59 STRUCTURAL STEEL COATINGS
59-1 General
59-1.01 General
59-1.01A Summary
Section 59 -1 includes general specifications for coating structural steel.
59-1.01B Definitions
Reserved
59-1.01C Submittals
Submit a ce rtificate of compliance and SDS for each shipment of blast cleaning material.
59-1.01D Quality Assurance
Measure coating dry film thickness with a calibrated Type 2 magnetic film thickness gauge under SSPC - PA 2 except there is no limit to the number or location of spot measurements that may be requested by the Engineer to verify coating thickness. Measure coating adhesion strength with a self -aligning adhesion tester under ASTM D4541, Test Method D, E, or F and Protocol 2. Measure levels of soluble salts on surfaces using a retrieval method specified in SSPC -Guide 15.
59-1.02 Materials
59-1.02A General
Water for pressure rinsing and pressure washing must be fresh potable water with a chloride content of not more than 75 ppm and a sulfate content of not more than 200 ppm. Continuous recycling of rinse water is not allowed. You may collect rinse water in a tank for reuse if test samples meet specified requirements and no water is added to the tank after sampling. Sealing compound must be a polysulfide or p olyurethane type complying with ASTM C920, Type M or Type S , Grade NS, Class 25, Use M.
59-1.02B Abrasives
Abrasives for blast cleaning must be of a grading suitable to produce satisfactory results. Unless other abrasives are authorized, use only:
1.Clean dry sand. Do not use unwashed beach sand containing salt or excessive silt.
2.Mineral grit.
3.Steel shot.
4.Steel grit.
5.Manufactured abrasives. Mineral, manufactured, and slag abrasives must comply with the requirements for Class A, Grade 2 to 3 abrasives in SSPC -AB 1 and must not contain hazardous material. Steel abrasive must comply with SSPC -AB 3. Recycled steel abrasive must comply with SSPC -AB 2.
59-1.02C Coatings
Coatings must comply with section 91. Coatings selected for use must comply with the volatile organic compound concentration limits specified for the air quality district where the coating is applied. The undercoats and finish or final coats selected for use must be compatible with each other.
59-1.03 Construction
59-1.03A Gener al
Notify the Engineer at least 5 business days before starting work. Provide protective devices to prevent damage to the work, property, or persons. SECTION 59 STRUCTURAL STEEL COATINGS Provide lighting under SSPC -Guide 12 during surface preparation, cleaning, painting, and inspection.
59-1.03B Weather Conditions
Apply paint only to thoroughly dry surfaces during periods of favorable weather. Do not perform blast cleaning or apply solvent -borne paint if any of the following atmospheric conditions exist:
1.Atmospheric or surface temperature is below 36 degrees F
2.Atmospheric or surface temperature is above 100 degrees F
3.Relative humidity i s more than 85 percent Do not apply water -borne paint if any of the following atmospheric conditions exist:
1.Atmospheric or surface temperature is below 51 degrees F
2.Atmospheric or surface temperature is above 100 degrees F
3.Relative humidity is mo re than 75 percent Do not apply paint if :
1.Freshly painted surfaces may become damaged by rain, fog, condensation, or moisture of any kind
2.Atmospheric temperature or relative humidity will not remain within the specified application conditions during the drying period
3.Steel surface temperature is less than 5 degrees F above the dew point Repair or replace paint damaged by weather. If authorized, you may perform cleaning and painting activities during inclement weather by creating artificial condit ions to within the specified limits inside an enclosure. Air movement within enclosures must be adequate to meet the atmospheric conditions throughout the entire enclosure .
59-1.03C Cleaning
59-1.03C(1) General
Prepare and clean surfaces before painting.
59-1.03C(2) Pressure Rinsing
Pressure rinse to remove dust or deleterious material from surfaces using a pressure wash system with a minimum nozzle pressure of 1,160 psi. Ke ep the nozzle tip from 12 to 18 inches from the surface. The nozzle must have a maximum fan tip angle of 45 degrees.
59-1.03C(3) Pressure Washing
Pressure wash to remove loosely adhered coatings and contaminants from surfaces. Use a pressure wash system with a nozzle pressure from 2,500 to 5,000 psi and a rotary tip.
59-1.03C(4) Steam Cleaning
Steam clean to remove dirt, grease, loose chalky paint, and other foreign material from surfaces under SSPC -SP 1 . Steam temperature at the nozzle must be from 265 to 375 degrees F. Use a biodegradable detergent during steam cleaning. After steam cleaning, pressure rinse cleaned surfaces with water. Do not perform steam cleaning more than 2 weeks before painting or other phases of cleaning. Do not paint steam -cleaned surfaces until they are thoroughly dry and at least 24 hours have elapsed.
