PUBLIC SECTOR Modifications

A. This Section specifies hot-dip galvanizing for all miscellaneous and structural steel exposed to the weather, moisture, or corrosive atmosphere including but not limited to the following:

1. Structural steel where indicated on the Drawings and in these Specifications.
2. Lintels.
3. Relieving angles.
4. Handrails/handicap railings.
5. Grating.
6. Stair stringers and steps.
7. Miscellaneous and ornamental iron consisting of fences, tree guards, benches, trash containers, and other landscape type structures.
8. Sign/map board supports.
9. Curb angles.
10. Light poles.
11. Items identified in other Sections of these Specifications.

B. Definitions

1. Hot-Dip Galvanizing: The dipping of steel members and assemblies into an alloy of molten special high grade zinc and other earthly materials for lasting long-term protection.
2. The resultant zinc alloys with the base metal.

A. Comply with applicable portions of the following reference standards:

1. American Galvanizers Association Inc. (AGA) : Publication entitled "Inspection Manual for Hot-Dip Galvanized Products."
2. American Society for Testing and Materials (ASTM):

   a. A123 - Zinc (Hot Galvanized) Coating on Products Fabricated from Rolled, Pressed, and Forged Steel Shapes, Plates, and Hardware.
   b. A153 - Zinc Coating (Hot Dip) on Iron and Steel Hardware.
   c. A143 - Safeguarding Against Embrittlement.
   d. A384 - Safeguarding Against Warpage.
   e. A385 - Providing High Quality Zinc Coatings.
   f. A780 - Repair of Hot-Dip Galvanizing.

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

1. Verification Sample: Provide verification sample to Authority for approval of surface texture and color prior to full fabrication and production. Direct fabricator to provide galvanizer with sample of actual material to receive hot-dip galvanizing and shop applied finish coating. Direct galvanizer to hot-dip galvanize and finish sample in selected color.

B. Certificate of Compliance from Galvanizer: Submit notarized Certificate of Compliance with application for payment for galvanizing, signed by galvanizer, indicating compliance with requirements of specifications. Include scope of services provided, and quantity and itemized description of items processed.

C. Visual Stamp: The galvanizer shall mark all lots of material with a clearly visible stamp or tag indicating the name of the galvanizer, the weight of the zinc coating, and the applicable ASTM Specification Numbers.

A. Pre-Construction Conference for Metal Fabrications: Contractor shall schedule a meeting to be attended by Contractor, Authority, fabricator, and galvanizer. Agenda shall include the following: Project schedule, scope of metal fabrications, coordination between fabricator and galvanizer, finish of surfaces, application of coatings, submittals, color matching, and approvals.

B. Coordination Between Fabricator and Galvanizer: Prior to fabrication, direct fabricator to submit approved shop drawings to the galvanizer for all fabrications. 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 done by the fabricator.

C. Steel Materials: For steel to be hot-dip galvanized, provide steel chemically suitable for metal coatings complying with the following requirements: Carbon below 0.25 percent, silicon below 0.24 percent, phosphorous below 0.05 percent, and manganese below 1.35 percent. Notify galvanizer is steel does not comply with these requirements to determine suitability for processing.

1. To prevent unnecessary damage to the galvanized coating by field welding, provide slip fit method of connecting pipe railings. Fabricate pipe railing from mechanical steel tubing internally vented with holes 3/4 the size of the pipe's internal diameter. For other fabrications, bolted connections shall be used wherever possible.
2. Assemblies: Where size of assembly is too large for galvanizing kettle, galvanize components prior to fabrication and assemble after galvanizing.

D. Engage the service of a galvanizer who has demonstrated a minimum of five (5) years experience in the successful performance of the processes outlined in this specification in the facility where the work is to be done and who will apply the galvanizing and coatings within the same facility as outlined herein. The Authority has the right to inspect and approve or reject the galvanizer/ galvanizing facility.

E. The galvanizer/galvanizing facility must have an ongoing Quality Control/Quality Assurance program acceptable to the Authority which has been in effect for a minimum of five years and shall provide the Authority with process and final inspection documentation.

F. The galvanizer/galvanizing facility must have an on-premise testing facility capable of measuring the chemical and metallurgical composition of the galvanizing bath and pickling tanks.

G. In process paint application shall be monitored with a wet film gage and the measurements recorded. Dry film thickness measurement shall be by Tooke Gage and Magnetic Coating Thickness gage.

