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These specifications are intended for use in Project Manuals organized according to CSI Masterformat. They are suitable for public-bid and private-bid projects.

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The coating systems described in Paragraph 1.1A are described in greater detail in Part 2 of this Section.

SECTION 050513

FACTORY-APPLIED COATINGS FOR METAL

PART 1 GENERAL

1.1 SECTION INCLUDES

A. This Section specifies factory-applied metal coatings including the following:

  1. Hot-dip galvanizing for iron and steel fabrications. (Duragalv®)
  2. Hot-dip galvanizing and factory-applied primer for iron and steel fabrications. (Primergalv®)
  3. Hot-dip galvanizing and factory-applied architectural finish for iron and steel fabrications. (Colorgalv®)
  4. Hot-dip galvanizing and factory-applied high-performance architectural finish for iron and steel fabrications. (Colorgalv® 10)
  5. High-performance thermosetting based durable coating for use over interior uncoated steel, interior aluminum and exterior aluminum fabrications. (Duncan Primer ThermosetSM)
  6. High-performance thermosetting based coating for use over interior uncoated steel and interior aluminum fabrications. (Duncan ThermosetSM)
  7. High-performance thermosetting based durable coating for exterior aluminum fabrications. (Duncan Thermoset 5SM)
  8. High-performance thermosetting based super-durable coating for exterior aluminum fabrications. (Duncan Thermoset 10SM)
  9. High-performance thermosetting based hyper-durable coating for exterior aluminum fabrications. (Duncan Thermoset 15SM)
  10. Hot-dip galvanizing and high performance thermosetting based, factory applied primer for exterior iron and steel fabrications. (Duncan Primergalv ThermosetSM)
  11. Hot-dip galvanizing and high-performance thermosetting based coating for exterior iron and steel fabrications. (Duncan Colorgalv ThermosetSM)
  12. Hot-dip galvanizing and high-performance thermosetting based durable coating for exterior iron and steel fabrications. (Duncan Colorgalv Thermoset 5SM)
  13. Hot-dip galvanizing and high-performance thermosetting based super-durable coating for exterior iron and steel fabrications. (Duncan Colorgalv Thermoset 10SM)
  14. Hot-dip galvanizing and high-performance thermosetting based hyper-durable coating for exterior iron and steel fabrications. (Duncan Colorgalv Thermoset 15SM)

1.2 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 033000 - Cast-In-Place Concrete.
  2. Section 042000 - Unit Masonry.
  3. Section 051200 - Structural Steel Framing.
  4. Section 053000 - Metal Decking.
  5. Section 055000 - Metal Fabrications.
  6. Section 055100 - Metal Stairs.
  7. Section 055200 - Metal Railings.
  8. Section 055900 - Metal Specialties.
  9. Section 057000 - Decorative Metal.
  10. Section 077100 - Roof Specialties.
  11. Section 107000 - Exterior Specialties.
  12. Section 107500 - Flagpoles.
  13. Section 129300 - Site Furnishings.
  14. Section 323000 - Site Improvements.
  15. Section 323100 - Fences and Gates

1.3 SUBMITTALS

  1. Product Literature: Submit galvanizer’s product literature for coatings specified in this Section indicating type of product and performance criteria.
  2. 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.
  3. 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.
  4. 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.
  5. 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.
  6. Galvanizer/applicator shall supply a certificate of compliance that all coatings have been performed in accordance with SSPC Qualification Procedure Standard QP 3.
  7. Substitutions: If substitutions or other products are proposed, submit this specification signed by the firm proposing the other products, indication line-by-line comparison of the proposed substitution or equal product with test results. Substitutions proposed with comparison test results will not be accepted.

1.4 QUALITY ASSURANCE

  1. 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.
  2. 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.
  3. 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.
  4. 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. Surface blasting prior to application of factory-applied post galvanizing wet coatings will produce a high rugosity and not be acceptable.
  5. 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.

