561COATING EXISTING STRUCTURAL STEEL

COATING EXISTING STRUCTURAL STEEL

561-1Description

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.

561-2Materials

561-2.1Coating Systems: 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 .

561-2.2Thinners , 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.

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

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

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

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

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

561-3Equipment

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

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

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

561-4Quality Control (QC)

561-4.1Field 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 Engineer 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. 800 FY 2023-24 Return to Table of Contents For work over navigable waters, submit a work plan to the United States Coast Guard including any scheduled restrictions to navigation channels or marine traffic. Obtain Coast Guard approval at least 30 days in advance of any restrictions.

561-4.2Inspection: Meet the requirements of 560 -5.3

561-5Qualificati ons

561-5.1Field Contractor : Meet the requirements of 560 -6.2

561-5.2Quality Control (QC) Personnel : Meet the requirements of 560 -6.3

561-5.3Certifications: Meet the requirements of 560 -6.4

561-6Surface Preparation

561-6.1General: When portions of the existing coating are designated in the Contract

Documents to be removed and replaced, clean, wash, test and remove soluble salts, and abrasive blast or hand and power tool clean to remove all existing coating and corrosion in the inte nded locations. Feather back the edges of all existing coating to remain a minimum of 3 inches around the area of existing coating removed to provide a smooth transition. Verify the edges of the existing coating are intact by probing with a dull putty knif e in accordance with SSPC SP 2. Roughen the existing coating in the feathered area to ensure proper adhesion of the new coating. Notify the Engineer immediately when any structural steel appears to be defective. When the existing coating is to remain, cl ean, wash, and test and remove soluble salts. 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. Sequence the surface preparations and coating operations so that freshly applied coatings will not be contaminated by dust or foreign matter. Protect all equipment and adjacent surfaces not to be coated from surface preparation operations. Protect working mechan isms against intrusion of abrasive. In the event that any rusting or contamination occurs after the completion of the surface preparation, prepare the surfaces again to the initial requirements. Perform surface preparation work only when the temperature of the steel surface is at least 5oF above the dew point temperature.

561-6.2Mechanical Removal of Surface Defects: Meet the requirements of 560 -7.2. In

addition, r emove all pack rust prior to solvent cleaning.

561-6.3Cleaning : Meet the requirements of 5 60-7.3

561-6.4Washing: Meet the requirements of 560 -7.4

561-6.5Soluble Salts Detection and Removal : Meet the requirements of 560 -7.5 except

test five random locations in the first 1 ,000 square feet and one random location for each subsequent 1 ,000 square feet.

561-6.6Abrasive Blast Cleaning : Meet the requirements of 560 -7.6

561-6.7Hand and Power Tool Cleaning: Prepare steel by power and hand tool cleaning

as defined in SSPC SP 11, SSPC SP 3, and SSPC SP 2 as stated in the Contr act Documents. Use SSPC VIS 3 as an aid in establishing cleanliness.

561-7Surfaces Not to be Coated

561-7.1Galvanized Surfaces: Meet the requirements of 560 -8.1

561-7.2Machine Finished Surfaces: Meet the requirements of 560 -8.4

801 FY 2023-24 Return to Table of Contents

561-8Application

561-8.1General: Apply a complete coating system to all structural steel surfaces except

surfaces indicated in 561-7. Prior to the application of any coating, inspect the substrate for contamination and defects, and prepare the surface in accordance with 561-6 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 meetin g FED-STD-595, Shade 36622, unless otherwise specified in the Contract Documents.

561-8.2Weather and Temperature Limitations: Meet the requirements of 560 -9.2

561-8.3Sealing Using Caulk: Meet the requirements of 560 -9.7

561-8.4Protection of Adjacent Surfaces: Meet the requirements of 560 -9.3

561-8.5Mixing and Thinning: Meet the requirements of 560 -9.4

561-8.6Application Methods: Meet the requirements of 560 -9.5

561-8.7Stripe Coating: Meet the requirements of 560 -9.6

561-8.8Thickness of Coats: Meet the requirements of 560 -9.8

561-8.9Coating Drying, and Curing: Apply coatings within the time specified by the

coating manufacturer ’s product data sheet for drying and recoating. B efore handling , test for cure in accordance with the manufacturer’s recommended method. Meet the requirements of ASTM D5402 for organic zinc primers when the manufacturer’s technical data sheet does not state a specified cure test. Obtain the acceptance criteria from the coating manufacturer and report the results to the Engineer.

