Section 563 — Coating

Description

563.01This work consists of removing and applying coatings.

Material

563.02Conform to the following Section and Subsection: Coating material 719 Water for cementitious materia ls 725.01(a)

Construction Requirements

563.03Qualifications. At least 30 days before starting coating work, submit the following for approval:

(a)Coating contractors . Coating contractors certified according to the following, as appropriate for the work:

(1)SSPC -QP1, Certification (Field Application to Complex Industrial and Marine Structures) ;

(2)SSPC -QP2, Certification Program (Field Removal of Hazardous Coatings) ; or

(3)SSPC -QP3, Certification Program (Shop Painting Certification Program).

(b)Personnel. Personnel with the following qualifications:

(1)SSPC Competent Person Certificate;

(2)Certificate of completion of lead exposure training according to 29 CFR 1926.62;

(3)Minimum of 2 years’ industrial field coating experience; and

(4)Minimum of 1 year’s field supervisory or management experience in coating removal projects.

563.04Submittals. At least 30 days before starting coating work, submit the following according to Subsection 104.06:

(a)A coating plan conforming to Subsection 563.05 . Indicate which products will be used, methods of application, and schedule of application, including hold points.

(b)SDS and product data sheets (P DS) for cleaning and coating products.

(c)A containment system, coating removal, and waste disposal plan conforming to Subsection 563.07.

(d)A worker protection plan conforming to Su bsection 563.08.

(e)Specific safety measures to comply with 29 CFR 1926.62, 40 CFR 50.6, 40 CFR 50.12, and 40 CFR Parts 260 -268, if coating being removed is a hazardous material.

(f)Emergency spill procedures.

(g)Site-specific plan for maintenance and protection of traffic.

(h)A topcoat coating sample at least 1 foot by 1 foot, using the same coating system to be used on the surface to be coated.

563.05General. Perform work according to the approved Coating Plan. Stop work and take corrective action if the measures fail to perform as intended.

(a)Hold points. Specific inspection items are designated as hold points. Notify the CO at least four hours before reaching a hold point. If the four -hour notification is provided and the work is ready for inspection at that time, the CO will conduct the necessary inspection, testing, and validation. If the work is not ready at the appointed time and unless other arrangements are made, an additional four - hour notification is required. Do not proceed beyond a hold point until approved.

(b)QC. Provide equipment to perform the QC inspections. At a minimum, provide the following:

(1)Psychrometer or comparable equipment for the measurement of dew point and relative humidity, together with weather bureau tables or psychrometric chart s;

(2)Surface temperature thermometer;

(3)Bresle Kits or equivalent for chloride determinations;

(4)Wet film thickness gauge;

(5)Blotter paper for compressed air cleanliness checks;

(6)Type 2 magnetic dry film thickness gauge according to SSPC -PA 2, Procedure for Determi ning Conformance to Dry Coating Thickness Requirements ;

(7)Calibration standards for dry film thickness gauge;

(8)Light meter for measuring light intensity during cleaning, coating, and inspection activities;

(9)Applicable ASTM and SSPC Standards used for the work;

(10)Putty knife of a minimum thickness of 40 mils and a width from 1 to 3 inches if there are touch-up areas where the coating is being feathered and tested with a dull putty knife ; and

(11)Procedures for chloride remediation and frequency of testing. Calibrate instruments according to the QC process and the equipment manufacturer’s recommendations. Make inspection equipment and calibration charts available to the CO for inspection and testing.

(c)Lighting. Inspe ction of lighting is designated as a hold point defined in Subsection 563.05(a) . Provide artificial lighting both inside and outside the containment system where natural light is inadequate, as determined by the CO, to allow proper cleaning, inspection, and coating. Provide 552 illumination for inspection of at least 30 foot- candles. Provide illumination for cleaning and coating, including the working platforms, access, and entryways, of at least 20 foot- candles. Provide general work area illumination outside the containment of at least 5 foot- candles. Design and operate the lighting system to avoid glare that interferes with traffic, workers, and inspection personnel.