PART 2 – PRODUCTS

2.0 COATING APPLICATOR

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

2.1 HOT-DIP GALVANIZING - DURAGALV®

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A. Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.

  1. Basis-of-Design: Duragalv by Duncan Galvanizing.
  2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
  3. Provide thickness of galvanizing specified in referenced standards.
  4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
  5. Fill vent holes after galvanizing, if applicable, and grind smooth.

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

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  1. Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.
    1. Basis-of-Design: Duragalv by Duncan Galvanizing.
    2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
    3. Provide thickness of galvanizing specified in referenced standards.
    4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
    5. Fill vent holes after galvanizing, if applicable, and grind smooth.
  2. Factory-Applied Primer over Galvanized Steel: Provide factory-applied prime coat, certified OTC/VOC compliant less than 2.8 lbs/gal. and conforming to EPA and local requirements. Apply primer within 12 hours after galvanizing at the same galvanizer’s plant in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer. Primer coat 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. Blast cleaning of the surface is unacceptable for surface preparation. Primer shall have a minimum two year re-coat window for application of finish coat. Coatings must meet or exceed the following performance criteria as stipulated by the coatings manufacturer:
    1. Basis-of-Design: Primergalv by Duncan Galvanizing.
    2. Abrasion Resistance: ASTM D 4060 (CS17 Wheel, 1,000 grams load).1kg load, 200 mg loss.
    3. Adhesion: ASTM D4541, 1050 psi.
    4. Corrosion Weathering: ASTM D5894, 13 cycles, 4,368 hours; rating 10 per ASTM D714 for blistering and rating 7 per ASTM D610 for rusting.
    5. Direct Impact Resistance: ASTM D2794, 160 in. lbs.
    6. Flexibility: Method: ASTM D522, 180 degree bend, 1 inch mandrel, passes.
    7. Pencil Hardness: ASTM D3363, 3B.
    8. Moisture Condensation Resistance: ASTM D4585, 100 degrees F, 2000 hours; passes, no cracking or delamination.
    9. Dry Heat Resistance: Method: ASTM D2485, 250 degrees F.
    10. Warranty: Provide galvanizer’s warranty that materials will be free from 10 percent or more visible rust for a period of 20 years.

2.3 HOT-DIP GALVANIZING AND FACTORY-APPLIED ARCHITECTURAL FINISH - COLORGALV®

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  1. Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.
    1. Basis-of-Design: Duragalv by Duncan Galvanizing.
    2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
    3. Provide thickness of galvanizing specified in referenced standards.
    4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
    5. Fill vent holes after galvanizing, if applicable, and grind smooth.
  2. Factory-Applied Architectural Finish Over Galvanized Steel: Provide factory-applied architectural coating over hot-dip galvanized steel matching approved samples.
    1. Basis-of-Design: Colorgalv by Duncan Galvanizing.
    2. Primer coat shall be factory-applied polyamide epoxy primer. Apply primer within 12 hours after galvanizing at the same galvanizer’s plant in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer.
    3. 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. Finish coat 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.
    4. Coatings shall be certified OTC/VOC compliant and conform to applicable regulations and EPA standards.
    5. Apply the galvanizing, primer, and coating within the same facility and provide single-source responsibility for galvanizing, priming and finish coating.
    6. Clean galvanized surface to create an acceptable profile for coatings. Galvanizer shall certify that performance will be met without blast cleaning and coating will be applied within 12 hours of galvanizing at the galvanizer’s plant. If blasted, galvanizer shall certify that rugosity standards are met.
    7. Primer shall meet or exceed the following performance criteria:
      1. Abrasion Resistance per ASTM D 4060 (CS17 Wheel, 1,000 grams load),1kg Load: 200 mg loss.
      2. Adhesion per ASTM D4541: 1050 psi.
      3. Corrosion Weathering per ASTM D5894, 13 Cycles, 4,368 Hours: Rating 10 per ASTM D714 for blistering; Rating 7 per ASTM D610 for rusting.
      4. Direct Impact Resistance per ASTM D2794: 160 in. lbs.
      5. Flexibility per ASTM D522, 180º Bend, 1 in. Mandrel: Passes.
      6. Pencil Hardness per ASTM D3363: 3B.
      7. Moisture Condensation Resistance per ASTM D4585, 100º F, 2000 Hours: Passes, no cracking or delamination.
      8. Dry Heat Resistance per ASTM D2485: 250º F.
    8. Topcoat shall meet or exceed the following performance criteria:
      1. Abrasion Resistance per ASTM D 4060, CS17 Wheel, 1,000 Cycles 1kg Load: 87.1 mg loss.
      2. Adhesion per ASTM D 4541: 1050 psi.
      3. Direct Impact Resistance per ASTM D2794: >28 in. pounds.
      4. Indirect Impact Resistance per ASTM D2794: 12-14 in. pounds.
      5. Dry Heat Resistance per ASTM D2485: 200° F.
      6. Salt Fog Resistance per ASTM B 117 9,000 Hours: Rating 10 per ASTM D714 for blistering.
      7. Flexibility per ASTM D522, 180° Bend, 1/8 in. Mandrel: Passes.
      8. Pencil Hardness per ASTM D3363: 2H.
      9. Moisture Condensation Resistance per ASTM D4585, 100° F, 1000 Hours: No blistering or delamination Xenon Arc Test per ASTM D 4798: Pass 300 hours

