521STEEL BRIDGE COATING

521.03 Selection of Co ating System.

520.05 Basis of Payment.

521.01 Description.

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 i s a separate payment for the field application of the coating on an existing bridge.

521.02 Materials.

Coating materials shall conform to the requirements given in Section 855, "Coatings, Paints, Enamels, and Varnishes for Metal and Wood Structures". Requi rements for coating are also given in Section 836, "Structural Steel, Fasteners and Miscellaneous Metals". There are three basic types of coating systems. These systems are: • System 1, zinc primer with various types (acrylic, epoxy, urethane) of intermediat e 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.

521.03 Selection of Coating System.

The type of required coat ing 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 Contra ctor 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 propos ed 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.

521.04 Blast Cleaning, Mechanical Cleaning and Surface Roughness.

521.04 Blast Cleaning, Mechanical Cleaning and Surface Roughness.

521.05 Containment 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 rem oval 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 equipme nt 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.

521.06 Collection and Disposal of Coating Material Waste from Existing Bridge.

Coating material and other debris remove d 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 debri s 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

521.07 Surface Preparation Plan Submittal for the Removal of Existing Coatings.

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 Proce dure (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 han dled 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 fo r 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 sta te, 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 a re 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 E ngineer.

521.07 Surface 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 Const ruction 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 th e 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 En gineer.); • description of the details, location and procedures for disposal of the blast debris.

521.08 Final Cleaning of Blast Cleaned Surfaces.

521.08 Final Cleaning of Blast Cleaned Surfaces.

Blast cleaned surfaces shall be cleaned immediately prior to the application of the primer coat. All weld spatt er, flux, slag, fume, and other objectionable deposits shall be removed prior to blast cleaning. 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 va cuumed 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.

521.09 Required Location for Application of Coats.

Unless noted otherwise on the plans, the primer coat for n ew 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.

521.10 Compliance 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 insure that the coatings are being applied satisfactorily and curing properly.

521.11 Equipment 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 insure complete coverage and to give the required thickness on all surfaces. Equipment for spraying shall produce sat isfactory 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.

521.12 Time 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.

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

If requested by the Engineer, the fabricator shall hav e 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 insure 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 accepta ble 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

521.16 Additional Requirements for Applying Primer Coat in the Shop.

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 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 an chor 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.

521.14 Worker 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 provi de 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 agen cies.

521.15 Ambient Conditions for Surface Preparation and Coating Application.

521.16 Ad ditional Requirements for Applying Primer Coat in the Shop.

521.17 Requirements for Applying Additional Coats over a Shop Primer Coat.

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. 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.

521.17 Requirements for Applying Additional Coats over a Shop Primer Coat.

521.20 Basis of Payment.

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 washe d from the structural steel prior to the mortar taking a set. 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 prote ct 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.

521.18 Additional 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 undern eath 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 C ontractor 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 priva te, from damage that may result from the cleaning and coating operations.

521.19 Method 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.

521.20 Basis of Payment.

522.01 Description.

SECTION 522 BRIDGE JOINT SEALS

522.01 Description.

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.

522.02 Materials.

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

Division 800 — , Materials, and the plan details.

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