(d)Inspection access. Facilitate the CO’s inspections as needed, incl uding allowing ample time to view the work. Provide and erect equipment to allow close observation of surfaces to be cleaned and coated. Provide this equipment during all phases of the work.

(e)Protection of the work. Use tarps, screens, paper, cloth, or othe r suitable means to protect adjacent surfaces that are not to be coated. Prevent contamination of freshly coated surfaces by dust, oil, grease, or other harmful or deleterious material. Repair damage caused to the bridge structure during construction.

(f)Coat ing material. Provide new coating material applied to a single structural component from the same coating manufacturer and coating system. Include both shop and field coating applications and components. Use safe handling practices conforming to the manufa cturer’s SDS and PDS. Store coating material in original unopened containers with labels intact and in weather -tight spaces where temperature is maintained between 40 and 100 °F. Do not open coating material containers until required for application that d ay. Do not use coating material from a punctured container or from a container with its lid seal broken. Do not use coating material with an expired shelf life. Mix coating material according to the manufacturer’s recommendations. Mix coating material with mechanical mixers for sufficient time to thoroughly blend the pigment and solvent together. Continue the mixing during application. Do not thin coating material that is formulated ready for application. Strain coating material after mixing, except where a pplication equipment is provided with strainers. Use strainers of a size to remove only skins and undesirable matter, but not to remove the pigment. Where a skin has formed in the container, cut the skin loose from the sides of the container and discard it. If the volume of the skin is visually estimated to be more than 2 percent of the remaining coating material, discard the coating material.

(g)Surface preparation and weather limitations. Remove dirt, dust, and other contaminants from the surface according to the coating manufacturer’s recommendations. Clean the surface to the specified cleanliness level. Thoroughly dry the surface to be coated. Apply coating when the following conditions are met or according to the manufacturer ’s recommendations, whichever is more restrictive:

(1)The surface temperature is between 50 and 100 ºF;

(2)The surface temperature is 5 ºF or more above the dew point measured according to ASTM D4230; and

(3)The humidity is 85 percent or less, unless otherwise specified on the manufacturer’s PDS. Continuously monitor, record, and provide temperatures and humidity at least every 15 minutes while coating. Check the dew point immediately before each coating, at least every 4 hours during coating, and as conditions change. Provide a controlled environment to meet weather limitations if necessary.

(h)Application. Apply coating material according to the manufacturer’s recommendations. Apply coating material by brush, sprayer , roller, or combination of methods recommended by the manufacturer’s PDS.

(1)Brushes. Use brushes with sufficient bristle body and length to spread the coating material in a uniform film. Use round, oval shaped brushes, or flat brushes no wider than 4½ inches. Evenly spread and thoroughly brush out the coating m aterial as it is applied.

(2)Sprayers. Use airless or conventional spray equipment with suitable traps, filters, or separators to exclude oil and water from the compressed air. Use compressed air that does not show black or wet spots when tested according to ASTM D4285. Use the spray gun tip sizes and pressures recommended by the manufacturer.

(3)Rollers. Select rollers and covers suitable for the surface and coating material to be applied. Use rollers only on flat, even surfaces. Do not use rollers that leave a stippled texture in the coating film. Use sheepskin daubers, bottle brushes, or other coating methods recommended by the manufacturer to coat surfaces that are inaccessible for coating by regular means. Coat surfaces in a manner that does not produce excessive coating build- up, runs, sags, skips, holidays, or thin areas in the coating film. Correct thin areas, skips, holidays, and other deficiencies before the next application of coating material. Tint succeeding applications of coating material to contrast with the coating being covered. Obtain color approval for the finish coat before application. Coat surfaces that will be inaccessible after erection with the full number of undercoats required before erection. After erection, clean areas where the undercoating is damaged or deteriorated, and spot coat with the specified undercoats to the required thickness before applying the final coat. Measure the wet film thickness during application and adjust the application rate to obtain the required dry fil m thickness.