H. Provide and apply materials complying with environmental requirements of authority having jurisdiction. All materials shall be delivered to the galvanizer with label or product data sheet affixed to the manufacturer's containers showing the manufacturer's name, batch number, type of paint, stock number, label analysis of solids and vehicle, reducing and thinning instructions, drying and recoat time, MSDS sheets, recommended application procedures and environmental restrictions. Paint materials shall be stored in an acceptable location reserved only for such materials and related equipment in compliance with applicable local health and fire regulations and OSHA requirements.

I. The galvanizer/galvanizing facility must have a dedicated, on premise painting and curing facility for the exclusive use of coating galvanized steel. Said facility shall utilize the following:

1. Recording hygrometer to measure air temperature and humidity.
2. A spray booth confirming OSHA regulations with filtered exhaust.
3. A convection hot air curing system with solvent vapor removal liability.
4. The curing booth shall be heated using an indirect thermostat controlled gas fired forced hot air blower. The booth shall be protected with a sprinkler system complying with NFPA 15. The air in the curing booth shall be continuously monitored by a lower explosive limit (LEL) monitoring device connected to the ventilation system. The booth shall be capable of reaching 150o F with a sustained capability of 100o F.

A.  For the purpose of establishing a standard of quality and performance, the Duragalv system as provided by Duncan Galvanizing of Everett, MA is referenced.

A. Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv by Duncan Galvanizing, Comply with ASTM A123 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.

B. If, for any reason, the galvanizing item is to be primed (for future field painting or finish coated), the coatings shall be applied by the galvanizer at same facility, within 12 hours of galvanizing, in accordance with Section 09910.

C. Field priming of hot dip galvanizing will not be permitted.

D. Safeguard against embrittlement in conformance with ASTM A143.

E. Warpage or Distortion Prevention:

1. To safeguard against warpage or distortion of steel members, in conformance with ASTM A384, steel fabricator shall submit shop drawings of non-standard fabrications, all tubular fabrications, all fabrications involving any dimension which exceeds the size of the galvanizer's kettle, and any fabrication involving materials of different thicknesses.
2. Submit these drawings to the galvanizer before fabrication to determine the suitability of the material for galvanizing.

F. To prevent unnecessary damage to the finished coating by field welding,use bolted connections for field connections wherever possible.

G. To ensure a smooth even coating, pipe rails should be fabricated from mechanical steel tubing with "slip fit" type connections.

A. Galvanize materials in accordance with referenced standards and this specification.

B. Galvanizing shall provide an acceptable substrate for applied coatings.

C. The dry kettle process shall be used to eliminate any flux inclusions on the surface of the galvanized material. Prior to galvanizing, the steel shall be immersed in a pre flux solution (zinc ammonium chloride). The pre flux tanks must be 12o to 14o Baume' and contain less than .4% iron. The wet kettle process shall be prohibited.

D. 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 a constant rang between 10-14%, iron content less than 8% and zinc content less than 3%. Titrations shall be taken weekly at a minimum.
3. Rinse tanks, for the removal of cleaning chemicals, shall contain water.
4. Water quenching of galvanized steel shall be prohibited.

E. 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-primed or factory-finished materials.

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

1. At galvanized surfaces, apply organic zinc repair paint complying with requirements of ASTM A780. 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 ASTM A123 or A153 ass applicable. Touch-up of galvanized surfaces with aerosol spray, silver paint, bright paint, brite paint, or aluminum paints is not acceptable.
2. At factory-primed or factory-finished surfaces, touch-up finish in conformance with manufacturer's recommendations. Provide touch-up such that repair is not visible from a distance of 6 feet.
3. The galvanizer/galvanizing facility must have an ongoing touch-up and repair program acceptable to the Authority which has been in effect for a minimum of five years.
4. A touch-up repair kit shall be provided with each order.

Measurement for hot-dip galvanizing will be measured as being included in the contract lump sum or unit price for said item.

Hot-Dip galvanizing will be paid for at the Contract price as specified above.

A. This Section specifies requirements for furnishing and applying shop-applied paint on structural steel, miscellaneous and ornamental metal which is exposed to view and is hot-dipped galvanized, as defined in Section 05041, including requirements for substrate surface preparation and related activities.

A. Abbreviations:

1. SSPC - Steel Structures Painting Council.
2. NFPA - National Fire Protection Association.
3. OSHA - Occupational Safety and Health Administration.

