560COATING NEW STRUCTURAL STEEL

560-1 Description .

Coat new structural steel in accordance with the requirements of this Se ction. Apply the coating system designated in the Contract Documents.

560-2 Materials.

560-2.1 Coating System: Use only coating products and systems meeting the

requirements of Section 975 and listed on the Department ’s Approved Product List ( APL). All components of coating systems must be from the same manufacturer. Use Type M coal tar epoxy coatings meeting the requirements of Section 926 and listed on the Department’s APL for coating of permanent bulkhead sheet piles and H piles.

560-2.2 Thinners, Solvents and Cleaners: Use thinners, solvents and cleaners listed on

the coating manufacturer’s product data sheet.

560-2.3 Caulking: Use caulks that are paintable, compatible with the coating system and

recommended by the coating manufacturer as part of the coating system.

560-2.4 Soluble Salts Test Kit: Measure the soluble salts using methods in compliance

with SSPC -Guide 15, Table 1. Use a fully automated conductivity meter, fiber strip or multi -step patch, cell, or ring. Ensure the test sleeve or cell creates a sealed, encapsulated environment during ion extraction and is suitable for testing all structural steel surfaces.

560-2.5 Abrasives: Use properly sized abrasives to achieve the required cleanliness and

anchor profile. Use abrasives meeting the requirements of SSPC -AB 1, Mineral and Slag Abrasives, SSPC -AB 2, Cleanliness of Recycled Ferrous Metallic Abrasives, or SSPC -AB 3, Newly Manufactured or Re -Manufactured Steel Abrasive and do not introduce any contamination that interferes with the coating application and performance. Submit certification to the Engineer that the abrasives used meet the requirements of this Section and do not contain any chlorides and other salts. For non- metallic abrasives, verify compliance with the conductivity and cleanliness requirements of SSPC -AB1. For recycled abrasives, verify compliance with the conductivity and cleanliness requirements of S SPC-AB 2 after each recycling or more frequently if required by the Engineer. Select a sample from each recycling machine in use and conduct the water-soluble contaminant and oil content tests outlined in SSPC -AB 2 at least one time each week or more frequ ently if directed by the Engineer. Conduct the non -abrasive residue and lead content tests as directed by the Engineer. If test results do not meet requirements, notify the Engineer immediately, remove and replace the abrasive, clean the recycling equipmen t, and conduct tests each day to confirm the equipment is functioning properly. Return to the weekly testing interval as directed by the Engineer.

560-2.6 Rust Preventative Compound: Use a Class 3 rust preventative compound

meeting the requirements of Military Specification MIL-C-11796C, Corrosion Preventative Compound, Petrolatum, Hot Applied.

560-2.7 Storage: Store materials in conformance with the manufacturer’s

recommendations . FY 2023-24 Return to Table of Contents

560-3 Equipment.

560-3.1 Compressed Air: Use a compressed air system capable of delivering clean, dry,

continuous nozzle pressure to achieve the required surface cleanliness and profile or spray pattern. The system must comply with the instructions and recommendations of the manufacturer of the abrasive blasting syst em or coating application system.

560-3.2 Abrasive Blasting System: Design the blasting system to produce the specified

cleanliness and profile.

560-3.3 Coating Application System: Use the coating application equipment approved

by and in accordance with the coating manufacturer’s technical data requirements.

560-4 Environmental, Health and Safety Requirements.

Isolate the work areas with containment devices, canvasses, tarpaulins or screens during all surface preparation and coating application operations. Dispose of all debris and waste products generated in accordance with all Federal, State and Local regulations.

560-5 Quality Control (QC).

560-5.1 Shop Preparation and Applicati on: Prior to applying coatings, submit a current

Corporate Quality Control Plan approved by the American Institute of Steel Construction (AISC) under the Sophisticated Paint Endorsement Program or SSPC under the SSPC -QP3 certification or NACE International Institute Contractor Accreditation Program (NIICAP) AS -1S certification program to the State Materials Office for approval.

560-5.2 Field Preparation and Application: For the surface preparation of steel and

application of coatings, s ubmit a current Corp orate QC Plan approved by SSPC under the SSPC - QP1 or NIICAP AS-1F certifications and a site specific coating plan to the Engineer at least 14 calendar days prior to beginning coatings work. For the removal of hazardous coatings, submit a current Corporate QC Plan approved by SSPC under SSPC-QP2 and a site specific coating plan to the Engineer at least 14 calendar days prior to beginning coatings work . Do not begin coatings work until the site specific coating plan has been approved by the Engineer .

