SECTION 05080

FACTORY-APPLIED METAL COATINGS

SECTION 05080

FACTORY-APPLIED METAL COATINGS

PART 1 GENERAL

1.01 SECTION INCLUDES

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

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

1.     Hot-dip galvanizing - Duragalv℠
2.     Hot-dip galvanizing and factory-applied polymer coating - Colorshield℠
3.     Hot-dip galvanizing and factory-applied primer - Primergalv®
4.     Hot-dip galvanizing and factory-applied architectural finish - Colorgalv®
5.     Hot-dip galvanizing and factory-applied architectural finish with clearcoat - Colorgalv Clearcoat®
6.     High-performance thermosetting based coating for uncoated steel - Duncan Thermoset℠
7.     Hot-dip galvanizing and high-performance thermosetting based coating - Duncan Colorgalv Thermoset℠
8.     Hot-dip galvanizing, thermosetting based tie-coat, and high-performance thermosetting based topcoat - Duncan Colorgalv Thermoset 5℠
9.     Hot-dip galvanizing, thermosetting based tie-coat, thermosetting based color coat and high-performance clear topcoat - Duncan Colorgalv Thermoset 10℠
10.   Hot-dip galvanizing and high-performance fluoropolymer based coating - Duncan Colorgalv Thermoset 20℠

1.02 RELATED SECTIONS

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

1.     Section 02800 - Site Improvements.
2.     Section 03300 - Cast-In-Place Concrete.
3.     Section 04200 - Unit Masonry.
4.     Section 05120 - Structural Steel.
5.     Section 05300 - Metal Decking.
6.     Section 05500 - Metal Fabrications.
7.     Section 07700 - Roof Specialties.
8.     Section 08410 - Aluminum Entrances and Storefront; fluoropolymer finishes.
9.     Section 08520 - Aluminum Windows; fluoropolymer finishes.
10.   Section 08900 - Curtain Wall Systems; fluoropolymer finishes.
11.   Section 10200 - Aluminum Louvers; fluoropolymer finishes.
12.   Section 10350 - Flagpoles.
13.   Section 10430 - Exterior Signage.
14.   Section 13120 - Pre-Engineered Buildings.
15.   Section 15400 - Plumbing.
16.   Section 15500 - HVAC.
17.   Section 16000 - Electrical.

1.03 SUBMITTALS

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

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

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

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

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

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

F. Substitutions shall not be considered unless approved by Architect, Owner/Owner's Representative, and Contractor.Substitution requests shall be accompanied by proof that the substitution meets or exceeds the performance, aesthetic and durability requirements of the specified Duncan process. Coatings not matching approved submittals shall be removed and replaced at no additional expense to the Owner.

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

1.04 QUALITY ASSURANCE

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

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

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

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

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

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

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

PART 2 – PRODUCTS

2.01 APPLICATOR

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

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

1.     Hot-dip galvanizing - Duragalv℠
2.     Hot-dip galvanizing and factory-applied polymer coating - Colorshield®
3.     Hot-dip galvanizing and factory-applied primer - Primergalv®
4.     Hot-dip galvanizing and factory-applied architectural finish - Colorgalv®
5.     Hot-dip galvanizing and factory-applied architectural finish with clearcoat - Duncan Clearcoat℠
6.     High-performance thermosetting based coating for uncoated steel - Duncan Thermoset℠
7.     Hot-dip galvanizing and high-performance thermosetting based coating - Duncan Colorgalv Thermoset℠
8.     Hot-dip galvanizing, thermosetting based tie-coat, and high-performance thermosetting based topcoat - Duncan Colorgalv Thermoset 5℠
9.     Hot-dip galvanizing, thermosetting based tie-coat, thermosetting based color coat and high-performance clear topcoat - Duncan Colorgalv Thermoset 10℠
10.   Hot-dip galvanizing and high-performance fluoropolymer based coating - Duncan Colorgalv Thermoset 20℠

2.02 HOT-DIP GALVANIZING - DURAGALV

2.03 HOT-DIP GALVANIZING AND FACTORY-APPLIED POLYMER FINISH-COLORSHIELD

A. Hot-Dip Galvanizing: Provide coating for iron and steel fabrications applied by the hot-dip process, Duragalv by Duncan Galvanizing. Comply with ASTM A 123 for fabricated products and ASTM A 153 for hardware. Provide thickness of galvanizing specified in referenced standards. The galvanizing bath shall contain special high grade zinc and other earthly materials. Galvanizing shall exhibit a rugosity (smoothness) not greater than 4 rug (16-20 microns of variation) when measured by a profilometer over a 1 inch straight line on the surface of architectural and structural elements that are less than 24 pounds per running foot. Profilometer shall be capable of operating in 1 micron increments.

