based, factory applied primer for uncoated Interior Steel use or for Interior and Exterior Aluminum use. -  Duncan Primer ThermosetSM

6.     High-performance thermosetting based durable coating for uncoated interior steel and interior or exterior aluminum - Duncan ThermosetSM

7.     High-performance thermosetting based super-durable coating for exterior aluminum - Duncan Thermoset 5SM

8.     High-performance thermosetting based ultra-durable coating for exterior aluminum - Duncan Thermoset 10SM

9.     High-performance thermosetting based hyper-durable coating for exterior aluminum - Duncan Thermoset 15SM

10.   Hot-dip galvanizing and high performance thermosetting based, factory applied primer for exterior steel use. - Duncan Primergalv ThermosetSM

11.   Hot-dip galvanizing and high-performance thermosetting based, factory applied durable coating for exterior steel use - Duncan Colorgalv ThermosetSM

12.   Hot-dip galvanizing and high performance thermosetting based, factory applied super-durable coating for exterior steel use - Duncan Colorgalv Thermoset 5SM

13.   Hot-dip galvanizing and high performance thermosetting based, factory applied ultra-durable coating for exterior steel use - Duncan Colorgalv Thermoset 10SM

14.   Hot-dip galvanizing and high performance thermosetting based, factory applied hyper-durable coating for exterior steel use - Duncan Colorgalv Thermoset 15SM

1.02         RELATED SECTIONS

A.       Examine Contract Documents for requirements that affect Work of this Section. Other Specification Sections that directly relate to Work of this Section include, but are not limited to:

1.     Section 02800 - Site Improvements.

2.     Section 03300 - Cast-In-Place Concrete.

3.     Section 04200 - Unit Masonry.

4.     Section 05120 - Structural Steel.

5.     Section 05300 - Metal Decking.

6.     Section 05500 - Metal Fabrications.

7.     Section 07700 - Roof Specialties.

8.     Section 08410 - Aluminum Entrances and Storefront; fluoropolymer finishes.

9.     Section 08520 - Aluminum Windows; fluoropolymer finishes.

10.   Section 08900 - Curtain Wall Systems; fluoropolymer finishes.

11.   Section 10200 - Aluminum Louvers; fluoropolymer finishes.

12.   Section 10350 - Flagpoles.

13.   Section 10430 - Exterior Signage.

17.   Section 16000 - Electrical.

1.03         SUBMITTALS

A.       Product Literature:  Submit galvanizer’s product literature for coatings specified in this Section indicating type of product and performance criteria.

B.       Verification Samples:  Submit two 3 inch by 6 inch samples of factory-applied coatings and colors proposed for use for approval prior to coating application.

C.       Certificate of Compliance for Items Coated by Galvanizer:  If requested, submit notarized Certificate of Compliance with application for payment for galvanizing, signed by the galvanizer, indicating compliance with requirements of specifications.  Include scope of services provided, and quantity and itemized description of items processed.

1.     Include galvanizer's certification that shop applied primer is completely compatible with field-applied topcoats provided under Section 09900 - Painting.

D.       Certificate of Compliance for Shop Drawing Review by Galvanizer:  If requested, submit galvanizer's certification that shop drawings for metal fabrications to receive metal coatings have been reviewed and that fabrications are acceptable to galvanizer for proper application of galvanizing and metal coatings. All drawings should be signed by the galvanizer to indicate acceptance of design for galvanizing.

E.       Certificate of Compliance of Item Identification by Galvanizer:  The galvanizer shall mark all lots of material with a clearly visible tag indicating the name of the galvanizer, the type and weight of the coating, and the applicable ASTM Specification Numbers.  If requested, submit certification of compliance that items have been tagged.

F.        Substitutions or APPROVED EQUALS are defined as meeting the, aesthetic, durability and all other performance criteria as detailed in this specification. Substitution and/or APPROVED EQUALS requests shall be accompanied by proof that the substitution or APPROVED EQUAL meets or exceeds the aesthetic, durability and all other performance requirements of the specified Duncan Processes. Approvals of the substitution and/or APPROVED EQUALS shall be the right of the Owner, Owner’s Representative, the Architect or the Engineer. Coatings or processes not matching or exceeding the approved specified process including aesthetic, durability and all other performance criteria shall be removed and replaced at the expense of the contractor and all subcontractors that were involved with the supply of, and the application of the non conforming product. Intentional misrepresentation of processes is fraud.