560-5.3 Inspection: Ensure that all inspection equipment is maintained in accordance

with the manufacturer’s instructions, calibrated, and in good working condition. Ensure that all activities are observed and approved by a quality control coatings inspect or meeting the requirements of this Section. Maintain daily inspection reports at the job site for review by the Engineer. Submit all daily inspection reports upon completion of the project to the Engineer or more frequently as requested by the Engineer.

560-6 Qualifications.

560-6.1 Shop: Submit documentation to the Engineer at least 14 days prior to beginning

work that the shop performing any work in accordance with this Section is certified by AISC Sophisticated Paint Endorsement or by SSPC to the requi rements of SSPC -QP3.

560-6.2 Field Contractor: Submit documentation to the Engineer at least 14 days prior

to beginning work that the field contractor performing any work in accordance with this Section is certified by SSPC to the requirements of SSPC -QP1 and/or SSPC -QP2 as appropriate.

560-6.3 Quality Control (QC) Supervisor in the Shop and Field: Personnel

performing inspection of coating activities in the supervisory position must visit the shop at suitable intervals throughout the coating process. Per sonnel performing inspection of coating activities in the supervisory position must visit the field location at suitable intervals throughout the coating process, as defined in the site specific coating plan . Submit documentation to the FY 2023-24 Return to Table of Contents Engineer that all acting as supervisors are certified , at a minimum , to one of the following certifications:

560-6.3 1 Certifications: Maintain certifications for the duration of the Contract.

If the certifications expire, do not perform any work until certifications are reissued. The QP-1 requirement for a Coating Application Specialist may be waived on a project when there is no media blasting involved in the operations. The request should be identified in the site specific coatings plan. Notify the Engineer of any change in certification sta tus.

560-7 Surface Preparation.

560-7.1 General: Ensure all surfaces to be coated are clean, dry, and free from oil,

grease, dirt, dust, soluble salts, corrosion, peeling coating, caulking, weld spatter, mill scale and any other surface contaminants. Prep are all surfaces that will become inaccessible after fabrication, erection, or installation while accessible. Sequence the surface preparations and coating operations so that freshly applied coatings will not be contaminated by dust or foreign matter. Prot ect all equipment and adjacent surfaces not to be coated from surface preparation operations. Protect working mechanisms against intrusion of abrasive. In the event that any rusting or contamination occurs after the completion of the surface preparation, p repare the surfaces again to the initial requirements. Perform surface preparation work only when the temperature of t he steel surface is at least 5º F above the dew point temperature.

560-7.2 Mechanical Removal of Surface Defects: Break all corners result ing from

sawing, burning, or shearing. In areas where burning has been used, remove the flame hardened surface of the steel to the extent necessary to achieve the required surface profile after abrasive blast cleaning. Remove all weld slag and weld spatter . Conduct all of this work in accordance with AASHTO/NSBA Steel Bridge Collaboration S 8.1.

560-7.3 Cleaning: Clean all steel surfaces in accordance w ith the requirements of SSPC -

SP 1.

560-7.4 Washing: Clean all steel surfaces in accordance with the requirements of SSPC -

SP 12 LPWC WJ4.

560-7.5 Soluble Salts Detection and Removal: When using SSPC Guide 15, Table 1

retrieval methods, determine the chloride, sulfate and nitrate concentrations on all steel surfaces using soluble salts test kits meeting the requirements of 560 -2.4. Perform the tests after washing and after each applied coat of the coating system. Ensur e the non-visible surface contaminant concentration on blast -cleaned surfaces do es not exceed the limits in Table 560 -1. When quality control documentation at a fixed location indicates 36 months of historical sequential contaminant levels below those spec ified in Table 560-1, the Department may allow testing frequency to be reduced to one chloride contamination test per day. When any concentration or conductivity measurement exceeds the levels given in Table 560-1, rewash the entire surface area and retest all potentially contaminated steel to the satisfaction of the Engineer. If additional washing does not reduce the concentration to the acceptable level, a surface treatment or water additive may be used. Use a surface treatment or water additive that is a pproved by the coating system supplier and the Engineer. FY 2023-24 Return to Table of Contents Table 560-1 Allowable Surface Contaminants Coating Stage Frequency of Test Acceptance Criteria Post-Blast, Pre -Coating 1 test (per 1,000 ft2) ≤ 17 µg/cm2 Sulfates ≤ 10 µg/cm2 Nitrates ≤ 70 µS/cm2 Conductivity ≤ 7 µg/cm2 Chlorides Between Coats 3 tests (first 1,000 ft2) 1 test (ea. Additional 1,000 ft2) ≤ 7 µg/cm2 Chlorides