2.4 HOT-DIP GALVANIZING AND FACTORY-APPLIED HIGH-PERFORMANCE ARCHITECTURAL FINISH - COLORGALV 10®

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  1. Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.
    1. Basis-of-Design: Duragalv by Duncan Galvanizing.
    2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
    3. Provide thickness of galvanizing specified in referenced standards.
    4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
    5. Fill vent holes after galvanizing, if applicable, and grind smooth.
  2. Factory-Applied High-Performance Architectural Finish: Provide factory-applied architectural coating over hot-dip galvanized steel, matching approved samples.
    1. Basis-of-Design: Colorgalv® 10 by Duncan Galvanizing.
    2. Primer coat shall be factory-applied. Apply primer within 12 hours after galvanizing and within 3 hours of surface preparation 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. Primer must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
      1. Abrasion Resistance: ASTM D4060 (CS17 Wheel, 1,000 grams load) 1kg load, 200 mg loss.
      2. Adhesion: ASTM D4541, 1050 psi.
      3. Corrosion Weathering: ASTM D5894, 13 cycles, 4,368 hours; rating 10 per ASTM D714 for blistering and rating 7 per ASTM D610 for rusting.
      4. Direct Impact Resistance: ASTM D2794, 160 in. lbs.
      5. Flexibility: Method: ASTM D522, 180 degree bend, 1 inch mandrel, passes.
      6. Pencil Hardness: ASTM D3363, 3B.
      7. Moisture Condensation Resistance: ASTM D4585, 100 degrees F, 2000 hours; passes, no cracking or delamination.
      8. Dry Heat Resistance: Method: ASTM D2485, 250 degrees F.
    3. 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. Finish must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
      1. Abrasion Resistance: ASTM D 4060, CS17 Wheel, 1,000 cycles 1kg load, 87.1 mg loss.
      2. Adhesion: ASTM D4541, 1050 psi.
      3. Direct Impact Resistance: ASTM D2794, greater than 28 in. pounds.
      4. Indirect Impact Resistance: ASTM D2794, 12-14 in. pounds.
      5. Dry Heat Resistance: ASTM D2485, 200 degrees F.
      6. Salt Fog Resistance: ASTM B117 9,000 hours, rating 10 per ASTM D714 for blistering.
      7. Flexibility: ASTM D522, 180 degree bend, 1/8 inch mandrel, passes.
      8. Pencil Hardness: ASTM D3363, 2H.
      9. Moisture Condensation Resistance: ASTM D4585, 100 degrees F, 1000 hours, no blistering or delamination.
      10. Xenon Arc Test: ASTM D 4798, pass 300 hours.
    4. Coatings shall be certified VOC compliant and conform to applicable regulations and EPA standards. Apply the galvanizing, primer and coating within the same facility and provide single-source responsibility for galvanizing, priming and finish coating. Blast cleaning of the galvanized surface is not acceptable.
    5. Warranty: Duncan warrants the Colorgalv 10 process to be free from 10 percent or more visible rust for a period of twenty years. Warranties for the finish shall be ten 10years in accordance with the performance specifications referenced above.