561-8.10Coating Finish: Meet the requirements of 560 -9.10

561-9Touchup and Repair

Clean and coat all welds, rivets, bolts, and a ll damaged or defective coating and rusted areas in accordance with 561-6 and 561-8. Upon approval by the Engineer, aluminum mastic may be used in accordance with the manufacturer’s recommendations . Aluminum mastic must contain aluminum pigment and minimum 80% volume solids.

561-10Protection of the Environment, Public, and Workers

561-10.1General: Establish plans and programs to protect the environment, public,

contractor employees, other workers, and property from overspray, exposure to toxic heavy metals and the release and emission of hazardous materials and nuisance dusts. Include in such plans and programs a procedure for the receipt, processing, evaluation and timely written response for claims by the public for damage resulting from the foregoing work. Submit to the Department any written response which denies such damage claims. Conduct all coating application and removal operations in compliance with EPA, OSHA, and other applicable Federal, State and local regulations. Submit a contingency plan for the remediation of water and land in the event of contamination by solid or liquid paint and c ontaminated water.

561-10.2Environmental Protection: Prepare and submit to the Engineer, plans and

programs for the protection of the environment and public based on the applicable EPA requirements, the requirements of this Section, and the Contract Documents. Include plans and programs for the protection of the air, soil/ground, and water. 561-10.2.1 Pollution Control: Submit a written pollution control and monitoring plan at the preconstruction meeting or as directed by the Engineer which clearly des cribes the means for complying with all Local, State and Federal regulations including pollution control provisions specified herein. The written plan must be in accordance with SSPC Project Design: Industrial Lead Paint Removal Handbook, Volume II, Phase 6, Environmental Monitoring, and 802 FY 2023-24 Return to Table of Contents specifically include, but not be limited to , providing a scaled map of the work site layout showing the proposed number and location of soil sampling, Total Suspended Particulate (TSP) monitoring sites, waste storage areas, staging areas , temporary waste storage areas , and ambient air and personnel sampling frequency . Comply with all applicable Federal, State, and Local rules and regulations. Immediately cease all operations i n the event a violation of any environmental regulation or a failure to properly execute any pollution control provisions occurs. R esume operations after written proposed corrective procedures have been submitted to and approved by the Engineer and implemented. 561-10.2.2 Permits: Submit all requi red permits from all applicable regulatory agencies to the Engineer prior to the commencement of any work. Seek permit determination from these regulatory agencies to avoid any potential permit non-compliance issues during work activities. The Contractor i s responsible for all liability resulting from non -compliance with pertinent rules and regulations including permit requirements. 561-10.2.3 Ambient Air Quality Compliance and Protection of the Air : 561-10.2.3.1 Visible Emissions: Assess the visible e missions using EPA Method 22, Timing of Emissions as defined by 40 CFR 60, Appendix A, Standards of Performance for New Stationary Sources. During abrasive blasting, do not allow visible emissions from a containment to exceed a random cumulative duration of more than one percent of the workday (SSPC Guide 6, Level 1 Emissions). During pressurized water cleaning, do not allow visible emissions from a containment to exceed a random cumulative duration of more than ten percent of the workday (SSPC Guide 6, Level 3 Emissions). 561-10.2.3.2 Total Suspended Particulate (TSP) Matter: Control emissions from the containment area to prevent exceeding the TSP lead of 1.5 μg/m over a

90 day period, or the daily and adjusted daily allowances of SSPC-TU 7. Conduct TSP Lead

monitoring in accordance with 40 CFR 50, Appendix B, Reference Method for Determination of

TSP Matter in the Atmosphere (high volume sampler required), and 40 CFR 50, Appendix G,

Reference Method for Determination of TSP Matter Collected from Ambient Air. Position the

TSP lead monitoring equipment in general accordance with 40 CFR 58, Ambient Air Quality

Surveillance.