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

B.       Factory-Applied Polymer Finish: Duncan Colorshield by Duncan Galvanizing, matching approved samples. Finish coating shall be applied within 12 hours of galvanizing in the same facility as the galvanizing.
1.      Surface of galvanized material shall be prepared by mechanical means so as to provide an architectural substrate which is free from runs, drips, spikes or other formations detrimental to the physical appearance.
2.      Topcoat shall be factory-applied color-pigmented, multi-component polymer, 1 - 5 g/m2 film thickness depending upon finish effect. 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 and coating within the same facility and provide single-source        responsibility for galvanizing and finish coating.
5.      Blast cleaning of the galvanized surface is not acceptable.

C.       Quality Assurance for Hot-Dip Galvanizing and Factory-Applied Metal Coatings:
1.     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.
2.     Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.
3.     Submit two 3 inch by 6 inch samples of factory-applied coatings and colors proposed for use for approval prior to coating application.
4.     Substitution requests shall be accompanied by samples and coating manufacturer's written certification that coatings proposed for use will have the same appearance and service life as the specified coatings.
5.     Handle and install materials with factory-applied coatings as recommended by galvanizer and coating manufacturer to prevent damage to coatings prior to and after installation.
6.     Touch-up factory-applied metal coatings as recommended by galvanizer and coating manufacturer.
7.     Coatings not matching approved submittals shall be removed and replaced at no additional expense to the Owner.

2.04 HOT-DIP GALVANIZING AND FACTORY-APPLIED "WET or "DRY" PRIMER - PRIMERGALV

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

C. Performance Criteria: Coatings must meet or exceed the following performance criteria:
ABRASION - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).
ADHESION - Method: ASTM D 3359, (Method B, 5 mm Crosshatch).
HUMIDITY - Method: ASTM D 4585.
SALT SPRAY (FOG) - Method: ASTM B 117.

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

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

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

1.     Primer coat shall be factory-applied prime coating. Apply primer within 12 hours after galvanizing at the same facility where the galvanizing is done in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer.
2.     Finish coat shall be factory-applied high performance architectural finish. Apply finish coating at the galvanizer’s plant, in a controlled environment meeting applicable environmental regulations and as recommended by the finish coating manufacturer.
3.     Coatings shall be certified VOC compliant and conform to applicable regulations and EPA standards.
4.     Apply the galvanizing, primer and coating within the same facility and provide single-source responsibility for galvanizing, priming and finish coating.
5.     Blast cleaning of the galvanized surface is not acceptable.

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

1.      Primer:
ABRASION - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).
ADHESION - Method: ASTM D 3359, (Method B, 5 mm Crosshatch).
HUMIDITY - Method: ASTM D 4585
SALT SPRAY (FOG) - Method: ASTM B 117
2.      Topcoat:
ABRASION - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).
ADHESION - Method: ASTM D 3359, (Method B, 5 mm Crosshatch).
GRAFFITI RESISTANCE - Method: The following graffiti materials applied to coating and allowed to dry for seven days: acrylic, epoxy-ester and alkyd spray paints, ballpoint ink, crayon, Markett marker, black shoe polish and lipstick.
EXTERIOR EXPOSURE - Method: Exposed at 45 degrees facing south
SURFACE BURNING CHARACTERISTICS: - Method: ASTM E-84
QUV - Method: ASTM G 53 (ES-40 bulbs, 4 hours light, 4 hours dark)
SALT SPRAY (FOG) - Method: ASTM B 117
FLEXIBILITY
PENCIL HARDNESS
3.      Duncan warrants the Colorgalv process to be free from rust for a period of twenty (20)    years. Warranties for fading or discoloration of the finish shall be that which is supplied       by the coating manufacturer.