2.5 HIGH-PERFORMANCE THERMOSETTING BASED PRIMER - DUNCAN PRIMER THERMOSETSM

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A. High-Performance Thermosetting Primer for Use Over Interior “Black” (Uncoated) Steel and Interior Aluminum: Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

  1. Basis-of-Design: Duncan Primer ThermosetSM by Duncan Galvanizing.
  2. Abrasion Resistance: ASTM D4060 (CS17 Wheel, 1,000 grams load) 1kg load, 200 mg loss.
  3. Adhesion: ASTM D4541, 1050 psi.
  4. Corrosion Weathering: ASTM D5894, 13 cycles, 4,368 hours, rating 10 per ASTM D714 for blistering, 7 per ASTM D610 for rusting.
  5. Direct Impact Resistance: ASTM D2794, 160 in. lbs.
  6. Flexibility: ASTM D522, 180 degree bend, 1 inch mandrel, passes.
  7. Pencil Hardness: ASTM D3363, 3B.
  8. Moisture Condensation Resistance: ASTM D4585, 100 degrees F, 2000 hours, passes, no cracking or delamination.
  9. Dry Heat Resistance: ASTM D2485, 250 degrees F.

2.6 HIGH-PERFORMANCE THERMOSETTING BASED COATING - DUNCAN THERMOSETSM

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A. High-Performance Thermosetting Based Coating for Use Over Interior “Black” (Uncoated) Steel and Interior Aluminum: Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

  1. Basis-of-Design: Duncan ThermosetSM by Duncan Galvanizing.
  2. Adhesion: ASTM D4541, 1050 psi.
  3. Flexibility: ASTM D522 (Cylindrical Mandrel), passes.
  4. Hardness: ASTM D 3363 (Pencil), 2H.
  5. Salt Spray: ASTM B117, passes 400 hrs.
  6. Humidity: ASTM D4585 , 100º F, 2000 hours, passes, no cracking or delamination.
  7. Impact Resistance: ASTM D2794, direct 120 in lbs.
  8. Color Retention: ASTM D 2244, 5 delta E after 1 year (based on inorganic resins).
  9. Chalk Resistance: ASTM D 4214, #8 rating.
  10. Gloss Retention: ASTM D 523, no loss 1 year.
  11. Xenon Arc Test: ASTM D 4798, pass 200 hours.
  12. Warranty: Warranties for fading or discoloration of the finish shall be that which is supplied by the coating manufacturer.

2.7 HIGH-PERFORMANCE THERMOSETTING BASED DURABLE COATING - DUNCAN THERMOSET 5SM

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A. High-Performance Thermosetting Based Durable Coating on Exterior Aluminum: Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

  1. Basis-of-Design: Duncan Thermoset 5SM by Duncan Galvanizing.
  2. Adhesion: ASTM D3359, 1050 psi.
  3. Flexibility: ASTM D522 (Cylindrical Mandrel), passes.
  4. Hardness: ASTM D 3363 (Pencil), 2H.
  5. Salt Spray: ASTM B117, passes 400 hrs.
  6. Humidity: ASTM D4585 , 100º F, 2000 hours, passes, no cracking or delamination.
  7. Impact Resistance: ASTM D2794, direct 120 in lbs.
  8. Color Retention: ASTM D 2244, 5 delta E after 5 years (based on inorganic resins).
  9. Chalk Resistance: ASTM D 4214, #8 rating.
  10. Gloss Retention: ASTM D 523, maximum 50 degree loss after 5 years.
  11. Xenon Arc Test: ASTM D 4798, pass 300 hours.
  12. Warranty: Duncan warrants the finish of the Thermoset 5SM process for a period of five years in accordance with the performance specifications referenced above.