When lead is present in the coating, perform TSP Lead background

monitoring for a period of 3 days prior to the beginning of abrasive blast cleaning operations.

Submit the results from background monitoring and the first week of monitoring during abrasive

blast cleaning to the Engineer for review within 5 calendar days after the first week of work.

Continue monitoring unless otherwise directed by the Engineer.

561-10.2.3.3 Regulated Area: Establish a regulated area around the work

site to prohibit unauthorized persons from areas where exposure to hazardous airborne metals

may exceed the following action levels:

Table 561-1

Hazardous Airborne Metals and Action Levels

Airborne Metals Action Level

Lead 30 μg/m

Cadmium 2.5 μg/m

Arsenic 5 μg/m

Hexavalent Chromium (Cr 6+ ) 2.5 μg/m 803FY 2023-24Return to Table of Contents

Conduct monitoring in accordance with the National Institute for

Occupational Safety and Health (NIOSH) procedures upon initiation of dust producing

operations and submit the test results to the Engineer within 72 hours of sampling. Report sample

results as eight-hour Time Weighted Averages (TWA). Reestablish the regulated area and

perform additional sampling when the results exceed the action levels or when directed by the

Engineer. Record all pertinent data. Position air-sampling pumps around the project perimeter

where the public or personnel can approach the work area. Place sampler inlets at breathing

height. Clearly mark the regulated area by the use of warning signs, rope, barrier tape, or

temporary construction fencing.

561-10.2.4 Soil/Ground Quality: Inspect the ground beneath and in proximity to

the structure in the presence of the Engineer for visible paint chips to establish an initial job site

cleanliness standard. When heavy metals are in the existing coatings, test soil samples prior to

the beginning of operations and after project completion for heavy metals. Document the number

and specific locations where the initial samples are taken as outlined in the SSPC Project Design-

Industrial Lead Paint Removal Handbook, Volume 2 to ensure the post samples are collected

from the same locations. Submit all samples to the Engineer for review. If the project activities

increase the heavy metal content in soil to more than 20% above the pre-job geometric mean or

100% at any one location, return the site to the pre-job levels. Conduct additional soil testing as

necessary to determine the extent of contamination.

For structures less than 14 feet minimum height, take one sample north,

south, east, and west (where soil is present) of the structure. If the structure is longer than 14 feet,

take one additional sample for every 14 feet in length.

For structures greater than 14 feet minimum height, take two samples

north, south, east, and west (where soil is present) of the structure. Locate the inner row of

samples within 14 feet of the structure. Locate the outer row of samples at a distance equal to the

height of the structure. If the structure is longer than 14 feet, take one additional sample for every

14 feet in length.

In addition, submit a pre- and post- soil sampling plan for storage areas

identifying the sample location, depth, analyses list, lab certification, and turnaround time. Once

approved by the Engineer, submit sampling results along with a scaled drawing indicating

designated sample locations.

561-10.2.5 Water Quality: Do not release, discharge or otherwise cause

hazardous materials, debris, waste, or paint chips to enter the water. Protect against releases due

to rain and methods of surface preparation from reaching rivers, streams, lakes, storm drains, or

other bodies of water.

561-10.3Containment System: Submit a written containment system design plan in

accordance with this section and the contract documents at the pre-construction conference or as

directed by the Engineer which clearly describes the proposed containment system applicable to

the intended removal method and in accordance with the requirements outlined herein and

SSPC Guide 6, Guide for Containing Debris Generated During Paint Removal Activities. Ensure

the plan includes, but is not limited to, removal method; methods for collecting debris; and

containment enclosure components. Use fire retardant materials. Submit containment drawings,

calculations, assumptions, ventilation criteria if applicable, and a structural analysis that verifies

the existing structure can withstand the additional dead, live and wind loads imposed by the

containment system, signed and sealed by a Specialty Engineer. However, for more complex

structures incorporating cables stayed, suspension, or truss designs, the analysis must be

performed by the Contractor’s Engineer of Record qualified in Type Work Category 4.3,