59-1.03C(5) Blast Cleaning
Blast clean surfaces to receive undercoat paint. Surfaces to be blast cleaned must be dry. Prime or treat blast -cleaned surfaces on the same day blast cleaning is performed unless otherwise authorized. SECTION 59 STRUCTURAL STEEL COATINGS
59-1.03D Painting
Each spray pot must have an authorized water trap installed. Do not thin paint unless authori zed. Before applying, mix paint using mechanical mixers to thoroughly blend pigment and vehicle together. Apply paint to clean dry surfaces in a neat and workmanlike manner. Apply by brush, spray, or roller in any combination. Gun extensions and aerosol cans are not allowed. Brushes must have sufficient bristle body and length to spread paint in a uniform film. Paint must be evenly spread and thoroughly brushed out. Rollers must not leave a stippled texture in the paint film. Apply paint to areas not accessible by regular means using daubers, bottle brushes, or other authorized methods. Thoroughly cure each application of paint and correct skips, holidays, thin areas, or other deficiencies before the next application. Painted sur faces being covered must be free from moisture, dust, grease, and deleterious material that would prevent bonding of succeeding coats. In spot painting, remove old paint that lifts after the first paint application by scraping and repaint the area before t he next application. Unless otherwise authorized, pressure rinse painted surfaces before applying the next coat for either of the following conditions:
1.7 days or more have elapsed after the application of the most recently applied coat
2.Dust or delete rious material is present on the painted surface The Engineer may require you to blast clean and reapply paint to areas with runs, sags, thin and excessively thick areas in the paint film, skips, holidays, or areas of non -uniform appearance. Repair painte d surfaces damaged during work activities with materials and to a condition equal to that of the specified coating. Remove paint or paint stains on surfaces not designated to be painted. Thoroughly clean painted surfaces after completing painting activitie s and other work that would deposit foreign material on the painted surfaces. Stencil the month and year of painting on structures at 2 locations selected by the Engineer. Use block letters 2 -1/2 inches high. The paint used must contrast with the backgroun d.
59-1.04 Payment
Not Used
59-2 Painting Structural Steel
59-2.01 General
59-2.01A General
59-2.01A(1) Summary
Section 59-2.01 includes general specifications for preparing and painting structural steel , except galvanized or thermal spray coated surfaces.
59-2.01A(2) Definitions
Reserved
59-2.01A(3) Submittals
59-2.01A(3)(a) General
Submit certificati on showing the maximum allowable dry film thickness for inorganic zinc -rich coatings to be used on faying surfaces of HS bolted connections as determined under appendix A of Specification for Structural Joints Using High -Strength Bolts of the RCSC. SECTION 59 STRUCTURAL STEEL COATINGS If requ ested by the Engineer, submit documentation from the coating manufacturer verifying the compatibility of the undercoats and finish or final coats selected for use. Submit quality control reports for cleaning and painting activities within 2 business days o f having performed work upon which reports are based.
59-2.01A(3)(b) Mandatory SSPC -QP Certifications
Reserved
59-2.01A(3)(c) Painting Quality Work Plan
Submit 3 copies of a painting quality work plan for each work item requiring structural steel painting or paint removal. Allow 20 days for the Department's review. Submit the work plan after attending the prepainting meeting and include:
1.Names of the painting contractor and any subcontractors to be used.
2.One copy of each current and applicable ASTM and SSPC specification and qualification procedure.
3.Coating manufacturer's guidelines and instructions for surface preparation, painting, drying, curing, handling, shipping, and storage of painted structural steel. Include testing methods and maximum allowable levels for soluble salts.
4.Materials, methods, and equipment to be used.
5.Proof of required SSPC -QP certifications. For work requiring SSPC -QP 1 or SSPC -QP 2 certifi cation, include: 5.1. List of all personnel who will perform surface preparation or paint application 5.2. Proof of CAS certifications, as required under (1) SSPC -QP 1, Mandatory Annex A and (2) the SSPC CAS Implementation Schedule in effect at the time of contract advertisement
6.Methods to control environmental conditions.
7.Methods to protect the coating during curing, shipping, handling, and storage.
8.Rinse -water collection plan.
9.Detailed paint repair plan for damaged areas.
10.Procedures for containing blast media and water.
11.Examples of proposed daily quality control reports for testing, measurements, and documentation to be performed, including type of testing, location, lot size, time, weather conditions, test personnel, and results.
12.Description of enclosures and other methods for preventing release of overspray and new paint into the surrounding environment.
13.Procedures for constructing demonstration panels on existing steel surfaces.
