Specifications

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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Note: Retain the coatings required for your projects and delete others

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

SECTION 050513

FACTORY-APPLIED COATING 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. Hot-dip galvanizing and factory-applied high-performance fluoropolymer architectural finish for iron and steel fabrications. (Colorgalv 15®)

  6. Hot-dip galvanizing and factory-applied high-performance architectural finish and anti-graffiti finish for iron and steel fabrications.  (Colorgalv® with Anti-Graffiti Protection)

  7. High-performance thermosetting polyester based durable for aluminum and steel fabrications. (Duncan ThermosetSM)

  8. Hot-dip galvanizing and high-performance super durable thermosetting based coating for iron and steel fabrications. (Duncan Colorgalv ThermosetSM)

  9. Hot-dip galvanizing and high-performance fluoropolymer coating for iron and steel fabrications. (Duncan Colorgalv Thermoset 10SM)

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 057000 - Decorative Metal.

  9. Section 077100 - Roof Specialties.

  10. Section 107000 - Exterior Specialties.

  11. Section 107500 - Flagpoles.

  12. Section 129300 - Site Furnishings.

  13. Section 323000 - Site Improvements.

  14. Section 323100 - Fences and Gates.

1.3    SUBMITTAL

A. Product Literature for Factory-Applied Metal Coatings:  Submit galvanizer’s product literature for coatings specified in this Section including test data.

B. Verification Samples for Factory-Applied Metal Coatings:  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.

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 shall 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 standards.  If requested, submit certification of compliance that items have been tagged.

F. Certificate of Compliance for Shop Application:  Galvanizer/applicator shall supply a certificate of compliance with SSPC-QP3 – Certification Standard for Shop Application of Complex Protective Coating Systems.

G. 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

A. Galvanizer’ Qualifications:  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. Coating Applicator’s Qualifications:  Galvanizing and factory-applied coatings 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.

C. 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, color selections, submittals, and approvals.

D. 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. 

E. Environmental Compliance:  Coatings shall be certified OTC/VOC compliant and conform to EPA standards and local regulations.

PART 2 – PRODUCTS

2.1 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.

2.2 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. Fill vent holes after galvanizing, if applicable, and grind smooth.

  5. Galvanizing shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments.

  6. Warranty:  Provide galvanizer’s standard warranty that materials will be free from 10 percent or more visible rust for 20 years.

2.3 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. Galvanizing bath shall contain special high grade zinc and other earthly materials.

    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. Fill vent holes after galvanizing, if applicable, and grind smooth.

    5. Galvanizing shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments.

  2. Factory-Applied Primer over Galvanized Steel: Provide factory-applied prime coat over hot-dipped galvanized steel.

    1. Basis-of-Design: Primergalv by Duncan Galvanizing.

    2. Primer shall be certified OTC/VOC compliant less than 2.8 lbs/gal. and conform 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 shall have a two year re-coat window for application of finish coat.

    3. Primer shall meet or exceed the following performance criteria as stipulated by the coatings manufacturer:

      a. Abrasion Resistance: ASTM D 4060 (CS17 Wheel, 1,000 graps load) 1 kg load, 200 mg loss. 

      b. Adhesion: ASTM D 4541, 1050 psi. 

      c. Corrosion Weathering: ASTM D 5894, 13 cycles, 4,368 hours, 10 per ASTM D 714 for blistering; 7 per ASTM D 610 for rusting. 

      d. Direct Impact Resistance: ASTM D 2794, 160 in. lbs. 

      e. Flexibility: ASTM D 522, 180 degrees bend, 1 inch mandrel, Passes. 

      f. Pencil Hardness: ASTM D 3363, 3H.

      g. Moisture Condensation Resistance: ASTM D 4585, 100 degrees F, 2000 hours, Passes no cracking or delamination. 

      h. Dry Heat Resistance: ASTM D 2485, 250 degrees F. 

      i. Accelerated Weathering: QUV- ASTM D 4587 QUV A 5000 Hours: Passes. 

      j. Salt Fog Resistance: ASTM B 117, 5,600 hours, No cracking or blisters. 

    4. Primer shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments. 

    5. Warranty:  Provide galvanizer’s standard warranty that materials will be free from 10 percent or more visible rust for 20 years.

2.4 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. Galvanizing bath shall contain special high grade zinc and other earthly materials.

    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. Fill vent holes after galvanizing, if applicable, and grind smooth.

    5. Galvanizing shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments.

  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 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.

    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: ASTM D 4060 (CS17 Wheel, 1,000 grams load) 1 kg load, 200 mg loss.

