520REPAIR OR RAISING EXISTING BRIDGES

388

517-A * Handrail - per linear foot {meter} 517-B Beam Type Handrail, Type Posts - per linear foot {meter} 517-C Type Railing Stair Railing - per set 517-D Aluminum/Galvanized Steel Sidewalk Handrail - per linear foot {meter} * Galvanized Steel, Galvanized Steel Pipe, Ornamental, or Cast-In-Place Concrete REPAIR OR RAISING EXISTING BRIDGES

520.01Description

This Section shall cover the work of furnishing all materials, tools, equipment, labor, falsework, or cribbing and all incidental items necessary to repair members or portions of an existing bridge or change the elevation of an existing bridge as may be required by the detailed plans. The work shall also include the removal and satisfactory disposal of all waste material, damaged portions replaced, and all falsework and/or temporary bracing, etc.

520.02Materials

Since the majority of the work required under this Section is primarily a work item, materials not to be incorporated into the completed structure shall be of such quality as to serve the needs adequately. However, any material which is to become a part of the completed structure shall meet the requirements of Division 800, Materials, for the respective type of member or part involved.

520.03Construction Requirements

The Contractor shall assemble all materials and equipment required to complete the repairs on any particular member of the bridge and shall adequately strut and brace members which are to be cut to ensure maintaining correct distance between joints and provide temporary load carrying members and supports during such time as members are cut, prior to the cutting of any main member. Prior to beginning work, the Contractor shall submit to the Engineer his plans for bracing main members for approval.

The Contractor shall furnish sufficient equipment of adequate capacity to raise any particular unit of the bridge, or the entire bridge, without injury to same, giving (1) uniform support and bearing at sufficient intervals and (2) adequate falsework, each as approved by the Engineer to support safely the portion of or the entire bridge while being raised until it is set on its new permanent supports. Prior to beginning work the Contractor shall submit to the Engineer (1) his plans for falsework and (2) list of equipment proposed for use. Both of these must be approved before the actual raising operation begins. When raising of a bridge involves a truss structure, the Contractor may be permitted to remove existing trusses from the bridge piers and store them at an approved storage site, provided a satisfactory method of removal, transporting, and re-installation of the trusses is submitted and approved by the Bridge Engineer. In such event the Contractor shall make all necessary arrangement for and furnishing of any storage area. NOTE: Storage areas must be approved by the Engineer, and a site will not be considered for approval unless the proposed site is under the direct control of the Contractor and its location is either on the project or in close proximity thereto.

520.04Method of Measurement

Each existing bridge to be repaired, raised, or bridge having a portion or portions of same to be repaired or raised will be shown on the plans and in the proposal by its station number, and for the purpose of measurement and payment will be considered a complete and separate unit. STEEL BRIDGE COATING 389

520.05Basis of Payment

Payment for repairs to existing bridge shall be made at the contract bid price (lump sum) which shall be payment in full for all material, equipment, tools, labor, falsework, struts, support, and incidentals necessary to complete the work required by this Section and detailed in the plans.

Payment will be made at the respective contract lump sum prices for items of raising existing bridges or portions of existing bridge at designated stations listed in the contract. The lump sum price shall be payment in full for the furnishing of all equipment, tools, labor, falsework and/or cribbing, storage area, and incidentals necessary to complete the work including the removal and satisfactory disposal of falsework and/or cribbing.

520-A Repairs to Existing Bridge, Station _____ - per lump sum 520-B Raising Existing Bridge, Station _____ - per lump sum 520-C Raising Portion of Existing Bridge, Station _____ - per lump sum STEEL BRIDGE COATING

521.01Description

This Section shall cover the work of applying coatings to steel for new construction and to existing bridges in the field for the protection of structural steel portions of bridges. Special requirements are given for the removal of coatings on existing bridges and for the disposal of the removed coating material. The requirements for coating are applicable regardless of whether or not payment for the coating is included in the payment for the steel (usually new construction) or is a separate payment for the field application of the coating on an existing bridge.