(i)Curing. Cure each coat according to the manufacturer’s recommendations, increasing cure times as needed for changes in surface and ambient temperatures, and humidity. Maintain a surface temperature of at least 5 ºF above the dew point measured according to ASTM D4230 for at least 12 hours after coating is finished. Continuously monitor, record, and provide temperatures and humidity at least every 15 minutes while curing. Maintain the coating manufacturer’s curing requirements for each coating a pplication for the entire curing duration. 554 Protect coated surfaces from direct exposure to rain for the time interval recommended by the coating manufacturer for proper cure.

563.06Protection of Public, Property, and Workers. Comply with SSPC -PA, Guide 10, Guide to Safety and Health Requirements for Industrial Painting Projects and OSHA standards. Handle all waste as hazardous material until tested and proven to be non- hazardous. If a hazardous material is removed, comply with the following:

(a)SSPC Guide 6, Guide for Containing Surface Preparation Debris Generated During Paint Removal Operations ;

(b)SSPC Guide 7, Guide to the Disposal of Lead-Contaminated Surface Preparation Debris ;

(c)29 CFR 1926.62, Lead (Safety and Health Regulations for Construction);

(d)40 CFR 5 0.6, National Primary and Secondary Ambient Air Quality Standards for PM 10;

(e)40 CFR 50.12, National Primary and Secondary Ambient Air Quality Standards for Lead; and

(f)42 U.S.C. §6901, Resource Conservation and Recovery Act. Collect and dispose of material i ncluding wastewater that is used in preparing, cleaning, or coating.

563.07Containment System, Coating Removal, and Waste Disposal. Design and construct safe containment system s to support the loads imposed. Do not apply loads to the existing structure more than the load carrying capacity of any part of the structure. Include details of attachment. Include connections with clamps or other approved devices that do not require welding or drilling holes in the existing structure. Include working drawings and construction details. Provide design calculations, manufacturer’s specifications, and certifications for the containment system’s working platform. Provide a platform that is fir m and stable, designed to support workers, authorized persons, spent abrasive material, and equipment during all phases of construction. Provide calculations and specifications stating the proposed containment system’s load bearing capacity and show that t he system will support imposed loads. Maintain minimum vertical and horizontal clearances for construction operations as approved. Fully enclose surface preparation and coating application operations to eliminate the emission of airborne blast debris, dust , and coatings from the containment, and ensure that no dust, debris, or coatings enter the water below. Comply with SSPC Guide 6 , Class 2. Provide a containment system with air impenetrable walls, a negative air pressure environment within the containment, and fresh air flow through the containment. Maintain an average negative pressure of 0.03 -inch water column inside the enclosure (as measured by manometer or differential pressure gauge) during blasting and blow down operations. Maintain a safe and unclu ttered passageway for foot traffic in the containment system, and between staging and work areas. Design air flow inside the enclosure to meet OSHA standards. Provide containment design and ventilation to allow for the maximum practical reduction in exposure of workers to airborne contaminants inside the containment system. Submit a list of the equipment, including operating capacities and manufacturer’s instructions. Prevent release of accumulated debris into the environment . Protect workers from exposure to hazardous materials. Immediately correct visible emissions from the containment enclosure. Ensure emissions from the containment enclosure conform to Federal and state air quality standards. Take at least eight representative soil samples, including at least one at each corner of the work site according to SSPC Guide 6 . Take samples and perform test analysis for toxic metals on samples before work start -up, during surface preparation and coating application operations, and after work operations are compl eted. If elevated levels of toxic heavy metals are found in baseline soil samples, obtain additional samples and retain for future analysis. Take water samples and perform test analysis for toxic metal content downstream before work start-up, every two weeks during work, and after work operations are completed, to demonstrate water purity. Clean up spilled waste materials immediately and take necessary actions to remedy resulting soil and water contamination. Comply with SSPC Guide 7. Seal collected waste materials in leak -proof drums. Place only spent abrasives, coating particles, and blast debris in the drums. Provide drums that are in new condition and approved for use. Clearly identify each drum according to EPA and state rules and regul ations, with the bridge number, contract number, Contractor’s name, contents, and the date waste material accumulation started. Obtain necessary permits for storage, transport, characterization, and disposal of waste. Store contaminated debris according to Federal and state rules and regulations. Store drums containing contaminated debris in a locked sea cargo trailer within a secured staging area. Remove the contaminated debris from the site within 30 days of collection. Obtain approval before storing drum s in the trailer. Prevent the entry of unauthorized persons, livestock, or wildlife into the staging area and the lead work area. Post warning signs with clearly visible legends, "DANGER - AUTHORIZED PERSONNEL ONLY", easily visible from routinely used approaches to the staging area and the work area. Sample and test the waste material according to EPA, SW- 846 Test Method 1311, Toxicity Characteristic Leaching Procedure . Test waste for lead and other elements shown in SSPC Guide 7, Table 1 . If waste material is determined to be hazardous, obtain an EPA Identification Number and prepare a manifest of hazardous waste to be transported to an approved waste storage site. Prepare the manifest according to Federal and state rules and regulations. Provide a certificate or manifest indicating the weight and the number of drums of waste to be disposed. Provide a testing manifest for hazardous waste and EPA Identification Number to the bridge owner before the material is transported. Provide proof of acceptance from an approved disposal site, including information required by state and local rules and regulations. Ensure that the hazardous waste hauler is licensed and has an EPA Identification Number. Conform to Federal and state rules and regulations regarding the maxim um volume of hazardous waste which may be stored on the site. Do not store the waste materials on the site for more than 90 days. Do not treat hazardous waste on site. If lead or any element shown in SSPC Guide 7, Table 1 does not meet or exceed the permis sible level of concentration as measured by the Toxicity Characteristic Leaching Procedure (TCLP), dispose of the 556 waste material as an industrial solid waste according to Federal and state rules and regulations. Dispose of waste at an approved facility. Provide the CO with an authorization before disposal. If waste material is transported outside the state for disposal, comply with Federal, state, and local rules and regulations.