      2. Adhesion: ASTM D 4541, 1050 psi.

      3. Corrosion Weathering: ASTM D 5894, 13 cycles, 4,368 hours, 10 per ASTM D 714 for blistering; 7 per ASTM D 610 for rusting.

      4. Direct Impact Resistance: ASTM D 2794, 160 in. lbs.

      5. Flexibility: ASTM D 522, 180 degrees bend, 1 inch mandrel, Passes.

      6. Pencil Hardness: ASTM D 3363, 3H.

      7. Moisture Condensation Resistance: ASTM D 4585, 100 degrees F, 2000 hours, Passes no cracking or delamination.

      8. Dry Heat Resistance: ASTM D 2485, 250 degrees F.

      9. Accelerated Weathering: QUV- ASTM D 4587 QUV A 5000 Hours: Passes.

      10. Salt Fog Resistance:  ASTM B 117, 5,600 hours No cracking or blisters.

    8. Topcoat shall meet or exceed the following performance criteria:

      1. Abrasion Resistance: ASTM D 4060, CS17 Wheel, 1,000 cycles 1 kg load, 87.1 mg loss.

      2. Adhesion: ASTM D 4541, 1050 psi.

      3. Direct Impact Resistance: ASTM D 2794, greater than 28 in. pounds.

      4. Dry Heat Resistance: ASTM D 2485, 200 degrees F (93 C).

      5. Salt Fog Resistance: ASTM B 117 9,000 hours, Rating 10 per ASTM D 714 for blistering, Rating 9 per ASTM D 610 for rusting.

      6. Flexibility: ASTM D522, 180 degrees bend, 1/8 inch mandrel, Passes.

      7. Pencil Hardness: ASTM D 3363, F.

      8. Moisture Condensation Resistance: ASTM D 4585, 100 degrees F, 1000 hours, No blistering or delamination.

      9. Xenon Arc Test: ASTM D 4798, Pass 200 hours.

      10. Corrosion Weathering: ASTM D 5894, 21 Cycles, 7056 Hours: Rating 10 per ASTM D714 for blistering. Rating 9 Per ASTM D 610 for Rusting.

      11. Thermal Shock: ASTM D 2246, 15 cycles, Excellent.

    9. Topcoat shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments.

    10. Warranty:  Provide galvanizer’s standard warranty that materials will be free from 10 percent or more visible rust for 20 years.

2.5 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. Galvanizing bath shall contain special high grade zinc and other earthly materials.

    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. Fill vent holes after galvanizing, if applicable, and grind smooth.

    5. Galvanizing shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments.

  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 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:

      a. Abrasion Resistance: ASTM D 4060 (CS17 Wheel, 1,000 grams load).1 kg load, 200 mg loss.

      b. Adhesion: ASTM D4541, 1050 psi.

      c. Corrosion Weathering: ASTM D5894, 13 cycles, 4,368 hours; rating 10 per ASTM D714 for blistering and rating 7 per ASTM D610 for rusting.

      d. Direct Impact Resistance: ASTM D2794, 160 in. lbs. 

      e. Flexibility: Method: ASTM D522, 180 degree bend, 1 inch mandrel, passes.

      f. Pencil Hardness: ASTM D3363, 3H.

      g. Moisture Condensation Resistance: ASTM D4585, 100 degrees F, 2000 hours; passes, no cracking or delamination.

      h. Dry Heat Resistance: Method: ASTM D2485, 250 degrees F.

      i.  Accelerated Weathering: QUV ASTM D 4587 QUV A 5000 Hours: Passes.

      j. Salt Fog Resistance:  ASTM B 117, 5,600 hours, No cracking or blisters.

    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:

      a. Abrasion Resistance: ASTM D 4060, CS17 Wheel, 1,000 cycles 1kg load, 154 mg loss.

      b. Adhesion: ASTM D 4541, 1766 psi.

      c. Direct Impact Resistance: ASTM D 2794, 176 in. pounds.

      d. Dry Heat Resistance: ASTM D 2485, 250 degrees F. 

      e. Salt Fog Resistance: ASTM B 117  9,000 hours, Rating 0 per ASTM D714 for blistering, Rating 10 per ASTM D 610 for Rusting.

      f. Flexibility: ASTM D 522, 180 degrees bend, 1/8 inch mandrel, Passes.

      g. Pencil Hardness: ASTM D 3363, HB.

      h. Moisture Condensation Resistance: ASTM D 4585, 100 degrees F, 4000 hours, No rusting, blistering or delaminating.

      i.  Corrosion Weathering: ASTM D 5894, 33  Cycles, 12,531 Hours:  Rating 10 Per ASTM D 714 for blistering. Rating 10 Per ASTM D 610 for Rusting.

      j. Thermal Cycling:  ASTM D 6677, 10 cycles, Excellent.

      k. Fade:  Defined as a loss of gloss in excess of 35 units of gloss, which shall be measured in accordance with ASTM D 523-89 with 60 degrees geometry.

      l. Color Shift:  Not to exceed 15 DE CIE LAB units for whites and light colors.  Dark colors not to exceed 25 DE CIE LAB units (yellows, oranges, and reds are excluded) measured by ASTM D 2244.