2.8 HIGH-PERFORMANCE THERMOSETTING BASED SUPER DURABLE COATING - DUNCAN THERMOSET 10SM.

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A. High-Performance Thermosetting Based Super Durable Coating on Exterior Aluminum: Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

  1. Basis-of-Design: Duncan Thermoset 10SM by Duncan Galvanizing.
  2. Adhesion: ASTM D3359, 1050 psi.
  3. Flexibility: ASTM D522 (Cylindrical Mandrel), passes.
  4. Hardness: ASTM D 3363 (Pencil), 2H.
  5. Salt Spray: ASTM B117, passes 400 hrs.
  6. Humidity: ASTM D4585, 100º F, 2000 hours, passes, no cracking or delamination.
  7. Impact Resistance: ASTM D2794, direct 120 in lbs.
  8. Color Retention: ASTM D 2244, 5 delta E after 10 years (based on inorganic resins).
  9. Chalk Resistance: ASTM D 4214, #8 rating.
  10. Gloss Retention: ASTM D 523, maximum 50 degree loss after 10 years.
  11. Xenon Arc Test: ASTM D 4798, pass 400 hours.
  12. Warranty: Duncan warrants the finish of the Thermoset 10SM process for a period of ten years in accordance with the performance specifications referenced above.

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

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A. High-Performance Thermosetting Based Hyper-Durable Coating on Exterior Aluminum: Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

  1. Basis-of-Design: Duncan Thermoset 15SM by Duncan Galvanizing.
  2. Adhesion: ASTM D3359, 1050 psi.
  3. Flexibility: ASTM D522 (Cylindrical Mandrel), passes.
  4. Hardness: ASTM D 3363 (Pencil), 2H.
  5. Salt Spray: ASTM B117, passes 400 hrs.
  6. Humidity: ASTM D4585, 100º F, 2000 hours, passes, no cracking or delamination.
  7. Impact Resistance: ASTM D2794, direct 160 in lbs.
  8. Color Retention: ASTM D 2244, 5 delta E after 15 years (based on inorganic resins).
  9. Chalk Resistance: ASTM D 4214, #8 rating
  10. Gloss Retention: ASTM D 523, maximum 50 degree loss after 15 years.
  11. Xenon Arc Test: ASTM D 4798, pass 400 hours.
  12. Warranty: Duncan warrants the finish of the Thermoset 15SM process for a period of fifteen years in accordance with the performance specifications referenced above.

2.10 HOT DIP GALVANIZING AND HIGH PERFORMANCE THERMOSETTING BASED PRIMER - DUNCAN PRIMERGALV THERMOSETSM

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  1. Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.
    1. Basis-of-Design: Duragalv by Duncan Galvanizing.
    2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
    3. Provide thickness of galvanizing specified in referenced standards.
    4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
    5. Fill vent holes after galvanizing, if applicable, and grind smooth.
  2. High-Performance Thermosetting Based Primer: Provide coating matching approved samples. Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. Galvanizer shall create a profile on the surface to provide adhesion for the coating. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
    1. Basis-of-Design: Duncan Primergalv Thermoset by Duncan Galvanizing.
    2. Abrasion Resistance: ASTM D4060 (CS17 Wheel, 1,000 grams load) 1kg load, 200 mg loss.
    3. Adhesion: ASTM D4541, 1050 psi.
    4. Corrosion Weathering: ASTM D5894, 13 cycles, 4,368 hours, rating 10 per ASTM D714 for blistering, 7 per ASTM D610 for rusting.
    5. Direct Impact Resistance: ASTM D2794, 120 in. lbs.
    6. Flexibility: ASTM D522, 180 degree bend, 1 inch mandrel, passes.
    7. Pencil Hardness: ASTM D3363, 3B.
    8. Moisture Condensation Resistance: ASTM D4585, 100 degrees F, 2000 hours, passes, no cracking or delamination.
    9. Dry Heat Resistance: ASTM D2485, 250 degrees F.
    10. Warranty: Provide 20 year warranty against 10 percent or more visible rust.