563.08Worker Protection Plan.

(a)Submit a worker health and protection plan that has been prepared by a Certified Industrial Hygienist who is certified by the American Industrial Hygienist Association, and according to Federal rules and state regulations. Include the following:

(1)Work practices;

(2)Engineering controls;

(3)Administrative cont rols;

(4)Training;

(5)Medical surveillance;

(6)Hazard identification;

(7)Protective clothing and respirator selection;

(8)Handling containers;

(9)Emergency responses;

(10)Decontamination;

(11)Illumination;

(12)Sanitation; and

(13)Site control.

(b)Train workers and persons exposed to coating o r cleaning operations according to the approved worker protection plan. Provide documentation of workers ’ safety training and education that requires instruction in recognizing and avoiding unsafe conditions and hazards, complying with OSHA 29 CFR 1910 and OSHA 29 CFR 1926, with emphasis on beryllium, cadmium, chromium, lead, and respirable crystalline silica .

(c)Require workers scheduled to receive lead exposure at or above the action level on any day during the project duration to have the following:

(1)An initial medical surveillance consisting of blood sampling and analysis for lead and zinc protoporphyrin level s (an indicator of lead levels in the blood).

(2)Follow- up blood tests for any worker whose initial medical surveillance results were at the permissible exposure limit or more.

(3)Thorough medical examinations for workers who are or may be exposed at or above the action level for 30 or more days in any 12-month period. Use OSHA- approved laboratories to perform blood analyses. Provide initial and follow -up medical surveillance to workers and the CO within 48 hours of a worker’s exposure. Do not use prophylactic or preventive chelation to keep blood lead levels down while workers are on the job.

(d)Designate a competent person who is knowledgeable about protection of workers from the hazards of lead exposure to be the Worker Health and Safety Officer and responsible fo r ensuring worker safety and remedying any hazardous situation. Submit certification signed by the Worker Health and Safety Officer at completion of the project that the worker health and protection plan complied with all regulations and was fully implemen ted.