Complex Bridge Design. Submit a contingency plan addressing natural weather events such as 804FY 2023-24Return to Table of Contents

tropical storms and hurricanes. Ensure the lighting inside the containment is in accordance with

SSPC Guide 12, Guide for Illumination of Industrial Painting Projects. Provide lighting to a

minimum intensity of 10 ft-cd for general, 20 ft-cd for work, and 50 ft-cd for inspection. All

drawings and calculations must be submitted and accepted before any work begins. Include a

clear description of the ventilation system components and information including the fan curve

and design point on the proposed dust collector. Design to provide ventilation according to the

notes provided in SSPC Guide 6: 100 feet per minute for cross draft and 50-60 feet per minute

for downdraft.

Isolate the immediate area of the structure to ensure compliance with current and

permit requirements for air, water, soil, and pollution prevention. Protect the containment system

from vehicular and pedestrian traffic. Ensure paint, paint chips, or other debris will not fall

outside of the containment area under any circumstances. Repair any damage created by

fastening, bracing, or handling the scaffolding and staging. If a suspended platform is

constructed, use rigid or flexible materials as needed to create an air and dust impenetrable

enclosure. Verify that the platform and its components are designed and constructed to support at

least four times its maximum intended load without failure, with wire cables capable of

supporting at least six times their maximum intended load without failure. Strictly comply with

all applicable OSHA regulations regarding scaffolding. The category and class of containment

shall be as required in the Contract Documents.

561-10.4Protection of Adjacent Areas: Protect all areas adjacent to abrasive blast

cleaning, including machinery and deck grating. Before the commencement of any cleaning and

coating operations, submit a control plan for the protection of adjacent surfaces from damage by

nearby blasting and coating to the Engineer for review. Repair any damage to adjacent areas. The

repair procedure must be submitted to the Engineer for acceptance prior to any remediation.

561-10.5Worker Protection: Comply with the requirements of OSHA 29 CFR 1926

and applicable portions of 29 CFR 1910. Include specific programs as required by

29 CFR 1926.62 (lead), 29 CFR 1926.1118 (inorganic arsenic), 29 CFR 1926.1126 (hexavalent

chromium), and 29 CFR 1926.1127 (cadmium) when these hazardous agents are present.

Implement appropriate safety procedures for all hazards on the job site whether specifically

identified herein or not.

561-11Waste Handling and Management

561-11.1General: Prepare a waste management program plan which addresses the

applicable requirements from EPA regulations for hazardous waste management and the

Contract Documents. Include provisions for the handling and disposal of non hazardous waste.

Dispose of all waste in accordance with all federal, state, and local laws and regulations.

561-11.2Collection and Handling of Waste: Properly classify, package, and store all

paint removal debris, both solid and liquid in accordance with SSPC Guide 7, Guide for the

Disposal of Lead-Contaminated Surface Preparation Debris, the Federal Water Pollution Control

Act with amendments, and all other current government regulations and guidelines. Comply with

the Resource Conservation and Recovery Act to include, at a minimum, CFR 40 260 through

CFR 40 268. Prior to identification and storage, separate solid and liquid waste, and separate

individual waste streams.

561-11.3Testing and Analysis: Laboratory analyses for all waste stream and

environmental samples shall be conducted by an EPA certified, independent laboratory with an

approved Quality Assurance Plan. Laboratory analyses for worker monitoring and regulated area

samples shall be conducted by an American Industrial Hygiene Association (AIHA) metals 805FY 2023-24Return to Table of Contents

accredited laboratory. Submit all sampling and test reports no later than 72 hours after collection

of samples.

561-11.4Waste Identification: Collect samples in accordance with EPA SW 846, Test

Methods for Evaluating Solid Waste - Physical/Chemical Methods. Use a random and

representative sampling technique. Collect a minimum of four representative samples of each

waste stream. These waste streams include, but are not limited to, water, paint chips, dust, and

paint chips mixed with disposable abrasives and debris. Complete the initial sampling of each

waste stream immediately upon filling the first drum, but do not allow waste to accumulate for

longer than 7 days before sampling.

