are protected with phenolic red-lead primer 5/ and phenolic aluminum
topcoats. 6/ The merits of zinc as an economical protective coating
have also been recognized by permitting these small turnout gates to be
galvanized as an alternate to painting, and reports from the projects
near Yuma, Arizona, indicate that zinc coating applied by flame spray
is proving effective in the corrosive waters of the Colorado River.

The exterior of piping to be buried will be in an environment in-
cluding most of the corrosive effects of fresh water immersion. To
this will be added potential damage to the coating from placement of
backfill materials and from subsequent soil stresses when the pipe is
in service. Extensive laboratory tests 7/ were conducted by the Bureau
to ascertain which pipe wrapping systems will provide protection against
damage to the coating from backfill and soil stresses. From these in-
vestigations, the Bureau has concluded that good protection against both
corrosion and damage to the coating can be provided by cement mortar
or coal-tar enamel. The integrity of the coal-tar enamel coating must
be assured by also specifying one or more embedded or bonded wrapping
materials. These includé a glass mat or fabric to be embedded in the
enamel and coal-tar-saturated asbestos felt and Kraft paper outer wraps.

Regarding the above selections, fresh water is considered to be a
generally corrosive medium; however, wide variations in corrosivity
have been encountered in waters of the Bureau of Reclamation area.
Protection of metalwork must be planned for lengthy periods, 50 years
and up, as opposed to the much shorter expected service periods in
other corrosion atmospheres such as in an industrial plant where obso-
lescence is more of a governing factor. To accomplish this protection,
mainly standard specification coatings are used, and the results with
these have been very good. Outstanding among these protective materi-
als are coal-tar enamel and cement mortar, the performance of which up
to the present time has generally been so good as to make their ultimate
service beyond accurate prediction. Among the thin-film paints, vinyl
resin-based paints have shown particularly good protective qualities.

There is, however, much more to effective protection of metalwork
than the selection of paint materials if the best service from the paints
selected is to be realized.

Quality Control

Quality control is an essential feature of the Bureau painting pro-
gram. The Bureau tests the particular batches of paint delivered to the
job site for conformance to the standard specifications. This assures
that the project owner gets what he pays for and is an important phase
of a satisfactory completed paint job.

17



SEALANT TIGHTENS BULLDOZER TRACKS

(An excerpt of an articlé in the June 1959 issue of
Western Construction. Copyright 1959 by King Publi-
cations, 609 Mission St., San Francisco 5, California;
further reproduction is prohibited.)

Keeping pad bolts tight on the tracks of bulldozers is a construc-~
tion job maintenance problem which the Construction Department of the
Merritt-Chapman & Scott Corporation has solved by using a locking
sealant. Ira Davidson, general maintenance superintendent, tried the
new thread-locking sealant on the pads of heavy equipment. Because of
the terrific impact loads experienced while working on rock and frozen
earth, maintenance crews had to retighten the pad nuts and bolts every
two or three weeks. This meant taking the equipment out of service for
half a day while two men tightened each of the 344 nuts and bolts on the
large tracks. Then, Davidson tried the sealant and after twelve weeks
of operation, working 132 hours per week, he found the bolts were
still tight.

These special heat-treated pad bolts are 7/8-inch in diameter,
have a special nut, and cost about $300 per set. Loosening causes ex-
cessive wear on both the bolts and the track rails. Replacement rails
cost from two to three thousand dollars. Merritt-Chapman & Scott use
a grade of the sealant which permits taking up on the nuts should stretch-
ing occur in the bolt.

The method of treating the parts with the sealant is simple. The
nuts and bolts are first soaked for a few minutes in a pail of degreas-
ing solution (Trichloroethylene preferred). After they have dried, the
bolts are inserted in their holes in the track which has been laid out
flat. Then a man with a box of nuts and a plastic squeeze bottle of the
sealant moves along beside the track first treating a nut by squeezing
a drop or two of the sealant into the threads and then applying it to the
bolt. The nut is just given a couple of turns to hold it on until tightened.
After all the nuts are in place, the bolts are tightened with a power im-
pact wrench. The sealant hardens in 3 to 4 hours at 70 degrees F (some-
what longer at lower temperature) after which the nut is locked on the
bolt.

The above method describes treatment of new bolts and nuts dur-
ing track overhaul. Treatment of installed parts is possible provided
bolt threads are clear enough to allow the sealant to penetrate.

Success on the pad bolts has led to the use of the sealant on a
variety of applications on several heavy construction vehicles. It is
being used to retain engine bearings, where wear has caused slippage.
In this application the sealant acts as a "liquid shim" and fills the
clearance between bearing and housing. The sealant is effectively used
to lock in the studs on the differential carrier, the studs which hold the
power take-off and on the track roll bolts. The sealant will lock

11



usually be empty during the winter months. Operations at the Southside
Canal will commence in 1960, and it is planned to inspect the linings
after the first, second, and fourth years of service, and thereafter as
indicated by their condition.

The new Southside Canal test includes 36 different coating systems
employing 42 separate materials (in this case, each combination of
materials applied has been considered a separate coating system; thus,
adjacent coatings may differ only in that a metal conditioner or a spe-
cial primer was used). In all, approximately 22 basic linings are rep-
resented in the 36 coating
systems. The linings were
applied as closely as possi-
ble in accordance with manu-
facturer's instructions and
with his representative on
hand to advise on procedures
and techniques in order to
obtain the best results. The
photograph at left shows test
lining material being applied
by conventional air spraying.
Other materials were applied
by brushing, rolling, and
hand daubing. The thickness
and characteristics of each
coat and the application con-
ditions were recorded, and
the appearance and continu-
ity of the final lining were
noted.