    4. Topcoat shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments.

    5. Warranty:  Provide galvanizer’s standard warranty that materials will be free from 10 percent or more visible rust for 20 years.  Warranty for the finish gloss and color shall be 10 years in accordance with the performance specifications referenced.

2.6 HOT-DIP GALVANIZING AND FACTORY-APPLIED ARCHITECTURAL FINISH  - COLORGALV 15® FLUOROPOLYMER

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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. Galvanizing bath shall contain special high grade zinc and other earthly materials.

  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. Fill vent holes after galvanizing, if applicable, and grind smooth.

  5. Galvanizing shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments. 

B. Architectural Finish:  Provide factory-applied architectural coating over hot-dip galvanized steel, Colorgalv 15 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.  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.

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

  1. Primer coat shall be factory-applied. 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. Primer must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

    a. Abrasion Resistance: ASTM D 4060 (CS17 Wheel, 1,000 grams load) 1kg load, 200 mg loss.

    b. Adhesion: ASTM D 4541, 1050 psi.

    c. Corrosion Weathering: ASTM D 5894, 13 cycles, 4,368 hours, Rating 10 per ASTM D 714 for blistering; Rating: 7 per ASTM D 610 for rusting.

    d. Direct Impact Resistance: ASTM D 2794, 160 in. lbs.

    e. Flexibility: ASTM D 522, 180 degrees bend, 1 inch mandrel, Passes.

    f. Pencil Hardness: ASTM D 3363, 3H.

    g. Moisture Condensation Resistance: ASTM D 4585, 100 degrees F, 2000 hours, Passes no cracking or delamination.

    h. Dry Heat Resistance: ASTM D 2485, 250 degrees F.

    i. Accelerated Weathering: QUV ASTM D 4587 QUV A 5000 Hours: Passes.

    j. Salt Fog Resistance:  ASTM B 117, 5,600 hours, No cracking or blisters.

  2. Intermediate Coat:

 

a. Abrasion Resistance: ASTM D 4060, CS17 Wheel, 1,000 cycles 1kg load, 87.1 mg loss.

b. Adhesion: ASTM D 4541, 1050 psi.

c. Direct Impact Resistance: ASTM D 2794, greater than 28 in. pounds.

d. Dry Heat Resistance: ASTM D 2485, 200 degrees F (93 C).

e. Salt Fog Resistance: ASTM B 117 9,000 hours, Rating 10 per ASTM D 714 for blistering, Rating 9 per ASTM D 610 for rusting.

f. Flexibility: ASTM D 522, 180 degrees bend, 1/8 inch mandrel, Passes.

g. Pencil Hardness: ASTM D 3363, F

h. Moisture Condensation Resistance: ASTM D 4585, 100 degrees F, 1000 hours, No blistering or delamination.

i. Xenon Arc Test: ASTM D 4798, Pass 200 hours.

j. Corrosion Weathering:  ASTM D 5894, 21 Cycles, 7056 Hours: Rating 10 Per ASTM D 714 for blistering. Rating 9 Per ASTM D 610 for Rusting.

k. Thermal Shock: ASTM D 2246, 15 cycles, Result - Excellent.

  3. Topcoat:

a. Adhesion: ASTM D 4541, 2,283 psi.

b. Direct Impact Resistance: ASTM G14, 120 in. pounds.

c. Dry Heat Resistance: ASTM D 2485, 200 degrees F.

d. Salt Fog Resistance: ASTM B 117  5,000 hours, Rating 10 per ASTM D 714 for blistering, Rating 10 per ASTM D 610 for Rusting.

e. Flexibility: ASTM D 522, 180 degrees bend, 1/8 inch mandrel, Passes.

f. Pencil Hardness: ASTM D 3363, F-H.

g. Moisture Condensation Resistance: ASTM D4585, 100 degrees F, 5000 hours, No blisters or rust.  No loss of gloss or adhesion.

h. Thermal Shock: 30 cycles, Result- No loss of adhesion, no cracking.

i. Fade:  Defined as a loss of gloss in excess of 20 units of gloss, which shall be measured in accordance with ASTM D 523 with 60 degrees geometry.

j. Color Shift:  Not to exceed 12 DE CIE LAB units for whites and light colors.  (yellows, oranges, and reds are excluded) measured by ASTM D 2244.