G.       Galvanizer/coater shall supply a certificate of compliance that all coatings have been performed in accordance with QP-3 standards and procedures.

1.04         QUALITY ASSURANCE

A.       Galvanizer:  Engage the services of a qualified galvanizer who has demonstrated a minimum of ten years experience in the successful application of galvanized coatings specified in this specification in the facility where the work is to be performed and who will apply the coatings within the same facility.

B.       Pre-Construction Conference for Metal Fabrications to Receive Factory-Applied Metal Coatings:  Contractor shall schedule a meeting to be attended by Contractor, Architect, fabricator, and galvanizer.  Agenda shall include the following:  Project schedule, scope of services, coordination between fabricator and galvanizer, finish of surfaces, application of coatings, submittals, and approvals.

C.       Coordination between Fabricator and Galvanizer:   Prior to fabrication and final submittal of shop drawings to Architect, direct fabricators to submit shop drawings to the galvanizer for all metal fabrications to receive factory-applied metal coatings.  Direct galvanizer to review fabricator's shop drawings for suitability of materials for galvanizing and coatings and coordinate any required modifications to fabrications required to be performed by the fabricator.

D.       Rugosity:  Factory-applied metal coatings shall exhibit a rugosity (smoothness) not greater than 4 rug (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of architectural and structural elements that are less than 24 pounds per running foot. Profilometer shall be capable of operating in 1 micron increments.

1.     Surface blasting prior to application of factory-applied post galvanizing wet coatings will produce a high rugosity and not be acceptable.

E.       Galvanizing shall be performed by a company with a minimum of ten years experience in the successful application of hot-dip galvanizing utilizing the dry kettle process.

F.        Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

PART 2 – PRODUCTS

2.01         APPLICATOR

A.       For the purpose of establishing a standard of quality and performance, provide factory-applied metal coatings as specified by Duncan Galvanizing, 69 Norman Street, Everett, MA, 02149, telephone 617-389-8440, fax 617-389-2831, www.duncangalvanizing.com.

NTS: This specification can be edited by deleting those paragraphs not applicable to the project.

1.     Hot-dip galvanizing - Duragalv®

2.     Hot-dip galvanizing and factory-applied primer - Primergalv®

3.     Hot-dip galvanizing and factory-applied architectural finish - Colorgalv®

4.     Hot-dip galvanizing and factory-applied ultra-durable architectural finish. Colorgalv 10®

5.     High Performance thermosetting based, factory applied primer for uncoated Interior Steel use or for Interior and Exterior Aluminum use. -  Duncan Primer ThermosetSM

6.     High-performance thermosetting based durable coating for uncoated interior steel and interior or exterior aluminum - Duncan ThermosetSM

7.     High-performance thermosetting based super-durable coating for exterior aluminum - Duncan Thermoset 5SM

8.     High-performance thermosetting based ultra-durable coating for exterior aluminum - Duncan Thermoset 10SM

9.     High-performance thermosetting based hyper-durable coating for exterior aluminum - Duncan Thermoset 15SM

10.   Hot-dip galvanizing and high performance thermosetting based, factory applied primer for exterior steel use. - Duncan Primergalv ThermosetSM

11.   Hot-dip galvanizing and high-performance thermosetting based, factory applied durable coating for exterior steel use - Duncan Colorgalv ThermosetSM

12.   Hot-dip galvanizing and high performance thermosetting based, factory applied super-durable coating for exterior steel use - Duncan Colorgalv Thermoset 5SM

13.   Hot-dip galvanizing and high performance thermosetting based, factory applied ultra-durable coating for exterior steel use - Duncan Colorgalv Thermoset 10SM

14.   Hot-dip galvanizing and high performance thermosetting based, factory applied hyper-durable coating for exterior steel use - Duncan Colorgalv Thermoset 15SM

2.02         HOT-DIP GALVANIZING - DURAGALV®

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel and other earthly materials.