It is interesting to observe
the trend which is evident
in this latest test. In the
Shasta test, nota single
lining included a material
of the multicomponent type,
that is, one which requires
mixing two or more components shortly prior to application, producing
a material with a limited pot life. In the Southside Canal test, 21 systems
had one or more coats of a multicomponent paint. Also, since Shasta,
various new resins and modifications thereof have performed well
enough in laboratory screening tests, or have achieved sufficient prom-
inence in the field to justify inclusion in this field test. In addition to
these, neoprene and chlorinated rubber, aluminum and zinc as sprayed
metals, zinc as the pigment in several paints, vinyl red-lead paint,
and asphalt enamel are represented in the test. By way of providing
"controls" and a comparison of present Bureau coatings for this ex-
posure with those which may someday replace them, Type IV red-lead
and VR-3 vinyl resin paints were also applied, and coal-tar enamel
protects the remainder of the siphon interior.

21


tor in each branch of the air piping.

Portable air tools, with few exceptions, are designed to operate
at 90 psi, gaged at the tool inlet while the machineis operating. This
means that the delivery pressure at the compressor must be greater
than 90 psi to compensate for the unavoidable pressure drop in the air
lines. It also means that all air piping, fittings, and hoses must be of
sufficient size to keep this pressure drop to a minimum.

If the air pressure falls below 90 psiat the toolinlet when the tool
is operating, it is likely that either the compressor is not capable of
delivering the required volume of air or the delivery pressure at the
compressor is not high enough to compensate for the pressure drop.

It is also important to bear in mind that other tools may be oper-
ating from the same air supply. Therefore all tools working off a par-
ticular air supply must be in normal operation if an accurate pressure
check is to be made.

Lubrication

An intelligent automobile owner would not use his car without having
it properly lubricated. An intelligent air tool operator should not try to
operate his equipment, without a similar lubrication.

Special oils are available for lubrication of air tools, and manu-
facturer's recommendations should be followed carefully. These spe-
cial oils have three important functions in addition to the obvious one
of friction reduction between moving parts.

First, oil serves as a sealer between closely fitting parts, limiting
air leakage and increasing efficiency. Second, it acts as a coolant, dis-
sipating heat from high friction surfaces. Third, oil actually absorbs
moisture in the air, forming an emulsion. This action does not interfere
with the oil's lubricating qualities, and rusting is unlikely even though
this emulsified moisture may remain in the tool during long periods of
idleness.

Many air tools have built-in oil reservoirs to provide continuous
lubrication. These should be filled daily, and a small amount of oil
should be poured into the tool's air inlet each morning prior to operation.

It is often difficult to provide adequate supervision to guarantee
that these reservoirs are kept filled. A widely used and highly recom-
mended method of assuring proper air tool lubrication is to install
lubricators in the air line.

These line oilers are available in various capacities and pipe sizes.
Keeping them filled becomes the job of regular maintenance personnel.


Job Site Application Inspection

Proper application of the protective coatings is considered to be at
least as important to corrosion control as paint selection and quality
control, and it is often more difficult to accomplish. Unlike many parts
of construction, the quality of an applied coating may not readily be as-
sessed by a final examination and knowledge of a few readily measured
materials properties. That each step in applying paint has been done
properly must be confirmed at the time, and the Bureau insists on full
specifications compliance at the time the job is accepted. Job site paint-
ing proceeds under such a wide variety of handicaps, such as weather,
accessibility, and shape of the metalwork, that it is sometimes remark-
able that results are as good as they are. Field inspection is the tool
which assures good results.

The Bureau's experience bears out that of others, that quality of
surface preparation is fundamental to the performance of coatings in
fresh water immersion. Paints purporting to immobilize rust by one
means or another have not been proved, to the Bureau's satisfaction at
least, for immersion exposure, and removal of rust, dirt, and mill
scale by sandblasting remains the best field method of surface prepara-
tion. Sandblasting is
considered essential prep-
aration for any continuously
submerged coating. In-
spection of the cleaning by
Bureau personnel at the
site assures that the ''sand-
blasting to base metal" re-
quirement of Bureau spec-
ifications has been met,
thus removing all contami-
nants and providing mechan-
ical "tooth" for adhesion of
the coatings.

Following surface prep-
aration and during applica-
tion of paint, the inspec-
tors make a variety of simple
but important tests, such
as the bond and continuity
testing of coal-tar enamel
and thickness and applica-
tion temperature for all
paints. As shown in the
photograph at left, a surface
temperature gage is being
employed to determine if
the metal surface is above the minimum temperature for painting; this is
one of several essential tests required during application to assure a
sound coating.

18


10.

11.

12.

13.

14,

Method 6061 of Federal Test Method Standard No. 141, Using
the 20% Salt Spray.

Method 6161 of Federal Test Method Standard No. 141, except
that the test is conducted at Denver, Colorado.

Method 6152 of Federal Test Method Standard No. 141.

Bureau of Reclamation Paint Laboratory Report No. P-66, Ero-
sion Studies of Pipe Lining Materials--A Progress Report.

Bureau of Reclamation Protective Coatings Laboratory Report
No. P-58, Experimental Coatings on 30-inch-diameter Pipe

Sections Exposed at Shadow Mountain Reservoir--Second In-
terim Report.

Bureau of Reclamation Paint Laboratory Report No. P-72, Eighth-

year Evaluation of Experimental Test Linings In Shasta Dam
Penstock.

OK KKK

24


during the summer months in the inlet canal and then stored on the
shore for the winter. Considerable information was gained from this
test during 6 years' exposure. 13/ Briefly, some of the more impor-
tant results follow:

1, Coal-tar enamel demonstrated its usual excellent protective
qualities, but did not perform satisfactorily when extreme cold was in-
volved. Hairline cracking was found even in 10-penetration enamel
after several years, and the damage worsened progressively as the
penetration decreased. Considerable portions of enamel, having pene-
tration below 5, disbonded and spalled off during the first winter's ex-
posure, when a temperature of minus 41° F. was recorded. One inter-
esting sidelight was that rusting progressed very slowly and caused
negligible damage to the metal at cracks in the enamel. Nonetheless,
enamel is not considered a suitable coating for the aboveground cold
weather exposures.