521.02Materials

Coating materials shall conform to the requirements given in Section 855, "Coatings, Paints, Enamels, and Varnishes for Metal and Wood Structures". Requirements for coating are also given in There are three basic types of coating systems. These systems are:  System 1, zinc primer with various types (acrylic, epoxy, urethane) of intermediate and top coats;  System 2, acrylic primer, intermediate and top coats;  System 3, epoxy mastic. The required dry film thickness and the required color of each coat are given in Article 855.05.

521.03Selection of Coating System

The type of required coating system will be shown on the plans or designated elsewhere in the contract. The coating system proposed for application shall be selected from the list of approved coating components if a proprietary coating system is not shown on the plans. The Contractor shall submit a written notification of the following:  the name and address of the supplier of the coating system;  the product names of each coat proposed for application;  the supplier number from the list of approved coating systems. If the coating is proposed for application on existing structures the Contractor shall give this written notification to the Project Manager at least 14 calendar days prior to the beginning of the application of the coating. If the coating system is proposed for new construction the Contractor shall give this written notice to the Project Manager and forward a copy of the notification to the Bridge Engineer prior to, or with the first submittal of the structural steel shop drawings. STEEL BRIDGE COATING 390

521.04Blast Cleaning, Mechanical Cleaning and Surface Roughness

Historically the results of testing performed on existing coatings shows that there is a strong likelihood that the blast waste will be hazardous due to the presence of the heavy metals lead and/or chromium. Existing coatings may be tested, prior to bidding, for potential hazardous materials. The results of this testing, should it be performed, will be provided to potential bidders by plan notes or other supplementary documentation that will be included in the bidding proposal. All cleaning waste (blast waste, mechanical cleaning waste, etc.) shall be handled as hazardous waste until appropriate testing (Toxicity Characteristic Leaching Procedure TCLP, EPA Test Method 1311 test given in the EPA manual SW-846) has been conducted and a determination has been made to the contrary. The Contractor shall be fully responsible for all expenses that may be due to the handling and disposal of hazardous waste that is generated from cleaning existing steel bridge surfaces.

Unless noted otherwise on the plans, the surfaces that are to be coated with Coating System 1 shall be blast cleaned to conform to the requirements given in Steel Structures Painting Council Specification SSPC-SP 10 "Near-White Blast Cleaning". Unless noted otherwise on the plans, the surfaces that are to be coated with coating system System 2 shall be blast cleaned to conform to the requirements given in Steel Structures Painting Council Specification SSPC-SP 6 "Commercial Blast Cleaning".

Unless noted otherwise on the plans, the surfaces that are to be recoated with Coating System 3 shall be prepared by SSPC-SP 2 “Hand Tool Cleaning” or SSPC-SP 3 “Power Tool Cleaning”, SSPC-SP 12 “Surface Preparation by High- and Ultrahigh-Pressure Water Jetting”, or other means to remove loose paint and loose rust prior to recoating.

After blast cleaning, the anchor pattern shall be from 25 m to 75 m deep in a dense and uniform pattern of depressions and ridges, as determined by use of a press-o-film type tape and a spring micrometer or equal as approved by the Department, for all coating systems. The press-o-film type tape and a spring micrometer shall be provided by the Contractor.

521.05Containment System for Removal of Coating from Existing Bridge

The preparation (blasting and final cleaning) of surfaces for the application of System 1 and System 2 coatings on an existing bridge shall be done in a containment system, unless designated otherwise on the plans. The preparation of surfaces for the application of System 3 coatings will not require a containment system unless designated otherwise on the plans. The containment system shall consist of vertical (and horizontal if necessary) screening with a collection/recovery area in position at all times that coating removal work is in progress. Screening material shall consist of approved material suitably stiffened by bracing to form an assembly with sufficient strength to withstand winds and adverse weather conditions normally encountered during the season in which the work is performed. The screening shall extend the full vertical distance between bridge steel and collection area. The containment system shall not cause a hazard to the traveling public. The containment system shall be designed to have air-moving equipment capable of:  maintaining OSHA acceptable airborne concentrations of hazardous material;  providing adequate worker visibility;  preventing any spent material or dust from leaving the enclosure and;  collecting the material for disposal. Air quality will be visually monitored by the Engineer. Any dust outside the containment structure shall be justification for suspension of the work.