  4. Galvanizing and finish coating 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.

 

  5. Warranty:  Provide galvanizer’s standard warranty that materials will be free from 10 percent or more visible rust for 20 years.  Warranty for the finish gloss and color shall be 15 years in accordance with the performance specifications referenced.

2.7 HOT-DIP GALVANIZING AND FACTORY-APPLIED ARCHITECTURAL FINISH - COLORGALV® WITH CLEAR COAT FOR ANTI GRAFFITI PROTECTION

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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. Galvanizing bath shall contain special high grade zinc and other earthly materials.

  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. Fill vent holes after galvanizing, if applicable, and grind smooth.

  5. Galvanizing shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments. 

B. Architectural Finish:  Provide factory-applied architectural coating over hot-dip galvanized steel, Colorgalv with Anti Graffiti Coating 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.  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.

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

  1. Primer coat shall be factory-applied. 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. Primer must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:

    a. Abrasion Resistance: ASTM D 4060 (CS17 Wheel, 1,000 grams load) 1kg load, 200 mg loss.

    b. Adhesion: ASTM D 4541, 1050 psi.

    c. Corrosion Weathering: ASTM D 5894, 13 cycles, 4,368 hours, Rating 10 per ASTM D 714 for blistering; Rating: 7 per ASTM D 610 for rusting.

    d. Direct Impact Resistance: ASTM D 2794, 160 in. lbs.

    e. Flexibility: ASTM D 522, 180 degrees bend, 1 inch mandrel, Passes.

    f. Pencil Hardness: ASTM D 3363, 3H.

    g. Moisture Condensation Resistance: ASTM D 4585, 100 degrees F, 2000 hours, Passes no cracking or delamination.

    h. Dry Heat Resistance: ASTM D 2485, 250 degrees F.

    i. Accelerated Weathering: QUV ASTM D 4587 QUV A 5000 Hours: Passes.

    j. Salt Fog Resistance:  ASTM B 117, 5,600 hours, No cracking or blisters.

  2. Topcoat:

a. Abrasion Resistance: ASTM D 4060, CS17 Wheel, 1,000 cycles 1kg load, 87.1 mg loss.

b. Adhesion: ASTM D 4541, 1050 psi.

c. Direct Impact Resistance: ASTM D 2794, greater than 28 in. pounds.

d. Dry Heat Resistance: ASTM D 2485, 200 degrees F (93 C).

e. Salt Fog Resistance: ASTM B 117 9,000 hours, Rating 10 per ASTM D 714 for blistering, Rating 9 per ASTM D 610 for rusting.

f. Flexibility: ASTM D 522, 180 degrees bend, 1/8 inch mandrel, Passes.

g. Pencil Hardness: ASTM D 3363, F

h. Moisture Condensation Resistance: ASTM D 4585, 100 degrees F, 1000 hours, No blistering or delamination.

i. Xenon Arc Test: ASTM D 4798, Pass 200 hours.

j. Corrosion Weathering:  ASTM D 5894, 21 Cycles, 7056 Hours: Rating 10 Per ASTM D 714 for blistering. Rating 9 Per ASTM D 610 for Rusting.

k. Thermal Shock: ASTM D 2246, 15 cycles, Result - Excellent.

  3. Clear Coat:

a. Abrasion Resistance: ASTM D 4060, CS17 Wheel, 1,000 cycles 1kg load, 55 mg loss

b. Adhesion: ASTM D 4541, 1250 psi.

c. Direct Impact Resistance: ASTM D 2794, 120 in. pounds.

d. Dry Heat Resistance: ASTM D 2485, 200 degrees F (93 C).

e. Salt Fog Resistance: ASTM B 117, 3,000 hours, Passes no blistering or rusting

f. Flexibility: ASTM D 522, 180 degrees bend, 1/8 inch mandrel, Passes.

g. Pencil Hardness: ASTM D 3363, HB.

h. Corrosion Weathering: ASTM D 5894, 9 Cycles, 3000 hours: Result Passes - no blistering, rusting, cracking or delamination.

i. Graffiti Resistance: Graffiti materials applied - epoxy ester spray, acrylic spray, alkyd spray, ballpoint pen ink, crayon, lipstick: All materials were removed easily and completely with either xylene or MEK.