2. Cement mortar containing entrained air and applied 1 hour after
mixing withstood the exposure quite well, sustaining only a few hairline
cracks which may have been caused by handling as well as by drying
shrinkage and temperature changes. However, caution is indicated by
the poor performance of another mortar lining tried in this test. This
mix had no air entrainment and exhibited excessive drying shrinkage,
and cracked and spalled severely, failing in less than 2 years.

3. Vinyl polysulfide and neoprene paints have done very well, as
have Bureau of Reclamation specification paints, cold applied coal-tar
paint, CA-50, and VR-6 vinyl resin paint.

The Shadow Mountain test has now been moved to Denver, the ex-
treme low temperature phase having been completed.

Another field test of considerable scope was begun at Shasta Dam
10 years ago. It is planned to inspect these lining materials again
later this year. However, in evaluating the performance of the coat-
ings after 8 years' service, the phenolics and vinyls predominate among
the Class A linings, and coal-tar enamel is so far unaffected by ex-
posure in the remainder of the penstock. 14)

Reminiscent of the extensive Shasta tests in which fairly large
areas of lining materials were applied in the field, and in considera-
tion of the very rapid progress being made these days in the field of
protective coatings, the Bureau has just initiated a sizeable new field
test. During August 1959, 280 linear feet of 6-foot-diameter piping
were lined with experimental materials in the pipe fabricator's plant
in Denver, and were then delivered to the Southside Canal, Collbran
Project, near Grand Junction, Colorado. When installed as part ofa
buried siphon, the piping will be exposed to continuous fresh water
immersion with water velocities up to 8.8 feet per second during the
operating season. It is expected that this portion of the siphon will

20


BARBED WIRE ON 6"

DMC PIPE LINE
CROSSING --------—

DMC PIPE LINE
CROSSING~____
+—TWO PIECE BAND

MAKE-UP EASIER
TO INSTALL AND

FIELD WELD

7-7 MAX. WS.
£

15


SCREW TYPE PARKING STAND
(Suggestion R2-60-40)

The Friant Division of the Fresno Operations Field Branch, Central
Valley Project, California, has several pieces of trailer-mounted equip-
ment that are front-end heavy. This causes unnecessary heavy lifting
and backstrain on the operators when hitching-up or unhitching the
equipment. To overcome this, Frank W. Athos made up some folding
screw-type parking stands for all equipment, one of which is shown in
the photographs below.

The stands are made of
a 1-1/2 inch bolt and nut
enclosed in a slotted 2-1/2
inch pipe, as shown in the
photograph at left. The
nut is welded to a support
plate and one end of the
bolt swivelled to a bottom
plate. The other end runs
through a guide plate at
the top of the 2-1/2 pipe
and a crank is attached.
By turning the crank, the
parking stand will adjust
the tongue to the height
desired.

The entire screw as-
sembly, including the sup-
port plate and guide, are
hinged to the trailer tongue
and positioned by a spring-
loaded pin making it pos-
sible to fold the assembly,
as shown in the lower photo-
graph, and provide clearance
during travel.

The stand incorporates
both mechanical and safety
features. It also is very
useful in the leveling of

ee equipment when it is park-

ed on rough terrain.

For further details of construction, write the Supervisor, Friant
Unit, Fresno Operations Field Branch, Bureau of Reclamation, Fresno,
California, or the Regional Director, Bureau of Reclamation, Sacramento,
California.



cleaning blades. They should never be cleaned with water solutions or
with any strong solvents but merely cleaned with a soft cloth moistened
lightly with kerosene, benzene, or diesel fuel. Deposits can be scraped
or sandpapered off.

Percussion tools such as chipping hammers, clay diggers, and back-
fill tampers should be disassembled and inspected periodically. Tools
used outdoors or stored in unheated areas should be inspected more fre-
quently than others.

Scored cylinders or "sloppy" fitting pistons should be replaced or
reconditioned. Most tool manufacturers either offer reconditioning serv-
ice or they can recommend reputable organizations which will do such
work, The valve parts should be carefully examined for wear, and all
air passages in the handle, valve case and cylinder should be blown clear.

A thorough inspection of the chisel bushing in the nose of the tool is
of particular importance. There are two reasons for replacing a worn
chisel bushing. First, when the chisel is inserted in the bushing, it
closes the lower end of the cylinder. Therefore, the better the fit be-
tween the bushing and the chisel shank, the less air leakage there will
be out the front of the tool on the return stroke. Second, the striking
faces of the piston and the chisel shank must be maintained parallel to
each other to minimize wear in the cylinder and maximize power. This
is impossible if the fit between the bushing and the shank is loose enough
to permit cocking the chisel in the tool.

Just as the use of an ineffective air tool can handicap a worker, so
can an ineffective accessory handicap the tool. Wrench sockets should
be the correct size for the particular nut or bolt and should fit snugly on
the wrench shank. Grinding wheels that are out of round should be
dressed. Wheels that cannot be balanced should be discarded. Hammer
chisel points should be ground to shape frequently, and chisels should be
discarded when the shanks are worn.

The importance of following the manufacturer's recommendations
on the proper maintenance of each tool cannot be over-emphasized. Do
not hesitate to consult a representative of the manufacturer regarding
any maintenance points that may not be completely covered in the in-
struction book that is furnished with the tool.

A thoughtfully planned and scrupulously supervised maintenance
program will improve the productive output of air tools, sharply reduce
downtime, improve safety records, and effect genuine savings in repair
costs.