2.03         HOT-DIP GALVANIZING AND FACTORY-APPLIED PRIMER - PRIMERGALV®

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel and other earthly materials.

B.       Factory-Applied Primer:  Provide factory-applied prime coat, Primergalv by Duncan Galvanizing, certified VOC compliant, conforming to applicable regulations and EPA standards.  Apply primer within 12 hours after galvanizing at the same facility where the galvanizing is done in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer.  Blast cleaning of the surface is unacceptable for surface preparation.

C.       Performance Criteria: Coatings must meet or exceed the following performance criteria:

  ABRASION RESISTANCE - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).1kg load
      Result: 200 mg loss
  ADHESION - Method: ASTM   D4541 Result: 1050 psi
  CORROSION WEATHERING: Method: ASTM D5894, 13 cycles, 4,368 hours
      Result: Rating 10 per ASTM D714 for blistering; Rating: 7 per ASTM D610 for rusting
  DIRECT IMPACT RESISTANCE: Method: ASTM D2794  Result: 160 in. lbs.
  FLEXIBILITY: Method: ASTM D522, 180º bend, 1” mandrel Result: Passes
  PENCIL HARDNESS: Method: ASTM D3363  Result: 3H
  MOISTURE CONDENSATION RESISTANCE: Method: ASTM D4585, 100º F,2000 hours
      Result: Passes, no cracking or delamination
  DRY HEAT RESISTANCE: Method: ASTM D2485  Result: 250º F

2.04         HOT-DIP GALVANIZING AND FACTORY-APPLIED ARCHITECTURAL FINISH - COLORGALV

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv® by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel, and other earthly materials.

B.       Architectural Finish:  Provide factory-applied architectural coating over hot-dip galvanized steel, Colorgalv® by Duncan Galvanizing matching approved samples.

1.     Primer coat shall be factory-applied prime coating. Apply primer within 12 hours after galvanizing at the same facility where the galvanizing is done in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer.

2.     Finish coat shall be factory-applied high performance architectural finish. Apply finish coating at the galvanizer’s plant, in a controlled environment meeting applicable environmental regulations and as recommended by the finish coating manufacturer.

3.     Coatings shall be certified VOC compliant and conform to applicable regulations and EPA standards.

4.     Apply the galvanizing, primer and coating within the same facility and provide single-source responsibility for galvanizing, priming and finish coating.

5.     Blast cleaning of the galvanized surface is not acceptable.

C.       Performance Criteria: Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

1.      Primer:

   ABRASION RESISTANCE - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams     load).1kg load
      Result: 200 mg loss
   ADHESION - Method: ASTM      D4541
      Result: 1050 psi
   CORROSION WEATHERING: Method: ASTM D5894, 13 cycles, 4,368 hours
         Result: Rating 10 per ASTM D714 for blistering; Rating: 7 per ASTM D610 for rusting
   DIRECT IMPACT RESISTANCE: Method: ASTM D2794  Result: 160 in. lbs.
   FLEXIBILITY: Method: ASTM D522, 180º bend, 1” mandrel Result: Passes
   PENCIL HARDNESS: Method: ASTM D3363  Result: 3B
   MOISTURE CONDENSATION RESISTANCE: Method: ASTM D4585, 100º F, 2000 hours
         Result: Passes, no cracking or delamination
   DRY HEAT RESISTANCE: Method: ASTM D2485  Result: 250º F