560-7.6 Abrasive Blast Cleaning: Prepare steel by abrasive blast cleaning to “ near-

white” metal condition as defined in SSPC -SP 10. Use SSPC VIS 1 as an aid in establishing cleanliness. After abrasive blast cleaning, ensure the surface profile meets the requirements of the coating manufacturer’s product data sheet. Determine the surface profile in accordance with ASTM D4417, Method B or C. Perform all abrasive blast cleaning within a containment system to ensure confinement of all particulates. Design the containment system to comply with all applicable Federal, State, and Local regulations. Ensure the abrasive blast cleaning does not produce holes, cause distortion, remove metal, or cause thinning of the substrate.

560-7.7 Hand and Power Tool Cleaning: Prepare steel by power and hand tool cleaning

as defined in SSPC -SP 11, SSPC -SP 15, SSPC -SP 3, and SSPC-SP 2 for touch up and repair when approved by the Engineer. Use SSPC -VIS 3 as an aid in establishing cleanliness.

560-8 Surfaces Not to be Coated.

560-8.1 Galvanized Surfaces: Do not coat galvanized surfaces unless specified in the

Contract Documents . When painting is required by the Contract Documents, perform sampling and testing in accordance with Section 649 and 975 -4.

560-8.2 Surfaces to be in Contact with Concrete: Do not coat the areas of contact

surfaces of steel to be encased or embedded in concrete, or coated with concrete unless specified in the Contract Documents. When specified, prepare the contact surfaces and apply primer.

560-8.3 Faying Surfaces: After application of the primer, protect the contact surfaces of

members to be joined by high-strength bolts in friction type joints from all other coatings and foreign material.

560-8.4 Machine Finished Surfaces: Apply a coating of rust preventative compound to

all machine finished or similar surfaces that are not to be coated, or will not b e coated immediately.

560-8.5 Surfaces to be Welded : Mask off surfaces within 1 inch of field welded

connections before the application of any shop coating. Apply a mist coat of primer that is less than 1 mil dry film thickness to surfaces where shear stu ds will be welded.

560-9 Application.

560-9.1 General: Apply a complete coating system to all structural steel surfaces except

surfaces indicated in 560 -8. Apply a complete coating system to all surfaces that will become inaccessible after fabrication, er ection, or installation . FY 2023-24 Return to Table of Contents Apply the prime coat in the shop . Apply the intermediate coat in the shop or field. Only apply the finish coat after erection and after concrete work is complete. Prior to the application of any coating, inspect the substrate f or contamination and defects, and prepare the surface in accordance with 560 -7 before application of the next coat. Apply each coat including a stripe coat in a color that contrasts with the substrate or preceding coat. For exterior surfaces, apply a finish coat color meeting FED-STD-595, Shade 36622, unless otherwise specified in the Contract Documents.

560-9.1 1 Interior Box or Tub Girders: Apply a coat of white amine epoxy

directly to the surface of all interior components of steel box or tub girders. Caulk and paint all bolted asse mblies and joints in accordance with 560-9.7. When stud welding is specified, apply a mist coat of inorganic zinc -rich primer to the top flange at a dry film thickness no greater than 1 mil. Prevent rust bleeding from the top flange from staining adjacent painted surfaces.

560-9.2 Weather and Temperature Limitations: Do not spray coating when the

measured wind speed in the immediate coating area is above 15 miles per hour. Do not apply coatings when contamination from rainfall is imminent or when the ambient air temperature, relative humidity, dew point temperature, or temperature of the s teel is outside limits of the coating manufacturer’s product data sheet.

560-9.3 Protection of Adjacent Surfaces: Protect all surfaces and working mechanisms

not intended to be coated during the application of coatings. Clean surfaces that have been contaminated with coatings until all traces of the coating have been removed. Do not allow material from cleaning and coating operations to be dispersed outside the work site.

560-9.4 Mixing and Thinning: Mix all coatings in accordance with the manufacturer’s

product data sheet. Only mix complete kits. Use thinners and solvents in accordance with the requirements of the coating manufacturer’s product data sheet and confirm that the amount of thinner added does not result in the coating exceeding VOC regulations stated in Section 975. Perform all mixing operations over an impervious surface with provisions to prevent runoff to grade of any spilled material.