OK OK OK OK


Where long hose lines are used, line oilers suitable for insertion be-
tween two lengths of hose or for attachment to the tool inlet are avail-
able.

Naturally, a filter or moisture separator should never be located
downstream from a lubricator. Conversely, if a pressure regulator
is required in the line, it should be located downstream from the filter
or separator and upstream from the lubricator.

Inspection

Despite careful lubrication and scrupulous observation of the air
supply, the constant use and abuse to which air tools are subjected mean
that a periodic maintenance plan must be scheduled, and worn parts re-
paired or replaced. Itis imperative that this schedule be maintained.
The particular tools to be inspected should be taken from production and
sent to the maintenance shop on schedule. Otherwise, one worn part
might cause irreparable damage.

Once a procedure is established and a schedule maintained, pre-
ventive maintenance is relatively easy. In the hands of skilled tool
maintenance personnel, the machines should be completely disassembled
and all parts washed. Kerosene will serve asan effective cleaner for
most parts. Maintenance personnel should be warned, however, not to
wash sealed bearings in a solvent.

Air screens and filters should be cleaned or replaced if damaged.
The felt wicks in the oil packets should be cleaned carefully or replaced
if hard.

Rotary Equipment

Rotary vane motors must be carefully inspected for wear. Exces-
sively worn or scored end plates and cylinder liners should be replaced.
If the blades are worn at the ends so that they are shorter than the rotor,
or if the long edges which contact the cylinder liner are worn noticeably,
they should be replaced.

Bearings in the end plates should be examined carefully. The outer
race should roll freely while the inner race is being held firmly. If
there is any perceptible play, either radially or axially, between the
inner and the outer race, the bearing should be replaced.

Clean the interior of the compressor portion if foreign matter is
present that would interfere with free movement of the blades within
the rotor. To clean, it is necessary to remove and disassemble the
compressor portion, but it is not usually necessary to pull the floating
head plates and bearing cones from the ends of the rotors.

Cleaning may be done by brushing and scraping, using solvents
when necessary to soften the deposits. Caution must be used when


RECLAMATION'S USE OF PROTECTIVE COATINGS
FOR
SUBMERGED AND BURIED METALWORK

(This paper written by P. W. Lewis and J. L. Kiewit,
Engineers, Bureau of Reclamation, Denver, Colorado,
is reproduced with the permission of the National
Association of Corrosion Engineers, who reserve publi-
cation rights. Further reproduction is prohibited)

The Bureau of Reclamation designs and constructs water conser-
vation projects and structures in the 17 Western States. On these proj-
ects, large areas of vital metalwork are exposed to corrosion in soil
and fresh water over a long period of time, such that corrosion becomes
an important factor in the life of the structure. To control corrosion,
the Bureau relies primarily on protective coatings. This paper discus-
ses coating selections for the most important exposures, and the job site
inspection and quality control which are instrumental in achieving ulti-
mate coating performance. It also reviews the Bureau's laboratory and
field evaluation testing of promising new coatings, giving the first report
on an important new field test.

Current Practice

In any major structure, several different fresh water corrosion en-
vironments will be found. Since penstock piping will usually be continu-
ously filled, coal-tar enamel provides excellent protection. For buried
piping and other water-bearing piping exposed aboveground and always
in service, and thus not subject to severe temperature fluctuations, coal-
tar enamel or cement mortar is used. However, when it is contemplated
that piping exposed aboveground may be empty for extended periods, the
Bureau has found that a 3-coat vinyl resin paint 1/ gives satisfactory pro-
tection, but of shorter duration and requiring more maintenance than coal-
tar enamel.

Certain other metalwork associated with the penstocks is not well
suited for protection with coal-tar enamel. Such metalwork as the
butterfly valves and wicket gates, through which water passes to the
generators, are usually coated with cold-applied coal-tar paint, CA-50.

_2/ At the head of the penstock, trashrack metalwork constitutes a shape
which is difficult to coat; and in this situation, coal-tar pitch, 3/ applied
by dipping, has been found very effective.

Many major structures and most canals include radial gates of vary-
ing sizes for controlling the flow of water; parts of these will be in sub-
merged, alternately submerged, and in atmospheric exposure. The
Bureau has found that a 6-coat vinyl resin paint 4/ provides excellent
protection against corrosion as well as resistance to abrasion and sun-
light on large gates.

Smaller gates, such as will be found on turnout structures,

Numbers refer to references at end of report.
16 -


P328-701-7562

In the above photograph, taken at the end of the irrigation season,
the downstream section of the treated Parshall flume and the untreated
section below the flume throat are shown. In the untreated area, long
strings of algae growth are visible, while there is practically no algae
in the treated section. The treated bottom has a very thin layer of
algae and much of the paint had started to wear. Also evident are areas
of loss of protective paint at the bottom of the sides of the flume.

The cost of applying a total of 2-1/2 gallons of the copper base
antifouling paint in two coats was approximately $63.00. The cost as
estimated by maintenance personnel is broken down as follows:

Labor and transportation of labor. ....... .$35.00
2-1/2 gallons of paint at $9.62........... 24.00
Muriatic acid (surface preparation of concrete). . 3.00
Broom... ee ee ee ee ee eee oe 1.00

Total... . $63.00

The paint used contained 14.7 percent active ingredients expressed
as metallic copper, and 85.3 percent inert ingredients. A source of
the paint may be obtained by writing the Project Manager, Kansas River
Projects, U. S. Bureau of Reclamation, P. O. Box 737, McCook, Ne-
braska, or the Commissioner's Office, U. S. Bureauof Reclamation,
Building 53, Denver Federal Center, Denver 25, Colorado, Attention:
D-400.

Ok
6


The linings in this test should provide some valuable and inter-
esting comparisons.

