521STEEL 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. STEEL BRIDGE COATING 395

A succeeding coat shall not be applied until the previous coat has dried throughout the full thickness of the coating film. The coatings shall be protected from discoloration and disfigurement by dust, insects, and other causes until dry. The Contractor shall protect pedestrian, vehicular, and other traffic that moves on or underneath the bridge from damage and disfigurement by errant spray and other coating operations. The Contractor shall protect all uncoated surfaces of the bridge from damage and disfigurement. If traffic produces an objectionable amount of dust and dirt, the Contractor shall, without extra compensation, take means to prevent the dust and dirt from coming in contact with the surfaces that are being cleaned and are being coated. It shall be the Contractor's responsibility to protect all property, public and private, from damage that may result from the cleaning and coating operations.

521.18Additional Requirements for Coating Surfaces on an Existing Bridge

Steel and other metals shall consist of the metals of the substructure and superstructure structural steel areas and contiguous metal surfaces, and such surfaces as galvanized pipe, conduits and junction boxes, metal ladders, gratings, railings, platforms, operator's houses (metal or other material), navigation light stands, guyed masts, supporting overhead cable (excluding public utility masts, cable brackets and appurtenances), traffic gate housing, metal drains on steel spans, and surfaces of all machinery housing and parts that do not require lubrication. Any cleaning that is deemed by the Engineer to be harmful to the metal shall be discontinued. A succeeding coat shall not be applied until the previous coat has dried throughout the full thickness of the coating film. The coatings shall be protected from discoloration and disfigurement by dust, insects, and other causes until dry. The Contractor shall protect pedestrian, vehicular, and other traffic that moves on or underneath the bridge from damage and disfigurement by errant spray and other coating operations. The Contractor shall protect all uncoated surfaces of the bridge from damage and disfigurement. If traffic produces an objectionable amount of dust and dirt, the Contractor shall, without extra compensation, take means to prevent the dust and dirt from coming in contact with the surfaces that are being cleaned and are being coated. It shall be the Contractor's responsibility to protect all property, public and private, from damage that may result from the cleaning and coating operations.

521.19Method of Measurement

The completed and accepted work shall be measured in lump sum units, each identified by station number or mile {kilometer} post number in the proposal. The quantities of surface area that may be shown on the Plans are approximate estimates of the surface area that will be required to be coated. The Contractor shall determine the actual amount of surface area that is required to be coated and base the bid on this actual amount.

521.20Basis of Payment

Separate payment for applying a coating to a new bridge will be made only when the proposal includes a pay item for this work. Otherwise, payment for this work shall be included in Items 508-A, 508-B, 508-E, or 508-F, whichever is appropriate. Items 521-A and 521-B, measured as provided above, will be paid at the contract lump sum prices for the specified units. These prices shall be full compensation for all shop or field cleaning of metal, for containing, collecting, storing, testing, transporting and disposing of cleaning debris, for furnishing abrasives and cleaning solvents, for furnishing a surface profile comparator, for furnishing and applying the coating material, for supplying safety equipment and clothing, and for all materials, equipment, labor, and incidentals necessary to complete the work.

521-A Coating New Bridge at ______ - per lump sum 521-B Coating Existing Bridge at ______ - per lump sum BRIDGE JOINT SEALS 396

BRIDGE JOINT SEALS

522.01Description

This Section shall cover the work of furnishing and installing bridge joint seals at the locations shown by the plans or directed, all in accordance with this specification and plan details. Said seals are for the purpose of preventing the passage of water and other materials through the joint. Types of bridge joint seals have been classified as follows: Compression Seals and Diaphragm Type Seals.

522.02Materials

Materials furnished for use under this Section shall conform to the appropriate requirements of

Bridge joint seals for existing bridges shall be the type of seal material shown on the plans.

522.03Construction Requirements

The sealing of bridge joints shall be limited to those joints noted by the plans to be sealed. The plans and proposal will designate the "total joint movement" for which a joint is to function. Shop drawings of the bridge joint seal system designated by the plans or, if allowed, selected by the Contractor from the plan designated alternates, must be approved by the Bridge Engineer. Shop drawings, etc. of the seal system shall be submitted to the Bridge Engineer for approval. After final approval of the drawings, the Contractor shall resubmit seven copies of the drawings plus one set of satisfactory reproducibles (Mylar or equal) for distribution.

Special attention shall be given to joint construction to ensure that proper allowances for temperature, skew, etc. are made in forming the joint width. In the same manner, the anchorage system (bolts, plates, etc.) or joint armor shall be carefully set in the formwork to ensure proper anchorage and functionability of the completed joint. All elements of the joint seal system shall be on hand before commencing forming of the joint.

It shall be the Contractor's responsibility to ensure that the joint width, alignment, etc. is in accordance with the bridge plan details and approved shop drawing. Any deviation from the plans and approved shop drawings shall be reported and corrective remedial action taken before installing the seal element. Installation of the seal element shall be in accordance with the manufacturer's recommendation and Departmental directives. Care shall be taken to ensure the proper cleaning of the joint and use of lubricants, adhesives, or combination lubricant-adhesive during the installation. Splicing of the seal elements will not be permitted in a joint system unless so noted by plan details or the approved shop drawings.

The Bridge Contractor shall install that portion of the bridge end joint anchorage system required to be installed in the bridge deck in accordance with bridge plan details and approved shop drawings. The remaining elements shall be match-marked and properly stored as directed until such time as the bridge end slab is constructed or the contract is terminated, at which time the stored elements shall be turned over to the Engineer. The Contractor constructing the bridge end slab shall have the responsibility of incorporating that portion of the joint seal system required by the bridge plans and approved shop drawings into the bridge end slab. It shall be the Contractor's responsibility to ensure that the joint width, alignment, etc. is in accordance with above noted requirements; any deviation shall be reported and corrective remedial action taken before installing the seal element. The portion of the joint seal system to be installed in the bridge end slab and the seal element will be made available to the bridge end slab Contractor along with installation details if such is not provided by the plan details. The Contractor shall have full responsibility for protection, etc. of elements of the joint seal system furnished him until the joint seal system is accepted. Any damage to the elements caused by his operations shall be corrected as directed