2.      Topcoat:

   ABRASION RESISTANCE - Method: ASTM D 4060, CS17 Wheel, 1,000 cycles 1kg load.
      Result: 87.1 mg loss
   ADHESION - Method: ASTM D 4541, Result: 1050 psi
   DIRECT IMPACT RESISTANCE: Method: ASTM D2794; Result: >28 in. pounds
   INDIRECT IMPACT RESISTANCE: Method: ASTM D2794; Result: 12-14 in. pounds
   DRY HEAT RESISTANCE: Method: ASTM D2485 Result: 200° F
   SALT FOG RESISTANCE:  Method: ASTM B 117  9,000 hours
       Result: Rating 10 per ASTM D714 for blistering
   FLEXIBILITY: Method: ASTM D522, 180° bend, 1/8” mandrel Result: Passes
   PENCIL HARDNESS: Method: ASTM D3363  Result: 2H
   MOISTURE CONDENSATION RESISTANCE: Method: ASTM D4585, 100° F, 1000 hours
       Result: No blistering or delamination
   XENON ARC TEST: ASTM D 4798
      Result: Pass 200 hours

3.      Duncan warrants the Colorgalv process to be free from 10% or more visible rust for a period of twenty (20) years. Warranties for fading or discoloration of the finish shall be that which is supplied by the coating manufacturer.

2.05         HOT-DIP GALVANIZING AND FACTORY-APPLIED LONG LASTING ARCHITECTURAL COAT - COLORGALV 10

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv® by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel, and other earthly materials.

B.       Architectural Finish:  Provide factory-applied architectural coating over hot-dip galvanized steel, Colorgalv® by Duncan Galvanizing matching approved samples.

1.     Primer coat shall be factory-applied prime coat. Apply primer within 12 hours after galvanizing at the same facility where the galvanizing is done in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer.

2.     Finish coat shall be factory-applied color-pigmented architectural finish. Apply finish coating at the galvanizer’s plant, in a controlled environment meeting applicable environmental regulations and as recommended by the finish coating manufacturer.

3.     Coatings shall be certified VOC compliant and conform to applicable regulations and EPA standards.

4.     Apply the galvanizing, primer and coating within the same facility and provide single-source responsibility for galvanizing, priming and finish coating.

5.     Blast cleaning of the galvanized surface is not acceptable.

C.       Performance Criteria: Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

1.      Primer:

   ABRASION RESISTANCE - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).1kg load;
      Result: 200 mg loss
   ADHESION - Method: ASTM      D4541 Result: 1050 psi
   CORROSION WEATHERING: Method: ASTM D5894, 13 cycles, 4,368 hours
       Result: Rating 10 per ASTM D714 for blistering; Rating 7 per ASTM D610 for rusting
   DIRECT IMPACT RESISTANCE: Method: ASTM D2794  Result: 160 in. lbs.
   FLEXIBILITY: Method: ASTM D522, 180º bend, 1” mandrel Result: Passes
   PENCIL HARDNESS: Method: ASTM D3363  Result: 3B
   MOISTURE CONDENSATION RESISTANCE: Method: ASTM D4585, 100º F, 2000 hours
   Result: Passes, no cracking or delamination
   DRY HEAT RESISTANCE: Method: ASTM D2485  Result: 250º F

2.      Topcoat:

   ABRASION RESISTANCE - Method: ASTM D 4060, CS17 Wheel, 1,000 cycles 1kg load.
       Result: 87.1 mg loss
   ADHESION - Method: ASTM D 4541, Result: 1050 psi
   DIRECT IMPACT RESISTANCE: Method: ASTM D2794; Result: >28 in. pounds
   INDIRECT IMPACT RESISTANCE: Method: ASTM D2794; Result: 12-14 in. pounds
   DRY HEAT RESISTANCE: Method: ASTM D2485 Result: 200° F
   SALT FOG RESISTANCE:  Method: ASTM B 117  9,000 hours
       Result: Rating 10 per ASTM D714 for blistering
   FLEXIBILITY: Method: ASTM D522, 180° bend, 1/8” mandrel Result: Passes
   PENCIL HARDNESS: Method: ASTM D3363  Result: 2H
   MOISTURE CONDENSATION RESISTANCE: Method: ASTM D4585, 100° F, 1000 hours
       Result: No blistering or delamination
   XENON ARC TEST: ASTM D 4798 Result: Pass 300 hours

3.      Duncan warrants the Colorgalv 10 process to be free from 10% or more visible rust for a period of twenty (20) years. Warranties for the finish shall be 10 years in accordance with the performance specifications referenced above.