First, the new resins; three samples are of the epoxy coal-tar
combination type. From the vigor with which the industry has pro-
moted this type of coating, others must have found it promising. Bureau
laboratory tests have indicated that good performance might be expected.
Straight urethane is represented in one lining, and urethane is com-
bined with coal-tar in another. Two linings are of the modified pheno-
lic and epoxy modified phenolic type. Straight vinyl and epoxy resins
are present as components of mastic paints. Thus, the test includes
the principal resin ingredients of protective coatings to achieve promi-
nence in the industry in recent years.

Second, this test examines the protective possibilities of zinc coat-
ings rather fully. Zinc is exposed asa flame-sprayed lining and as
the essential pigment in both organic and inorganic vehicles. In addition,
certain of these were topcoated with vinyl or phenolic materials. The
possibilities of the later systems are appealing: As is well known, zinc
protects steel by sacrificing galvanically at small exposed steel areas,
and the duration of such protection should be indicated by this test. In
theory, organic topcoats should, in themselves, offer additional pro-
tection; however, their combination with zinc should multiply their
period of effectiveness. Yet another advantage may exist when deteri-
oration of the topcoats is observed. Maintenance in the form of touch-
up painting or a complete single topcoat may restore the system as a
whole to nearly its original condition before the ferrous-base metal has
been attacked. In maintenance, it may prove feasible to replace sand-
blast surface preparation with the much cheaper and more expedient
wire brushing. Continued maintenance in this manner may offer the
possibility for very long-term protection of the base metal.

It may be well to consider what the Bureau expects to learn from a
field test such as the Southside Canal test. Durability is a primary con-
sideration, of course, and a rugged material having a potentiality of
over 20 years! service with a minimum of maintenance is sought in this
test. The desired lining should be suitable for exposure in empty steel
piping aboveground. It must, therefore, resist wetting and drying and
freezing and thawing and extremes of temperature.

Also of interest are the manner and ease with which the lining can
be applied in the field where conditions are often less than ideal. Heat
and cold, high humidity, difficult shapes to coat, and limited access
generally complicate the work to some degree on each job. Require-
ments for highly skilled applicators or specialized and unusual equip-
ment add to the cost and may make the best quality of work difficult to
obtain in some cases. For these reasons, particular note was taken
during application of the Southside Canal test lining materials of the
complexity of the operation. A record was made, for instance, where

22



Department of the Interior

Bureau of Reclamation

OPERATION AND MAINTENANCE
EQUIPMENT AND PROCEDURES

LAST COPY - DO NOT REMCVE

January, February and March 1960

RELEASE NO. 31

4036 yp last mght ~ we
~~ barfer Hae! tham
aces soose

from the

("4 SreEby —#

k

pease nmarHeRs. & M 3
— tis onl no OF 3

sealng machine a
opined ft ccpht

% bred ot

ttle, a
(ore

Cr Gon

a . eR le te

NOT Reve ‘AST COPY - DO NOT REMOVE

/

Contents

Cartoons Sell the Value of Preventive Maintenance
Air Tool Maintenance

Copper Base Paint Retards Algae Growth

Screw Type Parking Stand

Swivelled Tongue—Hitch

Starting Your Diesel Engine in Cold Weather
Sealant Tightens Bulldozer Tracks

Raising Dredger Bucket Assembly

Pla: y—pass Channel

Ba: ipe Safety Barrier

Re Use of Protective Coatings for Submerged

and Buried Metalwork

/



STARTING YOUR DIESEL ENGINE IN COLD WEATHER

(The following material was prepared by Herb Orwig,
development engineer for the Trojan Division, The
Yale & Towne Manufacturing Co. Reprinted by per-
mission of Pacific Builder and Engineer, 2418 3rd
Ave., Seattle 1, Washington, January 1960 issue;
further reproduction is prohibited).

Past experience has shown that owners of diesel powered equip-
ment often have difficulty starting the engine in cold weather because
of a lack of knowledge about diesels. Since the combustion principles
of diesels are different from gasolines, it naturally follows that the
starting technique is also different. A thorough understanding of cold
weather diesel facts will enable the diesel equipment owner to start
the engine quickly and efficiently and also eliminate possibility of
damage to the engine.

Let us first look at the rules:

1. Keep engine in good operating condition. Good valve and
ring seating provide maximum compression necessary for easier starts
and smooth running. Clean injector tips assure proper atomizing and
even distribution of fuel.

2. Keep battery at peak charge. Low temperatures alone re-
duce battery efficiency and rob cranking power.

3. For best results use either starting fluid or glow plugs as
directed.

4. Keep fuel clean and fuel lines free of water or air locks.
5. If shelter is available for your equipment, use it.

The diesel engine has no spark plugs so it relies on high compres-
sion in the cylinder to heat air in the cylinder enough to burn the fuel
injected into it. When the engine is cold the metal parts rapidly absorb
the heat in the cylinder and thus prevent ignition. This happens every
cold day so that the engine needs help to get started.

Assuming the starter is turning the engine at normal starting speed,
there are two ways to get proper starting conditions: One, heat the air
introduced into the cylinders; the other, help out with a fuel that burns
at a lower temperature than diesel fuel. In some open chamber diesels,
such as Cummins, a glow plug is mounted in the intake manifold. When
fuel is sprayed onto this glowing element a small fire is kindled in the
intake manifold and this heated air is drawn into the cylinder giving
enough boost to start the engine in most instances.


SWIVELLED TONGUE-HITCH
(Suggestion R2-60-41)

The tongue-hitch shown in the photographs below was developed on
the Friant Division of the Central Valley Project, California, by Frank W.
Athos, to facilitate hitching, unhitching and travel of trailer mounted
equipment. Due to the differences in the heights of the various tractor
hitches the equipment
hitch was often mis-
matched and not lev-
el, causing an unbal-
anced load on the
tongue.