560-9.5 Application Methods: Use coating application equipment and apply coatings

per the coating manufacturer’s product data sheet. Application with brushes may be permitted for minor touchup of spray applications, stripe coats, or when otherwise approved by the Engineer. Adjust spray equipment to produce an even, wet coat with minimum overspray. Appl y coatings in even, parallel passes, overlapping 50 percent. Agitate coatings during application as required by the coating manufacturer’s product data sheet.

560-9.6 Stripe Coating: Use an aluminum epoxy mastic that is at least 80% solids by

volume and is approved to be compatible with the coating system by the coating system manufacturer . Apply a stripe coat after the prime coat, but prior to applying the intermediate coat. Also , apply a stripe coat after the intermediate coat but prior to the finish coa t. Apply the stripe coat per the manufacturers published product data sheet but no less than 3 mils dry film thickness. Apply both stripe coats to achieve complete coverage on welds, corners, crevices, sharp edges, bolts, nuts, rivets, and rough or pitted surfaces. A stripe coat of translucent coatings is not required. Do not apply subsequent coats until the previous stripe coat has cured per the manufacturer’s product data sheet for recoating. Stripe coating is not required for the inside surface area of a ll steel box girders.

560-9.7 Sealing Using Caulk: Apply caulk after the intermediate coat has cured to a

condition suitable for recoating in accordance with the manufacturer’s product data sheet, and before application of the finish coat. Completely seal the perimeter of all cracks and cre vices, FY 2023-24 Return to Table of Contents joints open less than 0.5 inch, and skip -welded joints using caulk. Apply the caulk to the joint following the caulk manufacturer’s recommendations. Ensure the caulk bead has a smooth and uniform finish and is cur ed according to the caulk manufacturer’s curing schedule prior to the application of the finish coat. Caulking the perimeter of bolted splice plates are not required unless directed by the Engineer. Caulking cracks or crevices less than 0.003 inches in wid th within the interior surface of box girders is not required .

560-9.8 Thickness of Coats: Apply coatings to the thickness as identified in the

manufacturer’s product data sheet. After application of each coat, thoroughly inspect the surfaces and measure the dry film thickness (DFT) in accordance with SSPC -PA 2. As an exception to SSPC-PA2, the DFT of the prime coat shall not be less than the minimum specified by the manufacturer’s product data sheet. When the DFT is deficient or excessive, correct in acco rdance with the coating manufacturer’s recommendations and retest the area.

560-9.9 Coating Drying, and Curing: Apply coatings within the time specified by the

coating manufacturer’s product data sheet for drying and recoating. Test the coating for proper cure before handling and shipping. Test for cure in accordance with the manufacturer’s recommended method. Meet the requirements of ASTM D4752 for inorganic zinc primers or ASTM D5402 for organic zinc primers when the manufacturer’s technical data s heet does not state a specified cure test. Obtain the acceptance criteria from the coating manufacturer and report the results to the Engineer. Prior to assembling bolted connections, test and verify that the primer coating on the faying surfaces has cur ed to a resistance rating of 5 in accordance with ASTM D4752, ASTM D5402, or the coating manufacturer’s requirements. If cure testing is performed per the coating manufacturer’s requirements, submit the test results to the Engineer for approval prior to assembling the bolted connection.

560-9.10 Coating Finish: Apply each coat free of runs, sags, blisters, bubbles, and mud

cracking; variations in color, gloss, or texture; holidays; excessive film buildup; foreign contaminants; orange peeling; and overspray .

560-10 Touchup and Repair.

560-10.1 Faying Surfaces: Reapply primer to all damaged surfaces using an approved

organic zinc -rich primer. Do not use epoxy mastics on faying surfaces. Maintain a class B slip- critical coefficient by repairing faying surfac es in slip-critical connections in accordance with

560-8 3.

560-10.2 Repairs Other Than Faying Surfaces: Touch up all flaws and damaged areas.

Clean and coat all welds , rivets, bolts, and all damaged or defective coating and rusted areas in accordance wit h 560-7 and 560 -9. Repair damaged surfaces using an approved organic zinc -rich primer. Upon approval by the Engineer, aluminum mastic may be used in accordance with the manufacturer’s recommendations and approval by the coating manufacturer . Aluminum masti c must contain aluminum pigment and minimum 80% volume solids.