14.Proposed schedule of inspec tion hold points.
59-2.01A(4) Quality Assurance
59-2.01A(4)(a) General
59-2.01A(4)(a)(i) General
Reserved
59-2.01A(4)(a)(ii) Hold Points
Hold points are designated times that (1) provide safe access and (2) allow for quality assurance inspection of the work prior to proceeding to the next portion of the wor k. Designate hold points:
1.Prior to start of cleaning
2.After completion of pressure washing
3.Prior to the start of blast cleaning
4.After completion of all cl eaning work for any portion of a structure
5.Prior to each coating application
6.After completion of each coating application Add additional hold points if requested by the Engineer. Notify the Engineer a minimum of 24 hours prior to each hold point. SECTION 59 STRUCTURAL STEEL COATINGS
59-2.01A(4)( a)(iii) Demonstration Panels
Prepare demonstration panels on existing surfaces prior to starting surface preparation production work. Demonstration panels are regions on the existing structural steel surfaces that are prepared, cleaned, and p ainted for the purpose of demonstrating the methods, materials, and processes to be used during production work. Demonstration panels must:
1.Represent the variety of the work to be performed
2.Meet contract requirements for cleaning and painting structu ral steel
3.Be a total area of at least 50 square feet
4.Be kept accessible during production work , unless authorized At least 25 square feet of the completed demonstration panels must demonstrate the complete coating system. The remaining demonstration panel areas must demonstrate a variety of partially complete d stages of the coating system. Obtain authorization of the demonstration panels before starting production work. If authorized, demonstration panels, or portions thereof, may be incorporated int o the production work.
59-2.01A(4)(b) Certifications
You must hold SSPC certifications in good standing throughout the Contract to perform painting activities as shown in the following table: SSPC Certifications Painting activity SSPC certification Cleaning and painting structural steel in the field SSPC -QP 1 Removing hazardous coatings from structural steel SSPC -QP 2 Cleaning and painting structural steel in a permanent painting facility AISC -420-10/SSPC -QP 3, enclosed shop
59-2.01A(4)(c) Prepainting Meeting
Before starting painting activities, conduct a prepainting meeting to discuss painting quality work plan requirements. Meeting attendees must include the Engineer and all painting subcontractors.
59-2.01A(4)(d) Quality Control
59-2.01A(4)(d)(i) General
You must determine the sequence of testing. The Engineer selects test locations. If repairs are required, retest rejected areas after completing repairs. Test blast -cleaned steel for soluble salts using a Class A or B ret rieval method before applying the undercoat. Levels of soluble salts must not exceed the lesser of the coating manufacturer's recommendations or 10 μg/sq cm. Perform 3 tests for the first 1,000 sq ft prepared per shift and 1 test for each additional 1,000 sq ft or portion thereof. Perform at least 2 tests when less than 1,000 sq ft is prepared in a shift. Clean and retest areas represented by soluble salt tests exceeding specified limits.
59-2.01A(4)(d)(ii) Inorganic Zinc Coatings
Test the inorganic zinc u ndercoat before applying final or finish coats. Perform adhesion and hardness testing at least 72 hours after application. Test the inorganic zinc undercoat as follows:
1.Perform 3 adhesion tests per girder or 1,000 sq ft of painted surface, whichever is less. If less than 1,000 sq ft is painted in a work shift, perform 3 tests. The coating must have an adhesion to steel of at least 600 psi. If 2 or more locations fail adhe sion requirements, the area represented by the tests is rejected . If 1 of the locations fails adhesion requirements, test 3 additional locations. If any of the additional locations fail, the area represented by the tests is rejected. Repair rejected areas by blast SECTION 59 STRUCTURAL STEEL COATINGS cleaning and repainting. Repair test locations meeting adhesion requirements by applying organic zinc-rich primer to the specified dry film thickness.
2.Test surfaces where finish coats are to be applied for soluble salts. Soluble salt levels mus t not exceed the lesser of the coating manufacturer's recommendations or 10 μg/sq cm. Perform 3 tests for the first 1,000 sq ft prepared per day and 1 test for each additional 1,000 sq ft or portion thereof. Perform at least 2 tests when less than 1,000 sq ft is prepared in a shift. Clean and retest areas represented by soluble salt tests exceeding specified limits.
3.The inorganic zinc coating must exhibit a solid, hard, and polished metal surface when firmly scraped with the knurled edge of a quarter bef ore final or finish coats are applied. Repair areas that are powdery, soft, or do not exhibit a polished metal surface by blast cleaning and repainting. Perform the following additional testing for AASHTO M 300 Type II inorganic zinc primers:
1.Determine the dry -to-solvent insolubility under ASTM D4752 except use water as the solvent. The resistance rating must be at least 4. The test rate is 1 test per 500 sq ft or portion thereof. Repair inorganic zinc coating represented by tested areas that fail to me et solvent insolubility requirements by blast cleaning and repainting.