563.09Structural Iron and Steel. Provide the topcoat of coating material to match existing coating on structural iron and steel or as directed . Conform to SAE -AMS -STD -595. Comply with SSPC -VIS Standards or NACE Comparators for surface conditions and finished surface profile visual standards.

(a)Test blast. This Subsection is designated as a hold point defined in Subsection 563.05(a) . Perform a test blast on a portable steel plate, measuring approximately 1 foot by 1 foot, representative of those steel surfaces cleaned throughout the structure, and according to Subsection 563.09(c) . Produce an anchor profile height within the range recommended by the coating system manufacturer’s PDS. M easure anchor profile according to Subsection 563.09(c) . Start blast cleaning only after the CO has inspected and approved the test blast plate. Preserve and protect the test blast plate as a job standard with a clear sealer, an d photograph for documentation and project QC.

(b)Compatibility test. This Subsection is designated as a hold point defined in Subsection 563.05(a) . Select a test area of at least 30 square feet in a condition representative of the condition of the structure. Perform surface preparation according to Subsection 563.09(c) and apply the proposed system according to Subsection 563.09(f) . Perform tests according to ASTM D5064. Obser ve for lifting, bleeding, blistering, wrinkling, cracking, flaking, or other evidence of incompatibility. Verify that no indication of incompatibility exists at least 14 days after the application of each product. Perform adhesion tests according to ASTM D 4541, Methods C through F. Notify the CO if failure is due to adhesion (between coating and substrate or between applied coats) or cohesion (failure within a coating layer). If failure occurs, provide a compatible coating system and repeat the compatibility process. Remove dirt, dust, and other debris from the surface by vacuuming or other approved methods. 558 (c) Surface preparation. Prepare surfaces by removing the existing coating, which may contain lead and other contaminants, according to Subsection 563.07. Remove dirt, mill scale, rust, and other foreign material from exposed surfaces by blast cleaning to near-white metal according to SSPC -SP 10/NACE No. 2, Near -White Blast Cleaning . Prepare surfaces inaccessible to near -white metal blast cleaning according to SSPC -SP 11, Power Tool Cleaning to Bare Metal . Blast clean with clean dry slag, mineral grit, steel shot, angular steel grit, or chilled iron grit abrasives. Use a suitable gradation to produce a dense, uniform anchor pattern. Produce an anchor profile within the range recommended by the coating system manufacturer’s PDS. Measure anchor profile height according to ASTM D4417, Method C or Method D, or ASTM D7127. Follow SSPC -PA 1 7, Procedure for Determining Conformance to Steel Profile/Surface Roughness/Peak Count Requirements.

(d)Chloride testing. This Subsection is designated as a hold point defined in Subsection 563.05(a) . Test bare metal surfaces for the presence of chlorides. If chlorides are present, clean surfaces to remove chlorides. Methods of chloride removal may include, but are not limited to, steam cleaning, pressure washing (with or without the addition of a chemical soluble salt remover according to the coating manufacturer), and scrubbing. After completing the chloride remediation steps, use approved cell methods of field chloride extraction and test procedures to test representative surfaces for the presence of remaining chlorides. Test at frequencies shown in the approved QCP. Maintain remaining chloride levels less than 5 μg/sq cm as read directly from the surface without any multiplier applied to the results. Repeat solvent and surface cleaning if surfaces rust or become con taminated before coating. Repeat blast cleaning if surface cannot be made free of rust or contamination by other methods. Repeat blast cleaning on areas that have flash rusted from the chloride testing.

(e)Primer application. Apply primer to bare metal surfac es within 3 days of cleaning, and before the steel flash rusts. Repeat blast cleaning on areas that have flash rusted before applying primer.