B. Quality Control:

1. Requirements of Regulatory Agencies: Provide and apply materials complying with environmental requirements of authority having jurisdiction.
2. Required Conference: Arrange a conference to be attended by interested parties, including the Engineer, galvanizer, and others whose installed work is specified to be coated under this Section for the purpose to discuss conditions, interrelated responsibilities, application and inspection procedures, specification requirements, and other related matters with intention of avoiding misunderstandings and disputes during progress of the Work.
3. Tolerances:
   a. Thickness: Apply coating of specified dry film thickness (DFT) where the thickness shall be absolute minimum coverage at any point of measurement.

C. Mock-Up Surface Areas: Sample item may be designated as control for color, texture, and application for each paint system with the accepted item used as criteria for similar items, which shall match accepted mock-ups.

D. Certificates:

1. Provide certificates listing materials used in coating systems and certify compliance with standards designated.
2. Provide certificates stating that materials provided comply with requirements of this Section.

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

1. Verification Sample: Provide verification sample to Authority for approval of surface texture and color prior to full fabrication and production. Direct fabricator to provide galvanizer with sample of actual material to receive hot-dip galvanizing and shop applied finish coating. Direct galvanizer to hot-dip galvanize and finish sample in selected color.
2. This section will be for final finish coating only.

B. Certificates: Submit notarized certificates complying with requirements of this Section.   

A. Deliver paint materials to galvanizer with label or product data sheet affixed to the manufacturer's containers showing manufacturer's name, type of paint, stock number, batch number, label analysis of solids and vehicle, reducing instructions, thinning instructions, drying and recoat time, application instructions with recommended methods, environmental restrictions, MSDS sheets, and Paint System Number assigned in Material Schedule of this Section.

B. Remove permanently from premises containers without labels or illegibly defaced labels.

C. Store paint materials in an accepted location reserved only for such materials and related equipment in compliance with applicable health and fire regulations of authorities having jurisdiction.

D. Any containers showing damage to the extent that spillage of contents is visible shall be rejected and removed permanently from the site.

A. Apply primer hot-dip galvanizing within 12 hours after galvanizing in the galvanizer's facility in accordance with specified requirements and recommendations of galvanizer.

B. The primer and topcoat shall be applied under the following conditions:

1. Minimum air temperature shall be 65o F. Surface temperature of steel shall be 60o - 90o F and, in any event, be 5o F higher than the dew point. Humidity shall be 85% maximum.
2. Surface steel 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. The primer shall be applied by way of a plural component airless spray over a consistent surface profile, 1.5 mil minimum. The profile shall be measured and permanently recorded with Test-Tex tape.
4. The use of iron or steel shot and sand and aluminum oxide grit as a blast medium, and power wire brushes are not permitted.

C. Provide and apply materials complying with environmental requirements of authority having jurisdiction. All materials shall be delivered to the galvanizer with label or product data sheet affixed to the manufacturer's containers showing the manufacturer's name, batch number, type of paint, stock number, label analysis of solids and vehicle, reducing and thinning instructions, drying and recoat time, MSDS sheets, recommended application procedures and environmental restrictions. Paint materials shall be stored in an accepted location reserved only for such materials and related equipment in compliance with applicable local health and fire regulations and OSHA requirements.

D. The galvanizer/galvanizing facility must have a dedicated, on-premise painting and curing facility for the exclusive use of coating galvanized steel. Said facility shall utilize the following:

1. Recording hygrometer to measure air temperature and humidity.
2. A spray booth conforming to OSHA regulations with filtered exhaust.
3. A convection hot air curing system with solvent vapor removal ability.
4. The curing booth shall be heated using an indirect thermostat controlled gas fired forced hot air blower. The booth shall be protected with a sprinkler system complying with NFPA 15. The air in the curing booth shall be continuously monitored by a lower explosive limit (LEL) monitoring device connected to the ventilation system. The booth shall be capable of reaching 150o F with a sustained capability of 100o F.

A. For the purpose of establishing a standard of quality and performance, the Duragalv®, Primergalv® and Colorgalv® systems as provided by Duncan Galvanizing of Everett, MA are referenced.

A. Provide coating for iron and steel fabrications applied by the hot-dip process. Duragalv® by Duncan Galvanizing as referenced in Section 05041. Comply with ASTM A123 for fabricated products and ASTM A153 for hardware. Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc.

A. Provide factory-applied polyamide epoxy primer, 3.0 mils dry film thickness minimum, Primergalv® by Duncan Galvanizing. Apply primer within 12 hours after galvanizing at the galvanizer's plant in a controlled environment meeting applicable environmental regulations and as recommended by coatings manufacturer. Engage the services of a galvanizer who has demonstrated a minimum of five (5) years experience in the successful performance of the processes outlined in this specification in the facility where the work is to be done and who will apply the galvanizing and coating within the same facility as outlined herein.