2.Before applying finish coats, test the surface pH. Wet the surface with deionized water from 15 to 30 minutes. Apply pH paper with measuring increments of 0.5 pH units. Take at least 2 pH readings for every 500 sq ft or portion thereof. If less than 500 sq ft is coated in a single shift, take at least 2 pH readings. Do not apply finish coats until the surface pH is 7 or less. Perform the following additional testing for AASHTO M 300 Type I inorganic zinc primers:
1.Determine the dry -to-solvent insolubility under ASTM D4752. The resistance rating must be at least 4. The test rate is 1 test per 500 sq ft or portion thereof. Repair inorganic zinc coating represented by tested areas that fail to meet solvent insolubility requirements by blast cleaning and repainting.
2.Determine surface hardness under ASTM D3363. Hardness must be 2H or harder. The test rate is 1 test per 500 sq ft or portion thereof. Repair inorganic zinc coating represe nted by tests that fail to meet surface hardness requirements by blast cleaning and repainting.
59-2.01B Materials
59-2.01B(1) General
Inorganic zinc -rich primer used on faying surfaces must comply with the slip coefficient specifications for Class B co atings on blast -cleaned steel in appendix A of Specification for Structural Joints Using High - Strength Bolts of the RCSC.
59-2.01B(2) Design Criteria
59-2.01B(2)(a) General
Reserved
59-2.01B(2)(b) Ventilated Containment Systems
Ventilated containment sy stems must comply with the specifications for scaffolding in section 7 - 1.02K(6)(e). The minimum total design load for the ventilated containment system must consist of the sum of the dead and live vertical lo ads. Dead and live loads are as follows:
1.Dead load must consist of the actual load of the ventilated containment system .
2.Live loads for bridges with only spot blast cleaning work must consist of: 2.1. Uniform load of at least 25 psf applied over the supported area 2.2. Moving concentrated load of 1 ,000 lb to produce maximum stress in the main supporting elements of the ventilated containment system
3.Live loads for bridges with 100 percent blast cleaning to bare metal must consist of: 3.1. Uniform load of at least 45 psf, which includes 20 psf of sand load, applied over the supported area 3.2. Moving concentrated load of 1 ,000 lb to produce maximum stress in the main supporting elements of the ventilated containment system SECTION 59 STRUCTURAL STEEL COATINGS Assumed horizontal loads do not need to be included in the design of the ventilated containment system. Maximum allowable stresses must comply with section 48 -2.02B(3).
59-2.01C Construction
59-2.01C(1) General
Clean and paint all exposed structural steel and ot her metal surfaces. You must provide enclosures for cleaning and painting structural steel. Enclosures must prevent release of overspray and new paint into the surrounding environment during paint application. Maintain atmospheric conditions inside enclosu res within specified limits. Cleaning and painting of new structural steel must be performed in an enclosed shop as defined in AISC - 420-10/SSPC -QP 3.
59-2.01C(2) Containment Systems
59-2.01C(2)(a) General
Construct containment systems when disturbing existing paint systems during bridge rehabilitation. The containment system must be one of the following:
1.Ventilated containment system
2.Vacuum -shrouded surface preparation equipmen t and drapes and ground covers
3.Equivalent containment system if authorized The containment system must contain all water, resulting debris, and visible dust produced when the existing paint system is disturbed. Properly maintain the containment system while work is in progress and do not change the containment system unless authorized. Containment systems over railroad property must provide the minimum clearances for the passage of railroad traffic specified in the Information Handout in the document titled "Railroad Relations and Insurance Requirements."
59-2.01C(2)(b) Ventilated Containment Systems
59-2.01C(2)(b)(i) General
If flexible framing is used, support and fasten it to (1) prevent the escape of abrasive and blast materials due to whipping fro m traffic or wind and (2) maintain clearances. If the wind speed reaches 50 mph or greater, relieve the wind pressure on the containment system using an authorized method. Scaffolding or supports for the ventilated containment system must not extend below the vertical clearance level nor to the ground line at locations within the roadbed. For truss -type bridges, all connections of the ventilated containment system to the existing structure must be made through the deck, girder, stringer, or floor beam system. No connections are allowed that will cause bending stresses in a truss member.