2.06 HOT-DIP GALVANIZING AND FACTORY-APPLIED ARCHITECTURAL FINISH WITH CLEARCOAT - COLORGALV CLEARCOAT

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

1.     Primer coat shall be factory-applied prime coat. Apply primer within 12 hours after galvanizing at the same facility where the galvanizing is done in a controlled environment meeting applicable environmental regulations and as recommended by the primer coating manufacturer.
2.     Finish coat shall be factory-applied color-pigmented architectural finish. Apply finish coating at the galvanizer’s plant, in a controlled environment meeting applicable environmental regulations and as recommended by the finish coating manufacturer.
3.     Coatings shall be certified VOC compliant and conform to applicable regulations and EPA standards.
4.     Apply the galvanizing, primer and coating within the same facility and provide single-source responsibility for galvanizing, priming and finish coating.
5.     Blast cleaning of the galvanized surface is not acceptable.

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

1. Primer:
ABRASION - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).
ADHESION - Method: ASTM D 3359, (Method B, 5 mm Crosshatch).
HUMIDITY - Method: ASTM D 4585
SALT SPRAY (FOG) - Method: ASTM B 117
PENCIL HARDNESS
FLEXIBILITY
2. Topcoat:
ABRASION - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).
ADHESION - Method: ASTM D 3359, (Method B, 5 mm Crosshatch).
GRAFFITI RESISTANCE - Method: The following graffiti materials applied to coating and allowed to dry for seven days: acrylic, epoxy-ester and alkyd spray paints, ballpoint ink, crayon, Markett marker, black shoe polish and lipstick.
EXTERIOR EXPOSURE - Method: Exposed at 45 degrees facing south
SURFACE BURNING CHARACTERISTICS: - Method: ASTM E-84
QUV - Method: ASTM G 53 (ES-40 bulbs, 4 hours light, 4 hours dark)
SALT SPRAY (FOG) - Method: ASTM B 117
PENCIL HARDNESS
FLEXIBILITY

D. Clearcoat: Provide factory-applied clear coating over primed and coated galvanized steel, Duncan Clearcoat℠ by Duncan Galvanizing.

1. Performance Criteria: Coatings must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
ABRASION - Method: ASTM D 4060 (CS17 Wheel, 1,000 grams load).
ADHESION - Method: ASTM D 3359, (Method B, 5 mm Crosshatch).
GRAFFITI RESISTANCE - Method: The following graffiti materials applied to coating and allowed to dry for seven days: acrylic, epoxy-ester and alkyd spray paints, ballpoint ink, crayon, Markett marker, black shoe polish and lipstick.
WEATHERING: - Method: ASTM D 1014, 45 degrees south; Method: ASTM D 4141C EMMAQUA-NTW
QUV - Method: ASTM G 53 (FS-40 bulbs, 4 hours light, 4 hours dark)
SALT SPRAY (FOG) - Method: ASTM B 117
FLEXIBILITY – Method: ASTM D 522 (Method B, Cylindrical Mandrel)
HARDNESS: Method: ASTM D 3363 (Pencil)

2.07 HIGH-PERFORMANCE THERMOSETTING BASED COATING - DUNCAN THERMOSET

A. High-Performance Thermosetting Based Coating over Black (Uncoated) Steel
Duncan Thermoset℠ matching approved samples.

1.      Factory-applied metal coatings shall be performed in a facility acceptable to the coating manufacturer.
2.      Performance Criteria: Coating must meet or exceed the criteria for the following categories as stipulated by the coatings manufacturer:
ADHESION – Method: ASTM D-3359
FLEXIBILITY – Method: ASTM D-522 (Cylindrical Mandrel)
HARDNESS – Method: ASTM D-3363 (Pencil)
SALT SPRAY – Method: ASTM B-117
HUMIDITY – Method: ASTM D-4585
IMPACT RESISTANCE - Method: ASTM D-2794
3.      Galvanizer shall create a 1-3 mil profile on the surface to provide adhesion for the Duncan Thermoset℠. Surface 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 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.      All coating material shall be force cured in a calibrated oven capable of maintaining 500 degrees F.