560-11 Coating of Permanent Sheet, Pipe and H -Piles.

560-11.1 Surface Preparation: Prepare the substrate in accordance with 560 -7. Provide

a depth of anchor profile in accordance with the manu facturer’s product data sheet, but in no case less than 2.5 mils. Re-blast piles not coated during the same shift or if the surface to be coated no longer meets the requirements SSPC -SP 10.

560-11.2 Application of Coating: Unless otherwise shown in the Contract Documents,

apply the inorganic zinc primer to all surfaces of H and sheet piles and the exterior surface of FY 2023-24 Return to Table of Contents pipe piles in accordance with the limitations of 560 -8. Unless otherwise shown in the Contract Documents, app ly coal tar -epoxy coatings to the exposed side of sheet piles from the top of the piles to a depth of five feet below the lower of the design ground surface or the design scour depth in accordance with the limitations of 560 -8. Apply the inorganic zinc pri mer in accordance with this Section. Apply the coal tar -epoxy in accordance with the following specific requirements:

560-12 Method of Measurement .

For coating all new structural steel in I-girder and box or tub girder superstructures and bent caps, the quantity to be paid for will be the lump sum quantity, completed and accepted .

560-13 Basis of Payment.

For I-girder and box or tub girder superstructures and bent caps, price and payment will be full compensation for all work specified in this Section, including furnishing and applying all materials to complete the coating for the new structural steel. No separate payment will be made for coating all other structural steel. Payment for coating all new structural steel in I -girder and box or tub girder superstructures and bent caps will be made under: Item No. 560 - 1- Coating System for New Structural Stee l - lump sum. FY 2023-24 Return to Table of Contents SECTION 56 1 COATING EXISTING STRUCTURAL STEEL

561-1 Description .

Coat existing structural steel in accordance with the requirements of this Section by removing and replacing the existing coating or overcoating the existing coating as stated in the Contract Documents.

561-2 Materials .

561-2.1 Coating System s: For removal and replacement systems, u se coating products

and systems meeting the requirements of Section 975 and are listed on the Department ’s Approved Product List ( APL). For overcoating systems, use products and systems as designated in the Contract Documents. S ubmit product data sheets and product Material Safety Data Sheets (SDS), or in lieu of SDS, submit test reports showing percent weight compositional analysis , Chemical Abstract Number, American Conference of Governmental Industrial Hygienists ( ACGIH) time weighted average and ceiling exposure limits for all components, and lower and upper explosive limits, flash point, boiling point, amount of volatile organic compounds by weight, and specific gravity for each component of the coating system .

561-2.2 Thinners , Solvents and Cleaners: Meet the requirements of 560 -2.2. In

addition, for overcoating systems, use thinners, solvents, and cleaners that do not damage the existing coating system.

561-2.3 Caulking: Meet the requirements of 560 -2.3.

561-2.4 Soluble Salts Test Kit: Meet the requirements of 560 -2.4.

561-2.5 Abrasives: Meet the requirements of 560 -2.5.

561-2.6 Rust Preventative Compound: Meet the requirements of 560 -2.6.

561-2.7 Storage: Meet the requirements of 560 -2.7.

561-3 Equipment .

561-3.1 Compressed Air: Meet the requirements of 560 -3.1.

561-3.2 Abrasive Blasting System: Meet the requirements of 560 -3.2.

561-3.3 Coating Application System: Meet the requirements of 560 -3.3.

561-4 Quality Control (QC).

561-4.1 Field Preparation and Application: For the surface preparation of steel and

application of coatings, submit a current SSPC QP1 or National Association o f Corrosion Engineers (NACE) International Institute Contractor Accreditation Program (NIICAP) AS -1F certification with the Corporate QC Plan that was reviewed by SSPC or NIICAP under the current certification and a site specific coating plan to the Engine er at least 14 calendar days prior to beginning coatings work. For the removal of hazardous coatings, submit a current SSPC QP2 certification with the Corporate QC Plan that was reviewed by SSPC under the current certification and a site specific coating p lan to the Engineer at least 14 calendar days prior to beginning coatings work. Do not begin coatings work until the site specific coating plan has been approved by the Engineer. Prepare a traffic control plan for each phase of construction activities si gned and sealed by the Contractor’s Engineer of Record in accordance with the FDOT Design Manual. Do not begin work until the traffic control plan is approved by the Engineer. Maintain traffic in accordance with Section 102. FY 2023-24 Return to Table of Contents