59-2.01C(2)(b)(ii) Ventilation
The ventilation system in the ventilated containment system must be of the forced input airflow type with fans or blowers. Negative air pressure must be employed within the ventilated containment system and will be verified by visual methods by observing the concave nature of the ventilated containment system while taking into account wind e ffects or by using smoke or other visible means to observe airflow. The input airflow must be properly balanced with the exhaust capacity throughout the range of operations. The exhaust airflow of the ventilation system in the ventilated containment system must be forced into wet or dry dust collectors or bag houses. SECTION 59 STRUCTURAL STEEL COATINGS
59-2.01C(3) Surface Preparation
59-2.01C(3)(a) General
Corners must be chamfered and without sharp edges. Condition thermal -cut edges before blast cleaning by shallow grinding or other authorized method to remove the thin, hardened layer resulting from resolidification during cooling. Remove visually -evident base metal surface irregularities and defects under ASTM A6 before blast cleaning new structu ral steel. After removing material defects exposed by blast cleaning, restore the blast profile by blast cleaning or using mechanical tools under SSPC -SP 11.
59-2.01C(3)(b) Cleaning
59-2.01C(3)(b)(i) General
Clean previously painted surfaces by pressure washing or steam cleaning before performing other cleaning or painting activities. Remove gloss from existing paint without removing sound paint. Lightly roughen remaining areas of gloss using 100 -to 200 -grit sandpaper. Paint that becomes loose, curled, lifted, or that loses its bond after cleaning must be removed to sound paint or metal. After pressure washing or steam cleaning, spot blast clean painted surfaces having rust or foreign material remaining that would hinder bonding of new paint. If there is no bid item for spot blast cleaning, this is change order work. Spot blast clean surfaces under SSPC -SP 6. For small areas, the Engineer may allow cleaning under SSPC -SP 11. Clean previously painted surfaces under SSPC -SP 2. Feather edges of remaining pain t. Do not use pneumatic chipping hammers unless authorized.
59-2.01C(3)(b)(ii) Blast Cleaning
Blast clean steel surfaces to be coated with inorganic zinc under SSPC -SP 10. After blast cleaning, surfaces must have a dense, uniform, angular anchor pattern o f 1.5 to 3.5 mils when measured under ASTM D4417. Where shown, spot blast clean existing painted steel surfaces under SSPC -SP 6. After blast cleaning, surfaces must have a dense, uniform, angular anchor pattern of at least 1.5 mils when measured under ASTM D4417. Seal journals, bearings, motors, and moving parts before blast cleaning near machinery. Reblast cleaned surfaces that rust or become contaminated before paint is applied. Do not expose blast -cleaned steel to relative humidity exceeding 85 percent b efore painting.
59-2.01C(4) Painting
59-2.01C(4)(a) General
Paint new structural steel as follows:
1.Apply the total thickness of undercoats before erection. Apply finish and final coats after erection. If a concrete deck is placed on steel members, apply finish and final coats after deck placement.
2.After erection and deck placement, clean and spot paint areas of damaged or deteriorated coating and exposed unpainted surfaces with undercoats to the specified thickness before applying subsequent coatings.
3.Clean and paint surfaces exposed to the atmosphere and inaccessible for painting after erection with the full number of coats before erection. Paint existing structural steel as follows:
1.Apply a stripe coat of undercoat paint on all edges, corners, seams, crevices, interior angles, junctions of joining members, weld lines, and similar surface irregularities. The stripe coat must completely hide the surface being covered. If spot blast cleaning portions of the bridge, apply the stripe coat of undercoat paint before each undercoat and follow with the undercoat as soon as SECTION 59 STRUCTURAL STEEL COATINGS practical. If removing all existing paint from the bridge, apply the undercoat first as soon as practical and follow with the stripe coat of undercoat paint for each undercoat.
2.Apply the finish coats after the total dry film thickness of undercoat has been applied.
3.Apply all undercoats and the 1st finish coat within 30 days of initial cleaning activities. Caulk contact surfaces of st iffeners, railings, built -up members, or open seams more than 6 mils wide with sealing compound or other authorized material. Apply the sealing compound at least 72 hours after the last application of undercoat unless otherwise authorized. Cure the sealing compound under the manufacturer 's instructions before performing subsequent painting activities. If no finish coats are applied, the sealing compound color must be gray. Limit the thickness of each paint application to allow uniform drying throughout the paint film. Paint ungalvanized anchor bolt assemblies with 2 applications of organic zinc -rich primer before installation. You do not need to paint other metal surfaces to be embedded in concrete. Prepare and paint (1) the bottom surfaces of masonry plates and (2) structural steel surfaces contacting elastomeric bearing pads or preformed fabric pads with the full number of applications before erection. Except for (1) abutting chord and column splices and (2) column and truss shoe bases, coat machine - finishe d surfaces with an easily removed rust inhibitor. Paint machine -finished surfaces of iron and steel castings with 1 coat of shop paint. Where bridge deck drains are located over steel girders, paint the top and edges of top flanges beneath drains and for 2 inches on each side of drains before installing the drains. Paint surfaces of machinery exposed to air with 2 coats of organic zinc -rich primer before installation. Paint exposed surfaces after installation with 2 finish coats o f commercial -quality gray gloss enamel.