2.08 HOT DIP GALVANIZING AND HIGH PERFORMANCE THERMOSETTING BASED TOPCOAT - DUNCAN COLORGALV THERMOSET

B. Duncan Colorgalv Thermoset matching approved samples.

2.09 HOT DIP GALVANIZING WITH THERMOSETTING BASED TIE COAT AND HIGH PERFORMANCE THERMOSETTING BASED TOPCOAT - DUNCAN COLORGALV THERMOSET 5

B. Tie-Coat:

1.      Shall be applied over a clean, dry substrate, free from any contaminants or oxidation at the same facility as the galvanizing.
2.      Film Thickness shall be 2.4 - 2.6 mils.
3.      Performance Criteria: Coating must meet or exceed the following performance criteria:
CROSS HATCH ADHESION – Method: ASTM D-3359/ISO 2409: Pass 100%
MANDREL BENDING TEST – Method: ASTM D-522/ISO 1519: 5/32in./4mm (3/16 in./5mm)
IMPACT TEST 1/10 in. - Method: Distortion ISO 6272 ASTM D-2794-90: Up to 40 in./lbs
CUPPING: Method-ISO 1520: 5/16 in./mm (3/16 in./5mm)

C. Duncan Colorgalv Thermoset 5℠ matching approved samples.

2.10 HOT DIP GALVANIZING WITH THERMOSETTING BASED TIE COAT, THERMOSETTING BASED COLOR COAT AND HIGH PERFORMANCE CLEAR TOPCOAT - DUNCAN COLORGALV THERMOSET 10

B. Tie-Coat:

C. Duncan Colorgalv Thermoset 10℠ matching approved samples.

D. Clearcoat: Provide factory-applied clear coat over coated steel Duncan Clearcoat℠ by Duncan Galvanizing.

1. Performance Criteria: Coatings must meet or exceed the following performance criteria:
GLOSS - Method: ASTM D 523)
ADHESION - Method: ASTM D 3359, (Method 5B, Crosshatch).
IMPACT TEST - Method: ASTM D 2794
SALT SPRAY (FOG) - Method: ASTM B 117
HUMIDITY RESISTANCE – Method: ASTM D 2247
HARDNESS: Method: ASTM D 3363 (Pencil)

2.11 HOT DIP GALVANIZING AND HIGH PERFORMANCE FLUOROPOLYMER BASED COATING - DUNCAN COLORGALV THERMOSET 20

B. Duncan Colorgalv Thermoset 20℠ a Fluoropolymer based resin matching approved samples.

PART 3 - EXECUTION

3.01 APPLICATION OF FACTORY-APPLIED METAL COATINGS

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

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

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

1.     A monitoring recorder shall be utilized and inspected regularly to observe any variances in the galvanizing bath temperature.
2.     The pickling tanks shall contain hydrochloric acid with a constant range between 10 - 14 percent, iron content less than 8 percent and zinc content less than 3 percent. Titrations shall be taken weekly at a minimum.
3.     All chemicals and zinc will be tested at least once a week to determine compliance with ASTM standards. All testing will be done using atomic absorption spectrometry equipment at a lab in the galvanizing plant.

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

1.     Minimum air temperature shall be 65 degrees F. Surface temperature of steel shall be 60 degrees to 95 degrees F and, in any event, be 5 degrees F higher than the dew point. Humidity shall be 85 percent maximum.
2.     The use of iron or steel shot and sand and aluminum oxide grit as a blast medium, and power wire brushes are not permitted.
3.     Surface of substrate shall be dry and free from dust, dirt, oil, grease or other contaminants. Coating and cure facility shall be maintained free of airborne dust and dirt until coatings are completely cured.

3.02 INSTALLATION

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

1. Coatings not matching approved submittals shall be removed and replaced with specified material at no additional expense to the Owner.

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

1.     For galvanized surfaces, apply organic zinc repair paint complying with requirements of ASTM A 780, modified to 95 percent zinc in dry film. Galvanizing repair paint shall have 95 percent zinc by weight, ZiRP by Duncan Galvanizing. Thickness of applied galvanizing repair paint shall be not less than coating thickness required by ASTM A 123 or A 153 as applicable. Touch-up of galvanized surfaces with silver paint, brite paint, or aluminum paints is not acceptable.
2      For factory-applied finish coatings, the applicator shall be responsible for field-touch-up for up to 1 percent of the surface area at no additional expense to the Owner. Provide touch-up such that repair is not visible from a distance of 6 feet.
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

Duncan Galvanizing

1-800-638-1011

SECTION 05080