After the representative samples are collected, send them immediately to the EPA

certified laboratory for analysis. Unless otherwise directed by the Engineer, required by State

regulations, or required by the waste recycling or disposal facility, once each waste stream is

sampled, tested, and classified, additional sampling and analysis are not required for subsequent

shipments unless the waste stream changes. Submit samples to an approved laboratory to be

tested for arsenic, barium, cadmium, hexavalent chromium, lead, mercury, selenium, and silver

in accordance with EPA Method 3050 and Method 6010 (content) and EPA Method 1311,

Toxicity Characteristics Leaching Procedures (TCLP).Clearly label each sample with sample

number, date and time of sampling, name of collector, and location of collection.

Maintain chain of custody forms for each sample. Enter each sample on a sample

analysis request form. Record sample numbers, type of waste, amount of each sample,

distribution of samples, signature and all other information.

561-11.5Waste Storage: Collect waste from the control devices, equipment, and all

work surfaces on a daily basis. Keep hazardous and non-hazardous waste separate. Do not mix

blasting debris with any other type of waste. Place waste in approved storage drums.

Locate all hazardous waste within a regulated area. The maximum weight for

each drum, when filled, is 821 pounds. Properly seal and label all drums. Transport waste storage

drums to a secured, marked, temporary storage area. Locate the temporary storage area on well-

drained ground not susceptible to flooding or storm water run-off. Place drums on a pallet and

cover with fiber reinforced, impermeable tarpaulins. Store drums no more than two drums wide

and two drums high. Arrange drums so that labels are easily readable. Do not store waste in the

temporary storage area longer than 90 days.

561-11.6Waste Disposal: Transport, treat and dispose of all hazardous and non-

hazardous waste. Notify the Engineer a minimum of three weeks prior to the date of shipment of

any waste to an off- site facility. Submit to the Engineer documentation that the receiving

disposal facilities are properly licensed. Submit manifests for all hazardous and non-hazardous

waste shipments. Identify any waste disposal subcontractors and submit verification of their

licensing to perform waste disposal and transport operations.

561-11.7Permits: The Contractor is responsible for all liability resulting from non-

compliance with pertinent rules and regulations including permit requirements.

561-12Method of Measurement

When a lump sum pay item is provided, the quantity to be paid for coating existing

structural steel will be the lump sum quantity for the areas shown in the Plans, completed and

accepted.

When a square foot item is provided, the quantity to be paid for coating existing

structural steel will be the plan quantity in square feet of surface area as shown in the Plans,

completed and accepted. 806FY 2023-24Return to Table of Contents

561-13Basis of Payment

Price and payment will be full compensation for all work specified in this Section.

Payment will be made under:

Item No. 561- 1- Coating Existing Structural Steel - lump sum.

Item No. 561- 2- Coating Existing Structural Steel - per square foot. 807FY 2023-24Return to Table of Contents REPAIR OF GALVANIZED SURFACES

562-1Description

Apply a coating of galvanizing compound over welded areas of galvanized structural members and over areas of previously galvanized members on which the galvanizing has become damaged.

562-2Materials

562-2.1Areas 100 Square Inches or Less : Use a cold galvanizing compound containing

at least 92% zinc dust in the dry film.

562-2.2Areas Greater than 100 Square Inches: Use a galvanizing compound as

specified in 975 -2.4.1 and listed on the Approved Product List ( APL).

562-3Construction Methods

Prepare surfaces and apply the galvanizing compound according to ASTM A780 and manufacturer’s recommendations. Apply additional coats on rough or pitted surfaces, when in the opinion of the Engi neer it is necessary to obtain acceptable cover. Follow the manufacturer’s recommended dry time between coats. Re-clean the areas not coated on the same day the cleaning is accomplished, or surfaces that have rusted, prior to coating. Apply the galvanizi ng compound to attain a uniform appearance free from all defects or failures. Submit repair procedures to the Engineer for approval. All deficiencies will be corrected at no cost to the Department.

562-4Basis of Payment

No direct payment will be made fo r galvanizing compound coating of welded surfaces or for field repair of damaged galvanized surfaces . Include the cost to perform these operations, in the Contract price for the item which includes the member being so treated.

808 FY 2023-24 Return to Table of Contents