59-2.01C(4)(b) Zinc Coating System
59-2.01C(4)(b)(i) General
Coatings for new structural steel and connections between new and existing structural steel must comply with the requirement s shown in the following tabl e: SECTION 59 STRUCTURAL STEEL COATINGS Zinc Coating System Requirements Description Coating Dry film thickness (mils) All new surfaces: Undercoat Finish coata Inorganic zinc primer : AASHTO M 300 Type I or II Exterior grade latexb , 2 coats 4–8 2 minimum each coat, 4–8 total Total thickness, all coats -- 8–14 Connections to existing structural steelc Undercoat Finish coata Inorganic zinc primer : AASHTO M 300 Type I or II Exterior grade latexb , 2 coats 4–8 2 minimum each coat, 4–8 total Total thickness, all coats -- 8–14 aIf no finish coats are described:
1.A final coat of inorganic zinc primer is required .
2.Total thickness of undercoats and final coat must be from 5 to 9 mils . bExterior grade latex must comply with section 91 -2.02B unless otherwise specified. cIncludes the following locations:
1.New and existing contact surfaces .
2.Existing member surfaces under new HS bolt heads, nuts, or washers .
3.Bare surfaces of existing steel after trimming, cutting, drilling, or reaming .
4.Areas within a 4 -inch radius from the point of application of heat for welding or flame cutting . Strain inorganic zinc primer after mixing through a 30 -to 60 -mesh screen immediately before or when pouring into the spray pot. Use an agitating spray pot. The agitator or stirring rod must reach to within 2 inches of the bottom of the spray pot and be moving at all times during pai nting. The agitator must keep the coating well mixed. Apply inorganic zinc primer by spray. On areas inaccessible to spray application, you may make limited applications if authorized by brush, dauber, or roller. Zinc coatings must be free from dust, dirt, salt, and other deleterious deposits and thoroughly cured before applying subsequent coats.
59-2.01C(4)(b)(ii) Undercoat
Use inorganic zinc primer within 12 hours of initial mixing of components. Apply the undercoat in 2 or more applications within 8 hou rs of starting blast cleaning. Blast clean and repaint areas where mudcracking of the undercoat occurs. Protect surfaces coated with Type II inorganic zinc from conditions that may cause the coating film to dissolve. Blast clean and repaint areas of dissol ved coating. Remove dry spray by screening or other methods that minimize surface polishing before applying additional coats or final acceptance. Dry film thickness after dry spray removal must comply with the specified thickness. If damaged area of the un dercoat is:
1.More than 2 percent of the total undercoated surface, blast clean and repaint damaged areas with inorganic zinc
2.2 percent or less of the total undercoated surface, you may wire brush the damaged surfaces to remove loose or cracked coating and apply 2 coats of organic zinc -rich primer SECTION 59 STRUCTURAL STEEL COATINGS At faying surfaces , the total undercoat dry film thickness must be from 1 mil to the maximum allowable for Class B coatings as determined by certified testing under appendix A of Specification for Structural Joints Using High -Strength Bolts of the RCSC. Complete the field testing of the undercoat and correct deficiencies before applying subsequent coats.
59-2.01C(4)(b)(iii) Final Coat
Apply a final coat of inorganic zinc primer to undercoated surfaces that do not receive finish coats. Use the same coating as used for the undercoat. Lightly roughen areas to receive a final coat by abrasive blasting. Use an abrasive no larger than 30 mesh. Protect undersurfaces of girder fla nges from abrasive blasting. Apply the final coat in 1 application within 24 hours of roughening. The final coat dry film thickness must be from 1 to 3 mils.
59-2.01C(4)(b)(iv) Finish Coats
Pressure rinse undercoated surfaces to receive finish coats. Perf orm pressure rinsing at least 72 hours after the final application of the undercoat. Apply the 1st finish coat within 48 hours of pressure rinsing. Apply the 1st finish coat in 2 applications. The 1st application consists of a spray -applied mist applicatio n. Apply the 2nd application after the mist application has dried to a set -to-touch condition as determined using the procedure in section 7 of ASTM D1640. Apply the 2nd finish coat after the 1st finish coat has dried 12 hours unless authorized. You may ap ply the 2nd finish coat in a single application. The 1st finish coat color must match color no. 34272 of AMS -STD-595. The 2nd finish coat color must match color no. 14090 of AMS -STD-595.