2.06         HIGH-PERFORMANCE THERMOSETTING BASED DURABLE COATING - DUNCAN  PRIMER THERMOSET SM

A.       High-Performance Thermosetting Based Factory Applied Primer for Interior Black (Uncoated) Steel or for Interior or Exterior Aluminum

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ABRASION RESISTANCE - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).1kg load
      Result: 200 mg loss
   ADHESION - Method: ASTM      D4541 Result: 1050 psi
   CORROSION WEATHERING: Method: ASTM D5894, 13 cycles, 4,368 hours
   Result: Rating 10 per ASTM D714 for blistering; Rating: 7 per ASTM D610 for rusting
   DIRECT IMPACT RESISTANCE: Method: ASTM D2794  Result: 160 in. lbs.
   FLEXIBILITY: Method: ASTM D522, 180º bend, 1” mandrel Result: Passes
   PENCIL HARDNESS: Method: ASTM D3363  Result: 3B
   MOISTURE CONDENSATION RESISTANCE: Method: ASTM D4585, 100º F,2000 hours
         Result: Passes, no cracking or delamination
   DRY HEAT RESISTANCE: Method: ASTM D2485  Result: 250º F

3.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

2.07         HIGH-PERFORMANCE THERMOSETTING BASED DURABLE COATING - DUNCAN THERMOSET SM

A.       High-Performance Thermosetting Based Durable Coating for Interior Black (Uncoated) Steel or for Interior and Exterior Aluminum

           Duncan Thermoset® matching approved samples.

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ADHESION – Method: ASTM D-3359 Result: 1050 psi
   FLEXIBILITY – Method:  ASTM D-522 (Cylindrical Mandrel) Passes
   HARDNESS – Method: ASTM D-3363 (Pencil) 2H
   SALT SPRAY – Method: ASTM B-117 Result: Passes 400 hrs
   HUMIDITY – Method: ASTM D-4585 , 100º F,2000 hours
         Result: Passes, no cracking or delamination
   IMPACT RESISTANCE  - Method: ASTM D-2794 Direct 160 in lbs
   COLOR RETENTION – ASTM D 2244 Result: 1∆E after 1 year (Based on inorganic resins)
   CHALK RESISTANCE – ASTM D 4214 Result; None
   GLOSS RETENTION – ASTM D 523 Result: No Loss 1 year
   XENON ARC TEST: ASTM D 4798 Result: Pass 200 hours

3.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

2.08         HIGH-PERFORMANCE THERMOSETTING BASED SUPER-DURABLE COATING - DUNCAN THERMOSET 5 SM

A.       High-Performance Thermosetting Based Super-Durable Coating over Aluminum

           Duncan Thermoset 5 SM matching approved samples.

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ADHESION – Method: ASTM D-3359 Result: 1050 psi
   FLEXIBILITY – Method:  ASTM D-522 (Cylindrical Mandrel) Passes
   HARDNESS – Method: ASTM D-3363 (Pencil) 2H
   SALT SPRAY – Method: ASTM B-117 Result: Passes 400 hrs
   HUMIDITY – Method: ASTM D-4585 , 100º F,2000 hours
         Result: Passes, no cracking or delamination
   IMPACT RESISTANCE  - Method: ASTM D-2794 Direct 160 in lbs
   COLOR RETENTION – ASTM D 2244 Result: 1.5∆E after 5 year (Based on inorganic resins)
   CHALK RESISTANCE – ASTM D 4214 Result; None
   GLOSS RETENTION – ASTM D 523 Result: Maximum 30 degree loss 5 years
   XENON ARC TEST: ASTM D 4798 Result: Pass 300 hours

3.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

4.     Duncan Thermoset 5SM carries a five year warranty per the performance specifications referenced above.

2.09         HIGH-PERFORMANCE THERMOSETTING BASED ULTRA-DURABLE COATING - DUNCAN THERMOSET 10 SM

A.       High-Performance Thermosetting Based Super-Durable Coating over Aluminum

           Duncan Thermoset 10SM matching approved samples.