(f)Application. Use sheepskin daubers, bottle brushes, or other acceptable methods to coat surfaces that are inaccessible for coating by regular means. Coat in a manner that does not produce excessive coating build- up, runs, sags, skips, holidays, or thin areas in the coating film. Correct thin areas, skips, holidays, and other deficiencies before the next application of coating material. Apply coating material in the following order: primer, primer stripe, intermediate, intermediate stripe, and finish coat. Extend stripe coats at least 1 inch beyond welds, rivets, bolts, nuts, edges of plates and structural members, angl es, bearings, lattice pieces or other shapes, corners, crevices, and any area in which full coverage and film thickness are difficult to achieve. Provide a different color for each coat with substantial contrast to the underlying substrate and previous coa ts to verify complete coverage. Submit colors for the primer, stripe coat, and intermediate coat to the CO for approval. Apply according to the manufacturer’s recommendations. Do not use accelerator additives. Apply subsequent coats of coating material only when the receiving surface is dry and fully cured according to the manufacturer’s recommendations. Determine the dry coating thickness on steel structures using a Type 2 (electronic) film thickness gauge according to SSPC- PA 2 . Repair minor coating defects, handling damage, and other occasional non- conformances, according to SSPC -PA 1, Shop, Field, and Maintenance Coating of Metals and the manufacturer’s recommendations. Submit repair procedures for substantial damage, significant defects, or widespread (gross) non- conformances in the coated surface. Ensure that repairs to the topcoat of coating material result in an acceptable, uniform color, gloss, and texture on visible surfaces.

(g)Curing. Cure according to Subsection 563.05(i) .

563.10Lumber and Timber. Dry timber to a moisture content of 15 percent or less. Remove cracked or peeled coating, loose chalky coating, dirt, and other foreign material on previously coated timber. Use wire brushing, scraping, or other approved methods. If timber is treated with a waterborne preservative, wash and brush away visible salt crystals on the wood surface. Allow wood to dry before coating. Remove dust and other foreign material from the surface fed before coating. The primer may be applied before erection. After the primer dries and the timber is in place, fill cracks, checks, nail holes, and other depressions flush with the surface using an approved putty. After the putty has dried, evenly spread and thoroughly wor k the coating material into corners and recesses. Allow the full thickness of the applied coating material to dry before applying the next coat.

563.11Masonry Block and Concrete Structures. Remove laitance, dust, and other deleterious material from the c oncrete surface. Give the cleaned surface a light abrasive sweep blast to remove mortar wash and other contaminants. Remove residue and dust by vacuuming or other approved methods. Evenly spread and thoroughly work the coating material into corners and rec esses. Allow the full thickness of the applied coating material to dry before applying the next coat.

563.12Other Metals.

(a)Aluminum. Prepare aluminum surfaces to be coated according to ASTM D1730. Use the type of treatment and method of preparation appropr iate to the condition of the surface and coating to be applied.

(b)Galvanized surfaces. Prepare galvanized surfaces to be coated according to ASTM D6386. Use the type of treatment and method of preparation appropriate to the condition of the surface and coati ng to be applied. Use zinc -rich coating material conforming to SSPC Paint 20 to treat galvanized steel field cuts and damaged galvanizing according to the applicable requirements of ASTM A780. 560 563.13 Acceptance. Coating material will be evaluated under Subsections 106.02 and 106.03. Sample coating material according to ASTM D3925. Test coating properties according to FED -STD -141D, Paint, Varnish, Lacquer and Related Materials: Methods of Inspection, Sampling and Testing, if required. Coatings will be evaluated under Subsections 106.02 and 106.04. Containment systems will be evaluated under Subsections 106.02 and 106.03. Surface preparation will be evaluated under Subsection 106.02. Treating galvanized steel field cuts and repairing damaged galvanizing will be evaluated under Subsection 106.02.

Measurement

563.14Measure the Section 563 pay items listed in the bid schedule according to Subsection 109.02 .

Payment

563.15The accepted quantities will be paid at the contract price per unit of measurement for the Section 563 pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section. See Subsection 109.05 .