The problem was
solved by Mr. Athos
by fabrication of the
Swivelled hitch on
the trailers, as shown.
The hitch was made
from a 3-inch pipe
placed inside ofa
3-1/2 inch collar
welded to the front
sg and back of the in-
side pipe. The
larger pipe was
drilled for an oil
hole to provide for
lubrication and the
prevention of rust.

Using this type of
a swivelled tongue,
the equipment rides
level allowing the
correct amount of
weight to pull the
vehicle, It is also
much easier for the
equipment operator
to hitch and unhitch
the heaviest type of
trailer mounted equip-
ment with less danger
and strain. The photo-
graphs also show the
screw-type parking
stand developed by Mr. Athos and described in a previous article.

The swivelled tongue hitch has been adopted and installed on all
tongue pulled equipment used on the Friant Division.

OR OK KK OK


COPPER BASE PAINT RETARDS ALGAE GROWTH

During the 1958 irrigation season, a considerable growth of algae
formed on a Parshall flume on the Meeker-Driftwood Canal system,
Frenchman-Cambridge Division, Missouri River Basin Project, Nebraska.
The growth was so dense that it affected the rating of the flume used to
measure water deliveries to the canal. Periodic applications of copper
sulfate to the water in the canal helped kill some of the moss (algae),
but enough moss remained on the flume to affect the rating.

Prior to the 1959 irrigation season, two coats of copper-base pro-
prietory antifouling paint was applied to the throat of the 12-foot con-
crete Parshall flume as shown below. The result of this paint appli-
cation was that the growth of algae in the throat of the flume during
1959 was negligible.

°328-70)-7955

A view of the flume looking upstream is presented in the photograph
above showing the left side of the flume and the copper-base coating
applied. Growth of algae on the side of the flume downstream from the
painted throat is apparent.

Toward the end of the irrigation season there was evidence that
some of the protective paint was wearing off. This was especially true
of the bottom of the flume and the lower sides, as illustrated on the
following page. In order for the algae protection to be maintained, the
Project Manager, McCook, Nebraska, believes the flume must be
painted again before the next irrigation season.


Laboratory Evaluation Testing

The methods employed by the Bureau for the selection of coatings
may be of interest. Since it does no formulation preparation of its own,
the Bureau relies on the industry to supply it with superior paints. Un-
fortunately, new paints often fall considerably short of justifying ex-
aggerated claims made for them soon after they are placed on the market.
To save the cost of a field failure, four well known laboratory tests are
used by the Bureau to screen out the obviously unsuitable materials and
give a strong indication of fundamentally improved corrosion protection
offered by new products. These tests include:

1. Fresh water immersion 8/

2. Salt spray fog box 9/

3. Outdoor weathering exposure 10/
4, Weatherometer 11/

In addition, special tests are devised to evaluate coatings for special
needs. The Bureau's soil stress test of coatings for buried exposure is
one such test and is still in progress. As an example of a more recent
special test, a question arose as to which coatings would best resist the
effects of abrasion or erosion from sand- and silt-laden water in penstock
or siphon piping. Eight-inch-diameter, 8-inch long pipe sections were,
therefore, lined with coatings the Bureau uses and others being evalua-
ted by the laboratory. The test piping sections were sealed to contain a
sand or gravel slurry and then rotated for several hundred thousand rev-
olutions, This testing is still underway; however, in a progress report,
12/ cement mortar, neoprene, coal-tar enamel, a catalyzed phenolic
coating, pipeline asphalt enamel, and a high penetration asphalt are in-
dicated as having the best erosion resistance of about 15 linings tested
to date. The selection of a particular lining for use in siphon or pen-
stock piping where erosion is expected would, of course, depend upon
a number of its characteristics. This test, however, has provided
valuable data concerning this particular property.

Field Evaluation Testing

Often, of course, laboratory tests do not tell the whole story; much
remains to be learned in the field. Accordingly, the Bureau further
evaluates coatings showing promise in the laboratory by applying larger
areas of these coatings in a field test.

Bureau field tests of appreciable scope include the Shadow Mountain
Reservoir test for coatings for exposed irrigation piping, which carries
water in summer and is empty in winter. Thirty-inch-diameter pipe
sections were coated and lined, then trucked to Shadow Mountain Reser -
voir in the mountains of Colorado for exposure, being immersed

19


AIR TOOL MAINTENANCE

(Reprinted from the July 1959 issue of Construction
Methods and Equipment. Copyright 1959, McGraw-
Hill Publishing Company, 330 West 42nd St., New
York 36, New York; further reproduction is prohib-
ited.)

In the hands of good operators portable air tools can save time
and reduce costs on many jobs. Yet, the best operator is only as
good as the demolition tool, impact wrench, clay digger, backfill
tamper, or other air tool he is handling.

Too often, the performance of air tools is permitted to fall off
drastically because of lack of attention to basic maintenance. Poorly
maintained air tools are costly from two points of view. First, ex-
pensive labor produces less per hour as the tool's performance deteri-
orates. Secondly, worn tools consume more air.

John Scott Andrew, Sales Engineer in the Pneumatic Division of
the Chicago Pneumatic Tool Company, writing for Construction
Methods and Equipment, states that air tools, though precision-
engineered, are constructed to withstand a terrific amount of abuse.
But a little common sense goes a long way toward keeping perform-
ance up, repair bills down. Three "musts" for efficient air tool
performance are:

1. Aclean, dry, and ample air supply.
2. Adequate and proper lubrication.

3. Periodic inspection and replacement of worn parts.

Air Supply

In both reciprocating and rotary air tools, close clearances
between certain moving parts are essential. Dirt or dust in the air
supply cause rapid deterioration of these parts.