59-2.01C(4)(c) State Specification Paint Waterborne Coating System
The State Specification paint waterborne coating system for existing structural steel must comply with the requirement s shown in the following table: State Specification Paint Waterborne Coating System Requirements Surface Description State specification PWB coating Dry film thickness (mils) Surfaces cleaned to bare 1st undercoat 145 2–3 metala 2nd undercoat 146 2–3 1st finish coat 171 1.5–3 2nd finish coat 172 1.5–3 Total thickness, all coats -- 7–12 Existing painted surfaces Undercoat 146 2–3 to be topcoated 1st finish coat 171 1.5–3 2nd finish coat 172 1.5–3 Total thickness, new coats -- 5–9 aIncludes locations of spot blast cleaning Allow at least 12 hours of drying time before applying the subsequent undercoat or finish coats unless otherwise authorized.
59-2.01C(4)(d) Moisture -Cured Polyurethane Coating System
Reserved
59-2.01D Payment
Not Used SECTION 59 STRUCTURAL STEEL COATINGS
59-2.02 Painting Steel Soldier Piles
59-2.02A General
Section 59 -2.02 includes specifications for preparing and paint ing steel soldier piles. Where shown, prepare and paint steel soldier piles under the specifications for painting new structural steel in section 59 -2.01.
59-2.02B Materials
Not Use d
59-2.02C Construction
Repair damaged areas of the undercoat before installing piles. Protect the exposed exterior flange and flange edges of undercoated piles from lean concrete backfill to minimize undercoating repairs. After removing lean concrete bac kfill, repair damaged or deteriorated undercoat by blast cleaning and repainting with the same inorganic zinc coating as used for the undercoat. Where described, apply final or finish coats after installation and excavation are complete. For steel soldier piles that have no exposed surfaces or when finish coats are not required, you may apply the final coat before installation and erection. Caulk open joints between concrete and steel soldier piles with sealing compound or other authorize d material.
59-2.02D Payment
Not Used
59-2.03 59-2.05 Reserved
59-3 Painting Galvanized Surfaces
59-3.01 General
Section 59 -3 includes specifications for preparing and painting galvanized metal surfaces.
59-3.02 Ma Terials
Coatings must comply with either State Specification PWB -174A or with section 91 -2.02.
59-3.03 Construction
Clean galvanized surfaces by pressure washing or steam cleaning. Roughen galvanized areas after cleaning by abrasive blasting. Use an abrasive no larger than 30 mesh. Do not remove galvanizing. Apply 2 finish coats in at least 2 applications. Apply the 1st finish coat the same day abrasive blasting is performed unless otherwise authorized. Apply the 2nd finish coat after the 1st finish c oat has dried at least 12 hours unless otherwise authorized. The dry film thickness of each finish coat must be at least 2 mils. The dry film thickness of all coats must be from 4 to 8 mils. The 2nd finish coat color must match color no. 14090 of AMS -STD-595.
59-3.04 Payment
Not Used
59-4 Painting Sign Structures
59-4.01 General
Section 59 -4 includes specifications for preparing and painting sign structures. Preparing and painting of sign structures must comply with sections 59 -2 and 59 -3.
59-4.02 Mater Ials
Not Used SECTION 59 STRUCTURAL STEEL COATINGS
59-4.03 Construction
59-4.03A General
You may prepare and paint sign structures before or after erection. After erection, repair any damaged paint. The total dry film thickness of finish coats on contact surfaces of galvanized HS bolted con nections (1) must be from 1 to 4 mils and (2) may be applied in 1 application.
59-4.03B Undercoating of Ungalvanized Surfaces
Blast -cleaned surfaces must receive a single undercoat consisting of an inorganic zinc coating as specified in AASHTO M 300, Type I or Type II, except:
1.The first 2 sentences of section 5.6 do not apply
2.Section 5.6.1 does not apply If you propose to use a coating that is not on the Authorized Material List for inorganic zinc -rich primer , submit the required documentation speci fied in section 5.6 of AASHTO M 300. Allow 30 days for the Engineer's review.
59-4.03C Testing of Inorganic Zinc Coating
Reserved
59-4.03D Finish Coats
The exposed area of inorganic zinc coating must receive at least 2 finish coats of exterior grade latex paint. The 1st finish coat color must match no. 24558 of AMS -STD-595. The 2nd finish coat color must match no. 24491 of AMS -STD-595.
59-4.04 Payment
Not Used
59-5 Thermal Spray Coat Structural Steel
59-5.01 General
59-5.01A Summary
Section 59 -5 includes specifications for coating steel surfaces with a thermal spray coating.