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ADHESION – Method: ASTM D-3359 Result: 1050 psi
   FLEXIBILITY – Method:  ASTM D-522 (Cylindrical Mandrel) Passes
   HARDNESS – Method: ASTM D-3363 (Pencil) 2H
   SALT SPRAY – Method: ASTM B-117 Result: Passes 400 hrs
   HUMIDITY – Method: ASTM D-4585 , 100º F,2000 hours
         Result: Passes, no cracking or delamination
   IMPACT RESISTANCE  - Method: ASTM D-2794 Direct 160 in lbs
   COLOR RETENTION – ASTM D 2244 Result: 3∆E after 10 year (Based on inorganic resins)
   CHALK RESISTANCE – ASTM D 4214 Result; None
   GLOSS RETENTION – ASTM D 523 Result: Maximum 45 degree loss 10 years
   XENON ARC TEST: ASTM D 4798 Result: Pass 400 hours

3.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

4.     Duncan Thermoset 10SM carries a ten year warranty per the performance specifications referenced above.

2.10         HIGH-PERFORMANCE THERMOSETTING BASED HYPER-DURABLE COATING - DUNCAN THERMOSET 15 SM

A.       High-Performance Thermosetting Based Super-Durable Coating over Aluminum

           Duncan Thermoset 15SM matching approved samples.

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ADHESION – Method: ASTM D-3359 Result: 1050 psi
   FLEXIBILITY – Method:  ASTM D-522 (Cylindrical Mandrel) Passes
   HARDNESS – Method: ASTM D-3363 (Pencil) 2H
   SALT SPRAY – Method: ASTM B-117 Result: Passes 400 hrs
   HUMIDITY – Method: ASTM D-4585 , 100º F,2000 hours
   Result: Passes, no cracking or delamination
   IMPACT RESISTANCE  - Method: ASTM D-2794 Direct 160 in lbs
   COLOR RETENTION – ASTM D 2244 Result: 3∆E after 15 years (Based on inorganic resins)
   CHALK RESISTANCE – ASTM D 4214 Result; None
   GLOSS RETENTION – ASTM D 523 Result: Maximum 45 degree loss 15 years
   XENON ARC TEST: ASTM D 4798 Result: Pass 400 hours

3.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

4.     Duncan Thermoset 15SM carries a fifteen year warranty per the performance specifications referenced above.

2.11         HOT-DIP GALVANIZING AND FACTORY-APPLIED THERMOSETTING BASED PRIMER – DUNCAN PRIMERGALV THERMOSETSM

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel and other earthly materials.

B.       Factory-Applied Primer:  Provide factory-applied prime coat, Primergalv by Duncan Galvanizing, certified VOC compliant, conforming to applicable regulations and EPA standards.  Apply primer within 12 hours after galvanizing at the same facility where the galvanizing is done in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer.  Blast cleaning of the surface is unacceptable for surface preparation.

C.       Performance Criteria: Coatings must meet or exceed the following performance criteria:

  stipulated by the coatings manufacturer:

  ABRASION RESISTANCE - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).1kg load
       Result: 200 mg loss
  ADHESION - Method: ASTM      D4541 Result: 1050 psi
  CORROSION WEATHERING: Method: ASTM D5894, 13 cycles, 4,368 hours
         Result: Rating 10 per ASTM D714 for blistering; Rating: 7 per ASTM D610 for rusting
  DIRECT IMPACT RESISTANCE: Method: ASTM D2794  Result: 160 in. lbs.
  FLEXIBILITY: Method: ASTM D522, 180º bend, 1” mandrel Result: Passes
  PENCIL HARDNESS: Method: ASTM D3363  Result: 3B
  MOISTURE CONDENSATION RESISTANCE: Method: ASTM D4585, 100º F,2000 hours
         Result: Passes, no cracking or delamination
  DRY HEAT RESISTANCE: Method: ASTM D2485  Result: 250º F

2.12         HOT DIP GALVANIZING AND HIGH PERFORMANCE THERMOSETTING BASED DURABLE COATING - DUNCAN COLORGALV THERMOSET SM

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv® by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel, and other earthly materials.