521.06Collection and Disposal of Coating Material Waste from Existing Bridge

Coating material and other debris removed from an existing bridge shall be collected by the Contractor in the containment system. This material shall be stored in approved containers for subsequent transportation to an approved disposal site. The Contractor shall store and dispose of contaminated debris in accordance with the requirements of the ADEM. Any testing required by the ADEM to be performed on the collected waste shall be the responsibility of the Contractor. The Contractor shall collect representative samples of the waste, as generated, in a storage vessel. A composite sample shall be collected for each 20 cubic yards {15 m³} generated per bridge site. Adjacent STEEL BRIDGE COATING 391

dual bridges will be considered as one site, unless noted otherwise on the plans. A composite sample shall be made by taking several small samples from random locations in the collected waste. The Contractor shall have the sample tested for hazardous materials using the Toxic Constituents Leaching Procedure (TCLP) as specified in EPA manual SW-846. Test results shall be submitted to the Engineer within 7 days from the date that the results are received by the Contractor. Waste which exceeds any regulatory threshold for a characteristic waste shall be handled as a hazardous waste. The Contractor shall be responsible for complying with all hazardous waste rules and regulations of the EPA and the ADEM including, but not limited to, such things as generator I.D. numbers, labeling, manifesting, etc. The waste shall not be stored for over 90 days. It must be transported only by a permitted transporter, and must be disposed of in an authorized hazardous waste facility. No treatment shall be conducted at the coating removal site. Any land ban certifications shall be the responsibility of the Contractor. The Contractor, acting on behalf of the Department, is the generator of the waste and shall sign any manifest or similar documents as such. The Contractor shall secure the approval of the Engineer for the transporter and the disposal facility at least five days prior to initiation of a shipment of waste. All personnel involved in the waste generation or handling shall be trained in accordance with EPA/OSHA directives. The Contractor shall reimburse the Department for all costs that may be incurred by the Department due to the failure of the Contractor in complying with all regulatory requirements for the containment, collection, storage and disposal of the blast waste. Waste which does not exceed the regulatory threshold for a characteristic waste shall be handled as an industrial solid waste. It shall be stored in accordance with the ADEM (Land Division-Solid Waste Branch) directives. Disposal shall be in accordance with the ADEM guidelines at an ADEM approved facility. The Contractor shall secure, in writing, the ADEM authorization for said disposal. The Engineer shall be given a copy of the authorization upon receipt by the Contractor. If contaminated material is transported to or through another state, work performed in that state shall be in conformance with any applicable regulatory agencies in the state involved. Copies of all required regulatory documentation, including ADEM Form 8700-12, shall be delivered to the Engineer at the time that they are submitted to the regulatory agencies. The work will not be accepted until all required notifications and permit terminations have been completed and copies of the Receipt of Termination for all permits, including the ADEM Form 8700-12, provided to the Engineer.