59-5.01B Definitions
Reserved
59-5.01C Submittals
59-5.01C(1) General
Submit a certific ate of compliance for each shipment of wire feedstock.
59-5.01C(2) Coating Quality Work Plan
Submit 3 copies of a coating quality work plan for thermal spray coating activities. Allow 20 days for the Departm ent's review. Submit the work plan after attending the precoating meeting and include:
1.Names of the coating contractor and any subcontractors to be used
2.1 copy each of applicable ASTM and SSPC specifications or qualification procedures
3.Materials, methods, and equipment to be used
4.Proof of certification for each thermal spray coating operator
5.Methods to control environmental conditions
6.Methods to protect the coating during shipping, handling, and storage
7.Procedures for containing blast m edia
8.Examples of proposed daily reports for testing to be performed, including type of testing, location, time, weather conditions, test personnel, and results SECTION 59 STRUCTURAL STEEL COATINGS
59-5.01D Quality Assurance
59-5.01D(1) General
Each thermal spray coating operator must be certified under AWS C2.16/C2.16M.
59-5.01D(2) Precoating Meeting
Before starting coating activities, conduct a precoating meeting to discuss coating quality work plan requirements. Meeting attendees must include the Engineer and all coating subcontractors.
59-5.01D(3) Test Coupons
Thermal spray coating operators must prepare 3 test coupons for bend testing before each work shift. Test coupons must:
1.Be 2 by 6 inches by 1/16 -inch thick
2.Be of the same materia l as the surface to be coated
3.Pass bend test requirements before the operator starts production work Bend test coupons under section 6.5 of SSPC -CS 23 .00/AWS C 2.23M. Coupons must exhibit no cracking with lifting from substrate.
59-5.01D(4) Quality Co ntrol
The Engineer selects the test locations. If repairs are required, retest rejected areas after completing repairs. Test the surface profile of blast -cleaned steel under ASTM D4417, Method C. Perform 3 tests for the first 200 sq ft of blast -cleaned ste el and 1 test for every 200 sq ft thereafter. Test blast -cleaned steel for soluble salts before coating. Levels of soluble salts must not exceed 10 μg/sq cm. Perform 3 tests for the first 200 sq ft placed during a shift and 1 test for every 200 sq ft there after. Inspect surfaces for visual cleanliness under SSPC -SP 10 before applying coating. Test coating thickness under section 6.3 of SSPC -CS 23.00/AWS C 2. 23M. Perform 1 test for every 150 sq ft of coating and 1 test for each faying surface. Perform cut te sting under SSPC -CS 23.00/AWS C 2.23M . Perform 3 tests of 3 cuts for every 1,000 sq ft of coating. Surfaces must exhibit no peeling or delamination. Test coating adhesion to steel before applying seal coating. Thermal spray coating must have an adhesion to substrate of at least 850 psi. Perform 3 tests for every 200 sq ft of coating. Repair areas represented by tests failing adhesion or cut testing by removing and reapplying coating.
59-5.02 Materials
Abrasives must be (1) slag or mineral abrasive or (2) s teel or recycled steel. Wire feedstock must be 85/15 Zn/Al complying with ASTM B833. Seal coat paint must be authorized before use.
59-5.03 Construction
Do not apply coating when the steel surface temperature is less than 32 degrees F. Prepare the surfaces under section 59 -2.01C(3)(a). Blast clean surfaces under SSPC -SP 10. Surfaces must have a sharp, angular anchor pattern of from 2.5 to 4.0 mils. Reblast surfaces that rust or become contaminated before coating is applied. Apply coating using arc -spray equipment within 6 hours of starting blast cleaning. Coating thickness must be 10 ± 2 mils. Coating thickness on faying surfaces must be not more than 10 mils. SECTION 59 STRUCTURAL STEEL COATINGS Apply a seal coating to thermal spray -coated surfaces. Apply the seal coat within 6 hours of applying the thermal spray coating. Dry film thickness must be from 1.5 to 2.0 mils. Do not apply the seal coating to faying surfaces. You may field weld thermal spray -coated surfaces if authorized in advance. Remove thermal spray coating from weld locations by blast cleaning under SSPC -SP 10 or with power tools under SSPC -SP 11 immediate ly before welding. Recoat welded connections after fabrication . Repair test areas of thermal spray coating that meet adhesion and cut test requirements with 2 coats of organic zinc -rich primer.
59-5.04 Payment
Not Used
59-6 59-15 Reserved
Source: California Standard Specifications, 2024 Edition. Pages 903–918 of 1,372.