B.       Duncan Colorgalv ThermoseT SM matching approved samples.

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ADHESION – Method: ASTM D-3359
   FLEXIBILITY – Method:  ASTM D-522 (Cylindrical Mandrel)
   HARDNESS – Method: ASTM D-3363 (Pencil)
   HUMIDITY – Method: ASTM D-4585
   IMPACT RESISTANCE  - Method: ASTM D-2794
   COLOR RETENTION – AAMA 2603-02 No change 1 year

3.     Galvanizer shall create a profile on the surface to provide adhesion for the Duncan Thermoset.

4.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

5.      Duncan Colorgalv ThermosetSM carries a 20 year warranty against 10% or more visible rust. 

2.13         HOT DIP GALVANIZING WITH THERMOSETTING BASED TIE COAT AND HIGH PERFORMANCE THERMOSETTING BASED SUPER-DURABLE COATING - DUNCAN COLORGALV THERMOSET 5 SM

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv® by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel, and other earthly materials.

B.       Duncan Colorgalv Thermoset 5 SM matching approved samples.

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ADHESION – Method: ASTM D-3359 Result: 1050 psi
   FLEXIBILITY – Method:  ASTM D-522 (Cylindrical Mandrel) Passes
   HARDNESS – Method: ASTM D-3363 (Pencil) 2H
   SALT SPRAY – Method: ASTM B-117 Result: Passes 400 hrs
   HUMIDITY – Method: ASTM D-4585 , 100º F,2000 hours
         Result: Passes, no cracking or delamination
   IMPACT RESISTANCE  - Method: ASTM D-2794 Direct 160 in lbs
   COLOR RETENTION – ASTM D 2244 Result 1.5∆E after 5 year (Based on inorganic resins)
   CHALK RESISTANCE – ASTM D 4214 Result; None
   GLOSS RETENTION – ASTM D 523 Result: Maximum 30 degree loss 5 years
   XENON ARC TEST: ASTM D 4798 Result: Pass 300 hours

3.     Galvanizer shall create a profile on the surface to provide adhesion for the Duncan Thermoset 5.

4.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

5.     Duncan Colorgalv Thermoset 5SM carries a 20 year warranty against 10% or more visible rust and a 5 year warranty against coating failure per the performance specifications referenced above.

2.14         HOT DIP GALVANIZING AND HIGH PERFORMANCE ULTRA-DURABLE COATING - DUNCAN COLORGALV THERMOSET 10 SM

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv® by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel, and other earthly materials.

B.       Duncan Colorgalv Thermoset 10  matching approved samples.

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ADHESION – Method: ASTM D-3359 Result: 1050 psi
   FLEXIBILITY – Method:  ASTM D-522 (Cylindrical Mandrel) Passes
   HARDNESS – Method: ASTM D-3363 (Pencil) 2H
   SALT SPRAY – Method: ASTM B-117 Result: Passes 400 hrs
   HUMIDITY – Method: ASTM D-4585 , 100º F,2000 hours
         Result: Passes, no cracking or delamination
   IMPACT RESISTANCE  - Method: ASTM D-2794 Direct 160 in lbs
   COLOR RETENTION – ASTM D 2244 Result: 3∆E after 10 years (Based on inorganic resins)
   CHALK RESISTANCE – ASTM D 4214 Result; None
   GLOSS RETENTION – ASTM D 523 Result: Maximum 45 degree loss 10 years
   XENON ARC TEST: ASTM D 4798 Result: Pass 400 hours

3.     Galvanizer shall create a profile on the surface to provide adhesion for the Duncan Thermoset 10.

4.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

5.     Duncan Colorgalv Thermoset 10SM carries a 20 year warranty against 10% or more visible rust and a 10 year warranty against coating failure per the performance specifications referenced above.

2.15         HOT DIP GALVANIZING AND HIGH PERFORMANCE ULTRA-DURABLE COATING - DUNCAN COLORGALV THERMOSET 15SM

A.       Hot-Dip Galvanizing:  Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv® by Duncan Galvanizing.  Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.  Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc, nickel, and other earthly materials.