2.11 HOT DIP GALVANIZING AND HIGH PERFORMANCE THERMOSETTING BASED COATING - DUNCAN COLORGALV THERMOSETSM

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  1. . Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.
    1. Basis-of-Design: Duragalv by Duncan Galvanizing.
    2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
    3. Provide thickness of galvanizing specified in referenced standards.
    4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
    5. Fill vent holes after galvanizing, if applicable, and grind smooth.
  2. High-Performance Thermosetting Based Coating: Provide coating matching approved samples. Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. Galvanizer shall create a profile on the surface to provide adhesion for the coating. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
    1. Basis-of-Design: Duncan Colorgalv ThermosetSM by Duncan Galvanizing.
    2. Adhesion: ASTM D3359 Result: 1050 psi.
    3. Flexibility: ASTM D522 (Cylindrical Mandrel), passes.
    4. Hardness: ASTM D3363 (Pencil), 2H.
    5. Salt Spray: ASTM B117, passes 400 hrs.
    6. Humidity: ASTM D4585 , 100º F,2000 hours, passes, no cracking or delamination.
    7. Impact Resistance: ASTM D2794, direct 160 in lbs.
    8. Color Retention: ASTM D2244, 5 delta E after 1 year (based on inorganic resins).
    9. Chalk Resistance: ASTM D4214, minimal.
    10. Gloss Retention: ASTM D 523, minimal.
    11. Xenon Arc Test: ASTM D 4798, passes 200 hours.
    12. Warranty: Provide 20 year warranty against 10 percent or more visible rust. Warranties for fading or discoloration of the finish shall be that which is supplied by the coating manufacturer.

2.12 HOT DIP GALVANIZING AND THERMOSETTING BASED HIGH PERFORMANCE DURABLE TOPCOAT - DUNCAN COLORGALV THERMOSET 5SM.

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  1. Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.
    1. Basis-of-Design: Duragalv by Duncan Galvanizing.
    2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
    3. Provide thickness of galvanizing specified in referenced standards.
    4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
    5. Fill vent holes after galvanizing, if applicable, and grind smooth.
  2. High-Performance Durable Coating: Provide coating matching approved samples. Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. Galvanizer shall create a profile on the surface to provide adhesion for the coating. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
    1. Basis-of-Design: Duncan Colorgalv Thermoset 5SM by Duncan Galvanizing.
    2. Adhesion: ASTM D3359 Result: 1050 psi.
    3. Flexibility: ASTM D522 (Cylindrical Mandrel), passes.
    4. Hardness: ASTM D3363 (Pencil), 2H.
    5. Salt Spray: ASTM B117, passes 400 hrs.
    6. Humidity: ASTM D4585 , 100º F, 2000 hours, passes, no cracking or delamination.
    7. Impact Resistance: ASTM D2794, direct 120 in lbs.
    8. Color Retention: ASTM D2244, 5 delta E after 15 years (based on inorganic resins).
    9. Chalk Resistance: ASTM D4214, #8 rating.
    10. Gloss Retention: ASTM D 523, maximum 30 degree loss 5 years.
    11. Xenon Arc Test: ASTM D 4798, passes 300 hours.
    12. Warranty: Provide a 20 year warranty against rust and 5 year warranty against coating failure per the performance specifications referenced above.