521.07Surface Preparation Plan Submittal for the Removal of Existing Coatings

Prior to beginning the work of removing coatings from existing bridges, the Contractor shall submit a Surface Preparation Plan for review and distribution by the Construction Engineer. Copies of the plan shall be submitted as Working Drawings in accordance with the requirements given in Section 105. The Contractor will not be required to have the plan stamped and signed by a Licensed Professional Engineer unless the preparation of details shown on the plan (for example temporary structural supports) is addressed in Alabama law regulating the practice of engineering. The plan shall be created to comply with all rules and regulations of EPA, ADEM, OSHA and any other agency that has regulatory authority and shall include:  the cleaning methods and products proposed for removal of paint with product manufacturer documentation of the effectiveness of the cleaning methods and products in producing non hazardous blast waste;  a work phase diagram describing how the debris shall be contained while blasting and coating operations are conducted;  a detailed drawing and/or description of the enclosure listing the type of covering, details of the covering support materials, details of the connections to the bridge structure;  methods and equipment proposed for collecting the blast debris;  description of the containers and the location proposed for storing the blast debris;  drawing at an appropriate scale to show the location of the storage of the blast waste in relation to the location of the work;  copies of the submittal of ADEM’s Form 8700-12. (If TCLP testing of blast waste proves that it is non-hazardous the Contractor may request release from ADEM’s Form 8700-12 with approval of the Engineer.);  description of the details, location and procedures for disposal of the blast debris.

521.08Final Cleaning of Blast Cleaned Surfaces

Blast cleaned surfaces shall be cleaned immediately prior to the application of the primer coat. All weld spatter, flux, slag, fume, and other objectionable deposits shall be removed prior to blast cleaning. STEEL BRIDGE COATING 392

The area of the welds shall be neutralized with suitable chemicals if this is required for the successful application of the primer. All areas repaired after blasting by welding, grinding or any other method shall be reblasted if deemed necessary by the Engineer. Before the application of the primer to the blasted surfaces, the surfaces shall be brushed with clean bristle brushes, blown with compressed air or vacuumed to remove all abrasives and other loose material from the surfaces. This cleaning shall also be done to remove abrasive deposits from cracks, crevices, corners, and pockets. Oil and grease shall be removed from blast surfaces by means of a suitable solvent. Potentially hazardous materials collected from the final cleaning on existing bridges shall be collected for proper regulatory disposal.

521.09Required Location for Application of Coats

Unless noted otherwise on the plans, the primer coat for new construction shall be applied in the fabrication shop. All other coats for new and existing construction shall be applied in the field after the installation of the steel has been completed.

521.10Compliance with Coating Manufacturer's Requirements

All coats shall be installed in accordance with the manufacturer's instructions and precautions for use. If requested by the Engineer, the Contractor shall have a representative of the coating manufacturer present at the initial application of the coats. The representative shall remain for a period of time necessary to ensure that the coatings are being applied satisfactorily and curing properly.

521.11Equipment for the Application of the Coatings

Coats shall be applied by spray. Rollers and brushes may be used only on flat surfaces for stripe coating and small coating repairs as directed by the Engineer. Coats shall be applied uniformly to ensure complete coverage and to give the required thickness on all surfaces. Equipment for spraying shall produce satisfactory results without the use of thinner if the use of a thinner is not allowed by the coating manufacturer. If drift of the spray away from the surface to be coated becomes a problem, the Engineer may require spraying to be suspended until conditions are favorable. Spray equipment shall include traps or separators to remove oil and water from the compressed air. The spray equipment shall be kept clean so that dirt, dried coating material and other foreign materials are not deposited in the coat film. Subsequent coats shall not be applied over a previously applied coat prior to the time that is specified by the manufacturer for the applied coat to cure or dry.

521.12Time of Application of Primer Coat after Final Cleaning

The primer coat shall be applied at the time recommended by the coating manufacturer, if that time is less than 24 hours after final cleaning. The primer coat shall always be applied within 24 hours after final cleaning. Under no circumstances shall the steel be permitted to rust before coating, regardless of the time elapsed. Rust shall be cleaned by blasting or other methods approved by the Engineer.