  4. Galvanizing and finish coating 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.

   5. Warranty:  Provide galvanizer’s standard warranty that materials will be free from 10 percent or more visible rust for 20 years.

2.8 HIGH-PERFORMANCE THERMOSETTING POLYESTER 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. Coating shall meet or exceed the following criteria as established by the coating manufacturer.

a. Adhesion: ASTM D3359, no loss.

b. Hardness: ASTM D 3363 (Pencil), F.

c. Falling Sand ASTM D968 20L/mil.

d. Color Retention: ASTM D 2244, 5 year less than or equal to 5 delta E.

e. Chalk Resistance: ASTM D 4214, #8 rating.

f. Gloss Retention: ASTM D 523, greater than or equal to 30% retention.

g. Erosion Resistance: ASTM B 244 <10% film loss.

2.9 HOT DIP GALVANIZING AND HIGH PERFORMANCE SUPER DURABLE THERMOSETTING BASED COATING - DUNCAN COLORGALV THERMOSETSM

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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. Galvanizing bath shall contain special high grade zinc and other earthly materials.

    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. Fill vent holes after galvanizing, if applicable, and grind smooth.
    5. Galvanizing shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments.
B. 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.  Factory applied coating shall include an architectural grade primer. Full cure of the coating system shall be verified by the coating manufacturer’s recommended test methods. Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer. All testing was performed on lab prepared panels.
    1. Basis-of-Design: Duncan Colorgalv ThermosetSM by Duncan Galvanizing.

    2. Coating shall meet or exceed the following criteria as established by the coating manufacturer.

a. Adhesion: ASTM D 3359, no loss.

b. Hardness: ASTM D 3363 (pencil), H min.

c. Falling Sand: ASTM D 968 20L/mil.

d. Salt Spray: ASTM B 117, passes 3000 hrs.

e. Humidity: ASTM D 2247, 3000 hours, few #8 blisters.

f. Impact Resistance (3mm): ASTM D 2794, no loss.

g. Color Retention: ASTM D 2244, 5 year less than or equal to 5 delta E.

h. Chalk Resistance: ASTM D 4214, #8 rating.

i. Gloss Retention: ASTM D 523, greater than or equal to 30 percent retention.

j. Erosion Resistance: ASTM B 244, less than 10 percent film loss.

k. Compliance:  AAMA 2604.

3. Warranty: Provide galvanizer’s standard warranty that materials will befree from 10 percent or more visible rust for 20 years.

2.10 HOT DIP GALVANIZING AND HIGH PERFORMANCE FLUOROPOLYMER COATING - DUNCAN COLORGALV THERMOSET 10SM

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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. Galvanizing bath shall contain special high grade zinc and other earthly materials. 

  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. Fill vent holes after galvanizing, if applicable, and grind smooth.

  5. Galvanizing shall exhibit a rugosity (smoothness) 4 rug or less (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of elements that are less than 24 pounds per running foot.  Profilometer shall be capable of operating in 1 micron increments.

B. High-Performance Fluoropolymer Coating:  Provide coating matching approved samples.  Factory-applied metal coatings shall be applied in a facility acceptable to the coating manufacturer. Factory applied coating shall include an architectural grade primer. Full cure of the coating system shall be verified by the coating manufactures recommended test methods. Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings Manufacture. All testing was performed on lab prepared panels.

  1. Basis-of-Design: Duncan Colorgalv Thermoset 10SM by Duncan Galvanizing.

  2. Coating shall meet or exceed the following criteria as established by the coating manufacturer.

a. Adhesion: ASTM D 3359, no loss.

b. Hardness: ASTM D 3363 (pencil), H min.

c. Falling Sand ASTM D 968 40L/mil.

d. Salt Fog Resistance: ASTM B 117, passes 4000 hrs.

e. Humidity: ASTM D 2247, 4000 hours, few #8 blisters.

f. Impact Resistance (3mm): ASTM D 2794, no loss.

g. Color Retention: ASTM D 2244, 10 year less than or equal to 5 delta E.

h. Chalk Resistance: ASTM D 4214, #8 rating.

i. Gloss Retention: ASTM D 523, greater than or equal to 50 percent retention.

j. Erosion Resistance: ASTM B 244, less than 10 percent film loss.

k. Compliance:  AAMA 2605.

  3. Warranty:  Provide galvanizer’s standard warranty that materials will be free from 10 percent or more visible rust for 20 years.  Warranty for the finish gloss and color shall be 10 years in accordance with the performance specifications referenced.

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 density and contain less than 0.4 percent iron. Use of the wet kettle process is not acceptable. To provide the galvanized surface required, the following procedures shall be implemented:

  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