2.13 HOT DIP GALVANIZING AND HIGH PERFORMANCE SUPER-DURABLE COATING - DUNCAN COLORGALV THERMOSET 10SM

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  1. Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.
    1. Basis-of-Design: Duragalv by Duncan Galvanizing.
    2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
    3. Provide thickness of galvanizing specified in referenced standards.
    4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
    5. Fill vent holes after galvanizing, if applicable, and grind smooth.
  2. High-Performance Super-Durable Coating: Provide coating matching approved samples. Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. Galvanizer shall create a profile on the surface to provide adhesion for the coating. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
    1. Basis-of-Design: Duncan Colorgalv Thermoset 10SM by Duncan Galvanizing.
    2. Adhesion: ASTM D3359 Result: 1050 psi.
    3. Flexibility: ASTM D522 (Cylindrical Mandrel), passes.
    4. Hardness: ASTM D3363 (Pencil), 2H.
    5. Salt Spray: ASTM B117, passes 400 hrs.
    6. Humidity: ASTM D4585, 100º F, 2000 hours, passes, no cracking or delamination.
    7. Impact Resistance: ASTM D2794, direct 120 in lbs.
    8. Color Retention: ASTM D2244, 5 delta E after 10 years (based on inorganic resins).
    9. Chalk Resistance: ASTM D4214, #8 rating.
    10. Gloss Retention: ASTM D 523, maximum 50 degree loss 10 years.
    11. Xenon Arc Test: ASTM D 4798, passes 400 hours.
    12. Warranty: Provide a 20 year warranty against rust and 10 year warranty against coating failure per the performance specifications referenced above.

2.14 HOT DIP GALVANIZING AND HIGH PERFORMANCE HYPER-DURABLE COATING - DUNCAN COLORGALV THERMOSET 15SM

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  1. Hot-Dip Galvanizing: For steel exposed to the elements, weather or corrosive environments and other steel indicated to be galvanized, provide coating for iron and steel fabrications applied by the hot-dip process.
    1. Basis-of-Design: Duragalv by Duncan Galvanizing.
    2. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware.
    3. Provide thickness of galvanizing specified in referenced standards.
    4. Galvanizing bath shall contain special high grade zinc and other earthly materials.
    5. Fill vent holes after galvanizing, if applicable, and grind smooth.
  2. High-Performance Hyper-Durable Coating: Provide coating matching approved samples. Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. Galvanizer shall create a profile on the surface to provide adhesion for the coating. All coating material shall be force cured in a calibrated oven capable of maintaining curing temperatures per the coating manufacturer’s specification. Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
    1. Basis-of-Design: Duncan Colorgalv Thermoset 15SM by Duncan Galvanizing.
    2. Adhesion: ASTM D3359 Result: 1050 psi.
    3. Flexibility: ASTM D522 (Cylindrical Mandrel), passes.
    4. Hardness: ASTM D3363 (Pencil), 2H.
    5. Salt Spray: ASTM B117, passes 400 hrs.
    6. Humidity: ASTM D4585 , 100º F,2000 hours, passes, no cracking or delamination.
    7. Impact Resistance: ASTM D2794, direct 120 in lbs.
    8. Color Retention: ASTM D2244, 5 delta E after 15 years (based on inorganic resins).
    9. Chalk Resistance: ASTM D4214, #8 rating
    10. Gloss Retention: ASTM D 523, maximum 50 degree loss 15 years.
    11. Xenon Arc Test: ASTM D 4798, passes 400 hours.
    12. Warranty: Provide a 20 year warranty against rust and 15 year warranty against coating failure per the performance specifications referenced above.

PART 3 - EXECUTION

3.1 APPLICATION OF FACTORY-APPLIED METAL COATINGS

  1. 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.
  2. 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.
  3. 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 shall be tested at least once a week to determine compliance with ASTM standards. All testing shall be done using atomic absorption spectrometry or x-ray fluorescence (XRF) equipment at a lab in the galvanizing plant.
  4. 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.

3.2 INSTALLATION

  1. 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.
  2. 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