B.       Duncan Colorgalv Thermoset 15  matching approved samples.

1.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.

2.     Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

   ADHESION – Method: ASTM D-3359 Result: 1050 psi
   FLEXIBILITY – Method:  ASTM D-522 (Cylindrical Mandrel) Passes
   HARDNESS – Method: ASTM D-3363 (Pencil) 2H
   SALT SPRAY – Method: ASTM B-117 Result: Passes 400 hrs
   HUMIDITY – Method: ASTM D-4585 , 100º F,2000 hours
         Result: Passes, no cracking or delamination
   IMPACT RESISTANCE  - Method: ASTM D-2794 Direct 160 in lbs
   COLOR RETENTION – ASTM D 2244 Result: 3∆E after 15 years (Based on inorganic resins)
   XENON ARC TEST: ASTM D 4798 Result: Pass 400 hours

3.     Galvanizer shall create a profile on the surface to provide adhesion for the Duncan Thermoset 15.

4.     All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification.

5.     Duncan Colorgalv Thermoset 15SM carries a 20 year warranty against 10% or more visible rust and a 15 year warranty against coating failure per the performance specifications referenced above.

PART 3 - EXECUTION

3.01         APPLICATION OF FACTORY-APPLIED METAL COATINGS

A.       Galvanizing Application:  Galvanize materials in accordance with specified standards and this specification. Galvanizing shall provide an acceptable substrate for applied coatings.  The dry kettle process shall be used to eliminate any flux inclusions on the surface of the galvanized material.

B.       Prior to galvanizing, the steel shall be immersed in a pre flux solution (zinc ammonium chloride). The pre flux tank must be 12 to 14 Baumé and contain less than 0.4 percent iron. The wet kettle process shall be prohibited.

C.       To provide the galvanized surface required, the following procedures shall be implemented:

1.     A monitoring recorder shall be utilized and inspected regularly to observe any variances in the galvanizing bath temperature.

2.     The pickling tanks shall contain hydrochloric acid with an iron content less than 8 percent and zinc content less than 3 percent.  Titrations shall be taken weekly at a minimum. 

3.     All chemicals and zinc will be tested at least once a week to determine compliance with ASTM standards. All testing will be done using atomic absorption spectrometry or x-ray fluorescence (XRF) equipment at a lab in the galvanizing plant.

D.       Finish coatings shall be applied under the following conditions.

1.     Minimum air temperature shall be 65 degrees F. Surface temperature of steel shall be 60 degrees to 95 degrees F and, in any event, be 5 degrees F higher than the dew point.  Humidity shall be 85 percent maximum.

2.     The use of iron or steel shot and sand and aluminum oxide grit as a blast medium, and power wire brushes are not permitted.

3.     Surface of substrate shall be dry and free from dust, dirt, oil, grease or other contaminants. Coating and cure facility shall be maintained free of airborne dust and dirt until coatings are completely cured.

3.02         INSTALLATION

A.       Installation:  Comply with fabricator's and galvanizer's requirements for installation of materials and fabrications, including use of nylon slings or padded cables for handling factory-coated materials.

B.       Touch-Up and Repair:  For damaged and field-welded metal coated surfaces, clean welds, bolted connections and abraded areas. 

1.     For galvanized surfaces, apply organic zinc repair paint complying with requirements of ASTM A 780, modified to 95 percent zinc in dry film.  Galvanizing repair paint shall have 95 percent zinc by weight, ZiRP by Duncan Galvanizing.  Thickness of applied galvanizing repair paint shall be not less than coating thickness required by ASTM A 123 or A 153 as applicable.  Touch-up of galvanized surfaces with silver paint, brite paint, or aluminum paints is not acceptable.

2      For factory-applied finish coatings, field-touch-up shall be performed by factory approved personnel for warranties to apply. Touch-up shall be such that repair is not visible from a distance of 6 feet. If non factory-approved technicians are used for field touch-up, no warranties shall exist.

3      A touch-up repair kit or touchup instructions shall be provided to the Owner for each type of factory-applied finish.

END OF SECTION



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