A. Provide factory-applied architectural coating over primed galvanized steel as previously referenced, Colorgalv® by Duncan Galvanizing. Apply coating at the galvanizer's plant, in a controlled environment meeting applicable environmental regulations. Engage the services of a galvanizer who has demonstrated a minimum of five (5) years experience in the successful performance of the processes outlined in this specification in the facility where the work is to be done and who will apply the galvanizing and coating within the same facility as outlined herein and  will assume single-source responsibility for galvanizing, priming and finish coating.

A. Galvanize materials in accordance with referenced standards and this specification.

B. Galvanizing shall provide an acceptable substrate for applied coatings.

C. The dry kettle process shall be used to eliminate any flux inclusions on the surface of the galvanized material. Prior to galvanizing, the steel shall be immersed in a pre flux solution (zinc ammonium chloride). The pre flux tank must be 12o to 14o Baum/ and contain less than .4% iron. The wet kettle process shall be prohibited.

D. 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 a constant range between 10-14%, iron content less than 8% and zinc content less than 3%. Titrations shall be taken weekly at minimum.
3. Rinse tanks, for the removal of cleaning chemicals, shall contain water.
4. Water quenching of galvanized steel shall be prohibited.

E. The primer and topcoat material shall be certified VOC complaint and conform to all environmental and EPA requirements.

1. The primer shall be a high solid polyamide epoxy applied to a DFT of 3 mils minimum.
2. The topcoat shall be a color pigmented, two-component high build aliphatic polyurethane applied to a DFT of 3 mils minimum.

F.  Provide materials identified and specified by Authority's standards.

G. Apply coating materials to following surfaces as scheduled in Section 05041 and as noted on the Drawings.

A. Prepare surfaces for painting in accordance with the following requirements and applicable standards, as scheduled herein;

1. Hot-dip galvanize in accordance with Section 05041.

B. Apply all coating material of this Section, by the galvanizer in his own facility in strict conformance to requirements as specified in this Section.

C. Curing: Between galvanizing and application of coating materials of this Section, apply coating in min 0 hrs to max. 12 hrs after galvanizing has been applied.

A. Inspection:

1. Measure representative areas for DFT.
2. If thickness of coating does not comply with DFT requirements, apply additional applications of coating to attain specified DFT at no additional cost to Authority.     
3. Where characteristics of coating prohibit recoating, remove and replace unacceptable coating.
4. Where application of coating exceeds DFT and is considered detrimental to quality of Project, remove and recoat to specified DFT at no additional cost to Authority.
5. Where measurement DFT is impractical or impossible, determine the amount of coating necessary from manufacturer's published spreading rate calculated to specified DFT.
6. The manufacturer's stock and batch number will be compared with the assigned Paint System Number with color sample submitted for finished surfaces, and with mock-up for finished surfaces in accordance with requirements of this Section.

B. 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-primed or factory-finished materials.

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

1. At galvanized surfaces, apply organic zinc repair paint complying with requirements of ASTM A780. 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 A123 or A153 as applicable. Touch-up of galvanized surfaces with aerosol spray, silver paint, bright paint, brite paint, or aluminum paints is not acceptable.
2. At factory-primed or factory-finished surfaces, touch-up finish in conformance with manufacturer's recommendations. Provide touch-up such that repair is not visible from a distance of 6 feet.
3. The galvanizer/galvanizing facility must have an ongoing touch-up and repair program acceptable to the Authority which has been in effect for a minimum of five years.
4. A touch up repair kit shall be provided with each order.

If the primer is to be applied in the field the following  paragraph should be inserted into Section 09900-Painting. Generally, it will appear in Part 3-Execution in Paragraph 3.5-Prime coats:

Where ferrous metals are indicated to receive a field applied prime coat, the primer shall be applied after fabrication and within twelve hours after blasting and surface preparation to prevent rust from re-forming on the steel. In order to achieve adequate film build on the corners and edges, the fabricator/paint contractor shall prepare the corners and edges of all WF members by the common shop grinding practice of "breaking the edge" (i.e. MR-1 or 1/16th inch flat). Where hot dip galvanizing is used as the prime coat, the requirement for grinding is not necessary.

Measurement for galvanizing and painting of surfaces or items according to the paint systems specified will be measured as being included in the Contract lump sum of price for said item.

Painting of surfaces will be paid for at the Contract prices determined as specified above.