Most air tools have wire-mesh strainers in their air inlets to
prevent entry of foreign particles. However, if the air is not filtered
before it reaches the air inlet of the tool, these screens quickly be-
come clogged, choking the air supply and necessitating frequent clean-
ing. Wherever possible, porous element-type air filters should be in-
stalled in the air lines and cleaned frequently.

Moisture in the air supply adversely affects tool performance in
several ways. Excessive moisture interferes with proper lubrication
and can result in rusting of internal parts. Ice formation within the
tool's air passages creates back pressure that restricts the output.
Again, moisture exhausted by the tool can be extremely irritating to the
operator. Most air line filters are reasonably effective in removing
moisture, but unusually wet air may require the use of a moisture separa-

1


track roller bushings in cases where wear has caused slippage.

The sealant is a thin liquid which hardens in a metal joint to form
a tough seal. It comes fully prepared...no mixing and no heat are re-
quired. Catalytic action of the metal surfaces, aided by the absence of
air, causes the sealant to harden into a tough heat and oil resistant bond.
This tough plastic grips threaded fasteners so securely that no amount
of vibration will shake them loose, yet they can be removed with ordinary
tools. It comes in different strengths which apply any desired locking
torque, ranging from a light drag suitable for adjustment screws toa
locking force exceeding the torsional strength of large screws.

In addition to locking threaded fasteners, the sealant is used to
mount bearings and bushings without press fits, to hold hardened sleeves
to shafts, and to seal threaded and sleeve joints against fluids under high
pressure.

The sealant is carried in stock by selected bearing distributors and
industrial distributors throughout the country. For further information,
write King Publications at the above given address.

HK Kk

RAISING DREDGER BUCKET ASSEMBLY
(Suggestion R5 RG-59-12)

The operation of a dredger for canal maintenance on the Las Cruces
Field Branch, Rio Grande Project, New Mexico, had been hampered be-
cause the bucket assembly could not be raised high enough to clear turn-
outs and checks. This inconvenience interrupted the productive work of
the machine--making it necessary to move the machine out of position
and re-position it again on the other side of the structure.

General main-
tenance operator,
Ramon M. Carrillo's
solution to the
problem is shown
in the illustration
at left. In order
to raise the bucket
assembly to a
higher level
than is possible
in the normal
position, he
itgcr Se disconnects the
hitch from lo-
cation "A" and moves it to an eyehole on the crossbeam marked "B",



BARBED WIRE PIPE SAFETY BARRIER
(Suggestion R2-59-183)

Despite daily patrols, fences, locked gates, barriers and signs, the
Central Valley Project, California, must be continuously alert to canal
safety. A recent addition to the canal safety installations is a barbed
wire barrier placed around pipe lines that must cross the waterways, and
which as shown below, are used by the careless or adventurous as walk-
ways.

The Bureau of Reclamation has tried safety education programs,
safety devices, and trespassing citations to keep fishermen and children
away from the more dangerous locations along the canals. Even so,
twenty persons have found death in the swift, concrete -lined canals of
the project. Use of the pipe lines across the canals as walkways resulted
in two drownings during 1958. To prevent the dangerous use of the pipe
lines as walkways, Edward J. Deleski, Foreman, Water Operations
Section, Tracy Operations Field Branch of the project suggested the
barbed wire barrier shown below and in the sketches on the following page.

The barrier can be constructed for use on pipe lines that are well
above the maximum water surface, as shown in the photographs above
and on the lower sketch on the following page, or for those that are
partly awash, as shown in the upper sketch. Steel bands to which 1-
inch steel reinforcing bars are welded provide for quick field assembly.
The barbed wire is strung on the bars at about 6-inch centers.

14


OPERATION AND MAINTENANCE

EQUIPMENT AND PROCEDURES

Release No. 31
January, February and March - 1960
INTRODUCTION

This is the time of year that many operators on our Northern
Irrigation Projects are overhauling and repairing maintenance equip~-
ment. Accordingly, we have asked permission of several publishers
to reprint articles in this issue of the bulletin relating to general and
preventive maintenance. The cartoon on the cover of this issue is
one of a series that you may obtain that are aimed toward encouraging
proper care, operation and maintenance. To obtain the series see
back of front cover page.

This bulletin, published quarterly, is circulated for the benefit of
irrigation project operation and maintenance people. Its principal
purpose is to serve as a medium of exchanging operation and mainte-
nance information. It is hoped that the labor-saving devices or less
costly equipment developed by the resourceful water users will be a
step toward commercial development of equipment for use on irriga-
tion projects in a continued effort to reduce costs and increase opera-
ting efficiency.

To assure proper recognition of those individuals whose sugges-
tions are published in this and subsequent bulletins, the suggestion
number as well as the person's name is given. All Bureau offices are
reminded to notify their Suggestions Awards Committee when a sugges-~
tion is adopted.

OK OK OK OK

Division of Irrigation Operations -
Commissioner's Office
Denver, Colorado



extraordinarily high quality surface preparation was required, where
the nature of material raised obstacles, and where spray techniques
were likely to baffle the ordinary painter. Fortunately, few serious
problems arose among the coatings selected for the test, and most of
the linings appear well adapted for Bureau field application.

Last, and certainly not least, cost will strongly affect the eventual
selections from among the better performing lining materials. The
initial cost reflects material costs and the applicator's expenses in
coping with the conditions discussed, while applying the required number
of coats. If these costs are reasonable and the expected long service
with minimum maintenance is realized through the use of superior coat-
ing materials, then the ultimate objective of the protective coatings in-
vestigations will be achieved as lower annual cost per square foot for
corrosion control.