521.13Quality Control for Application of Coatings in the Fabricator's Shop

If requested by the Engineer, the fabricator shall have a representative of the coating manufacture present at the initial application of the coating. The representative shall remain for a period of time necessary to ensure that the coatings are being applied satisfactorily and curing properly. The fabricator shall keep a daily record of each coating operation. The record shall be kept more frequently if the materials or coating operations change during the coating process. The coating records shall be kept on a form furnished by the fabricator that is acceptable to the representative of ALDOT. Each coating record shall contain the ambient temperature, steel temperature, relative humidity, dewpoint, average anchor profile, coating system number, batch number, time and date blasted, time and date coated and all other information that is pertinent to the application of the coating. After each required coat of paint has cured, the average coating thickness of each member shall be recorded. The minimum and maximum thickness as specified on the coating manufacturer’s written data shall be required. The averages shall be taken from three evenly divided sections over the length and on each side of the member under examination. The averaging shall be based on SSPC-PA 2 guidelines. Each coating record form shall be signed by the fabricator's quality control supervisor. A copy of each coating record form shall be given to the ALDOT representative within five working days that coating STEEL BRIDGE COATING 393

work was performed. A copy of the manufacturers’ certifications of all batch numbers of the applied coatings shall also be submitted to the ALDOT representative with the coating record forms. Average anchor profile of blasted steel shall be checked using press-o-film type tape. The actual press-o-film type tape used for the measurement of the anchor profile shall be included with the copy of the coating record. Where materials other than beams and girders have been accumulated during a single shift or production run, the anchor profile of randomly selected members shall be checked. Coatings shall not be applied until the surface to be coated has been inspected and approved by the fabricator's quality control inspector or coatings shop supervisor after final cleaning. This prior approval also applies to additional coats that may be required.

521.14Worker Protection

The Contractor shall comply with all requirements of the Occupational Safety and Health Administration (OSHA) and other applicable regulatory agencies with regard to exposure to hazardous materials in construction. The Contractor shall be responsible for the training of all workers exposed to hazardous materials. The workers shall be informed of the hazards of exposure to these materials and shall be trained in the precautions to take when performing the work. The Contractor shall provide respiratory protection and protective clothing to all workers and persons entering an area where there is the possibility of exposure to hazardous materials. Protective clothing and equipment shall be approved by OSHA or other applicable regulatory agencies.

521.15Ambient Conditions for Surface Preparation and Coating Application

Final surface preparation shall not be performed on steel surfaces which may come into contact with rain, fog, snow, or dew prior to application of the coating. Final surface preparation operations, specifically meaning the 24 hour period within actual coating of steel surfaces, shall not take place when the steel surface is within 5 °F {3 °C} of the dew point or when the steel surface is below 32 °F {0 °C}. The equipment to check the dew point, humidity, and steel temperature shall be furnished by the Contractor. Surface preconditioning such as SSPC-SP 7 “Brush-Off Blast Cleaning” is allowable when dew point, steel surface temperatures or other conditions are outside of allowable ranges as long as final surface preparation requirements specifically regarding SSPC-SP6 and SSPC-SP10 are completed within the 24 hour period of coating steel surfaces.

Coating operations shall take place only when the surrounding air temperature or temperature of the steel is above 40 °F {5 °C} and not expected to drop to or below 32 °F {0 °C} prior to drying of the coating. Coatings shall not be applied to damp or frozen steel surfaces. Coatings shall not be applied when the steel surface is within 5 °F {3 °C} of the dew point or at a relative humidity above 85% unless the conditions of application recommended by the coating manufacturer are different and are allowed by the Engineer. Coatings shall not be applied during rain, snow, or fog conditions or when it is likely that moisture in the form of rain, fog, snow, or dew will contact coated surfaces which have not cured to water resistance.

521.16Additional Requirements for Applying Primer Coat in the Shop

Unless designated otherwise on the plans or in these specifications, all steel surfaces that will be exposed, with the exception of weathering steel, shall be coated in the shop with a primer coat. Limited painting of weathering steel is required. Only the exposed, non-contact surfaces of weathering steel within a distance from an open joint or finger tooth joint of 1.5 times the depth of the girder (depth at the bearing) shall be painted unless noted otherwise on the plans.