In summary, the Bureau's more commonly used coatings have been
given for the principal corrosive fresh water and buried exposures as-
sociated with large and small Reclamation projects. The desired end
product is a durable, economical coating which will do its job of pro-
tecting metalwork with dependability and a minimum of maintenance.
Such a coating will result not only from correct selection, but from
careful attention to its proper application to a well prepared surface.
Diligent inspection serves to insure the success of the application.
Also, control testing of coating materials is essential to maintain
quality standards. These are the steps necessary to assure a success-
ful coating for the protection of Bureau metalwork against corrosion.

References
1, Bureau of Reclamation Specifications for Vinyl Resin Paint, VR-3.

2. Bureau of Reclamation Specifications for CA-50 Cold Applied
Coal-tar Paint.

3. Federal Specifications R-P-381, Type II.
4, Bureau of Reclamation Specifications for Vinyl Resin Paint, VR-6.
5. Federal Specifications TT-P-86a, Type IV.

6. Federal Specifications TT-V-119, with Aluminum Paste TT-A-
468a, Type II, Class B.

7. Bureau of Reclamation Paint Laboratory Report No. P-57, Per-
formance of Exterior Pipe Coatings and Wraps in Laboratory
Soil Test--Progress Report.

8. Bureau of Reclamation Paint Laboratory Report No. P-59, Fresh
Water Immersion Tests of Protective Coatings for Iron and Steel.

23


COVER
CARTOONS SELL VALUE OF PREVENTIVE MAINTENANCE

(Reproduced from the December 1959 issue of Western
Construction, Copyright 1959 by King Publications, 609
Mission St., San Francisco 5, California; further repro-
duction is prohibited.)

A series of clever original cartoons, pointing up the importance
of preventive tractor maintenance, is offered free to owners and
operators of construction equipment. Printed in four colors on heavy
paper, the eye-catching 11- by 13-inch posters contain no advertising
and are suitable for tacking on field shacks, shop walls, and bulletin
boards. Featuring cartoon characters in typical job situations, the
series sélls proper tractor maintenance ina humorous, enjoyable manner
and is keyed to seasonal problems. You can order as many copies as
you need of this cartoon (shown on the cover) by sending your name,
title, address and company name to J. I. Case Company, Industrial
Advertising Department, Racine, Wisconsin. New cartoons will be
mailed to you as released.

KOR RK K


Engines with a precombustion chamber design usually mount the
glow plug in this small precombustion chamber so that ignition begins
in a fractional part of compressed air in each cylinder where fuel is
injected. Usually failure in starting with glow plugs comes because
the operator is too impatient to allow the plug to heat fully before he
begins cranking.

Ether and ether base fluids are fuels with a lower flash point, or
temperature, at which they begin to burn. This method is better liked
because it gives instantaneous results. Ether fluids are high energy
fuels and if used carelessly or too freely can cause serious mechanical
engine damage because of abnormal compression pressures.

In an engine with a glow plug in the intake manifold NEVER use
ether and the glow plug at the same time. A nasty backfire or perhaps
even more serious damage could result.

Very cold weather causes crankcase oil to become very viscous or,
in other words, thick. Obviously it is difficult for the oil pump to cir-
culate thickened oil so that the initial start starves cylinder walls and
bearings of oil for a short time. It is especially important to avoid
speeding the engine during this critical period. There are multiple
viscosity oils on the present market which are thinner when they are
cold. These oils have a low viscosity oil base with certain resins
added and thicken as they warm up. Diesel engine makers have been
reluctant to approve their use, therefore, always follow your engine
maker's oil recommendation.

Most automotive type diesels have an electric cranking motor asa
utility starter. Since accessory loads vary so widely, the choice of
batteries has always been the result of experience. Under normal con-
ditions most batteries are adequate but cold weather causes frequent
failures. Generally speaking, more and larger plates mean a greater
reserve of cranking power. If your battery is in good condition but
fails to start your engine by not lasting long enough, a larger battery
will crank your engine longer. Price, physical size and weight are all
good indications of battery size. Gasoline starting engines give un-
limited cranking duration once started. Air starters are excellent since
they usually give higher cranking speed but a regular mobile compressor
unit is usually needed to supply enough air.

If a shed is available to shelter your equipment use it to your advan-
tage. Fully enclosed sheds can be heated enough to be of real benefit in
starting the engine since the air crankcase oil and coolant all get the
benefit of the warmth.

After your diesel engine is started and running smoothly it will
warm up to its most efficient operating temperature more quickly if it
is run through its ordinary work cycle at a moderate pace. A good
rule is to let the engine temperature come up to nearly normal before
demanding full engine power.


PLASTIC LINING A BY-PASS CHANNEL

Construction of the West Main Canal of a unit of the Harlingen Divi-
sion, Lower Rio Grande Rehabilitation Project, Texas, was complicated
by the necessity of supplying water to the irrigators during the growing
season. Accordingly, it was necessary to construct a by-pass channel
around the construction area. The channel had to be lined to prevent seep-
age and the wetting of adjacent earth materials, A polyetheylene plastic
material 6 milsin thickness was used for the lining as shown below.

The plastic material was purchased from a local distributor in 100
foot rolls 24 feet wide for $37 per roll. The plastic was black in color.

Adjacent sheets of the material were joined by folding or rolling the
ends together on the underside of the lining. A small transverse groove
was excavated in the subgrade to receive this fold. As shown in the
photograph, the top edges were weighted with earth after installation.

The original installation consisted of approximately 1,000 linear
feet. After the adjacent reach of canal had been completed and returned
to service, the polyethylene plastic was taken up and reinstalled along
with additional material in a second by-pass channel 2,600 feet in
length. There was no wasteage in re-use of the material, except for
a section that had to be cut to accommodate a temporary pipe access
crossing.

The plastic lining proved very effective and the only difficulty en-
countered was that of handling the large sheets during installation on
windy days.