Shop contact (faying) surfaces shall not be coated. Surfaces that are not in contact, but will be inaccessible after assembly or erection, shall be coated with all required coats before assembly or erection except for bolted field splice surfaces. All areas required to be painted that are not readily accessible to spray painting operations shall have primer applied by other means. These areas include, but shall not be limited to, all holes in fabricated items and all clips of stiffeners or gusset plates. STEEL BRIDGE COATING 394

All seams of fabricated items that will not be sealed by welding shall receive a brush applied stripe coat of inorganic zinc prior to the application of the primer coat. The inorganic zinc coating shall be the same as that used for the primer coat. Additional touch up of the stripe coat will be required, if necessary, before final approval is given to the primer coat.

Primer coats shall not be applied in the shop to machined surface finishes noted in Article 836.50.

All surfaces of expansion dams shall be coated with primer to the maximum thickness recommended by the coating manufacturer.

When an inorganic zinc primer coat is required, the area of the girder (web and flange), the splice plates, filler plates, gusset plates for all diaphragms, crossframes and lateral bracing, top of the top flange of steel members supporting concrete slabs, and the edges of the top flange shall be coated with the inorganic zinc primer in the shop. The zinc primer shall have been tested for the determination of the slip coefficient as described in Article 855.03. When an inorganic zinc primer coat is required, the intermediate coat shall not be applied until the primer coat has cured. The Contractor shall ensure that this does not occur by testing the primer coat curing by means of a method recommended by the coating manufacturer. All overspray, loose or foreign, that would inhibit successful bonding of a subsequent topcoat shall be removed by a method approved by the manufacturer of the product.

The freshly coated steel shall not be handled or moved, except when unavoidable, until the primer coat is dry. All handling shall be performed using methods that will prevent the primer coat from being damaged. Storing shall be done in such a manner that the coating will not be removed or covered with dust, dirt, or other foreign material. In the case that debris does settle and harden on the coated surfaces during periods of extended shop storage, power washing shall be required before materials are staged for delivery. Any surfaces which require cleaning shall be restored to the original acceptable conditions prior to delivery to the project site. Loading, supporting and securing the steel for shipping shall be done in a manner to prevent damage the primer coating during loading and shipping. Nylon tie–downs, or other materials that will not damage the coating shall be used to secure the steel members during shipment.

Erection marks corresponding to those of the erection diagram submitted by the Contractor shall be plainly marked on primer coated surfaces.

521.17Requirements for Applying Additional Coats over a Shop Primer Coat

All debris shall be cleaned from the primed and bare surfaces before the application of additional coats. The Contractor shall use cleaning methods and materials that will not damage the primer coat. Oil and grease shall be removed by the use of a suitable solvent. Care shall be taken not to damage an underlying coat; however, if damage occurs, the underlying coat or coats shall be immediately repaired. On welded work all slag, flux, and spatter shall be removed prior to coating.

Immediately after the erection of materials (all connections complete), all bolted connections such as girder connection plates, diaphragm connection plates, field splice plates, galvanized bolts, nuts, washers, and other portions of the structure (except portions in contact with the concrete) which have received a shop applied primer coat and all completed bolt assembly installations shall be cleaned. All surfaces that have been scraped, chipped, or damaged during shipping and erection and all surfaces of the prime coat that have deteriorated shall be coated as per the coating manufacturers recommendations to restore the prime coat to an acceptable condition prior to top coating operations. All surfaces that have been scraped, chipped, or damaged during shipping and erection and all surfaces of the prime coat that have deteriorated shall be coated to restore the prime coat. The coating of structural steel bridge superstructure with a concrete deck shall not be done until after the construction of the deck has been completed. All concrete spills and splashes shall be washed from the structural steel prior to the mortar taking a set.