535Painting Structures

535.1General Description

This work consists of painting new and existing steel structures, steel H-piling and metal shell piling, and steel swaybracing. The work includes applying special protective coatings to piling and swaybracing, complete in place. The work also includes protecting traffic and property. 535.1.01 Definitions EPA: Environmental Protection Agency OSHA: Occupational Safety and Health Administration PCCP: Painting Contractor Certification Program QP1: SSPC Contractor Certification program evaluates contractors who perform surface preparation and industrial coating application on steel structures in the field. QP2: SSPC Contractor Certification program evaluates the contractor's ability to perform industrial hazardous paint removal in a field operation. Two QP 2 categories are available based on the type of equipment and containment • Category A - Negative Air Containment • Category B - No Negative Air Containment SSPC: The Society for Protective Coatings 535.1.02 Related References

SSPC-Guide 6, Guide for Containing Debris Generated During Paint Removal Operations SSPC-Guide 7, Guide for the Disposal of Lead-Contaminated Surface Preparation Debris SSPC-SP 6/NACE No. 3, Commercial Blast Cleaning SSPC-SP 7/NACE No. 4, Brush-Off Blast Cleaning OSHA Standards 29 CFR 1910 and 29 CFR 1926 EPA Uniform Hazardous Waste Manifest EPA Method 1311, Toxicity Characteristics Leaching Procedure (TCLP) 844 844 844 844 844 844

535.1.03 Submittals Provide evidence to the Department prior to beginning The Work that any Contractor or Subcontractor that performs surface preparation or coating application is currently QP1 certified by the Society for Protective Coatings (SSPC). Provide evidence to the Department prior to beginning The Work that any Contractor or Subcontractor performing cleaning, rehabilitation, and painting work on bridge components coated with lead-based paint or paint containing hazardous material is currently QP2, Category A certified by the Society for Protective Coatings (SSPC). At the Preconstruction Conference or at least four (4) weeks before mobilization, make the following submittals to the Engineer for acceptance as appropriate:

Provide effective engineering and work practice controls to protect employee health and safety.

(RCRA), Comprehensive Environmental Response, Compensation and Liability Act (CERCLA), Occupational Safety and Health Act (OSHA), and Environmental Protection Division (EPD) Regulations.

material handling personnel) have received training and understand the applicable parts of the latest edition of OSHA Standards 29 CFR 1910 and 29 CFR 1926, including any amendments. Have the certification signed by all personnel involved with lead paint removal.

exposed to lead during the project.

project is completed.

the Engineer for review and approval. Include tarpaulin data sheets to verify that the material is airtight, and tightly secured at the seams. Do not use burlap or open weave materials.

direct the Contractor to submit an analysis of the load that will be added to the existing structure by the containment system and blast waste. Have a licensed Professional Engineer registered in the State of Georgia with bridge experience perform and stamp the load analysis. Ensure that the analysis shows that the system will not induce a load on the bridge that overstresses it or affects the structural integrity of the bridge.

plans, unless otherwise approved by the Engineer.

Submit to the Engineer for review and approval an emergency contingency plan for cleaning up spills from failure of the containment system, spent material recovery system, or storage containers. Define procedures for spills or releases of waste and indicate the training of workers handling the waste as required by RCRA.

Submit in writing to the Engineer for review and approval the proposed method for collecting the spent material. Include a sampling plan that conforms to EPA SW849 or a statement of intent to use the DOT sampling plan (Subsection 535.3.03.B.9). This submittal will also include the name of the company(ies) and responsible person(s) that will sample, treat, and haul the spent material.

Submit Material Safety Data Sheets on the abrasive and paint materials that will be used. 845 845 845 845 845 845

Provide the name and EPA identification number of each licensed Transporter used for shipping hazardous waste to a treatment, storage, or disposal facility.

Provide the name and EPA identification number, phone number, and address for each permitted off-site treatment, storage, or disposal facility to which the waste will be shipped.

Provide the name of the Environmental Lead Laboratory Accreditation Program (ELLAP) accredited laboratory that will perform the TCLP tests.

Submit a written QC Program that identifies the following:

program and conducting quality control tests Include the GA DOT Quality Control Daily Report form as supplied by the Engineer. Include SSPC Painting Contractor Certification Program (PCCP) certifications The Engineer will forward a copy of these submittals to the Office of Materials and Research for review.

535.2Materials

Ensure that materials meet the requirements of the following specifications: Material Section Abrasives for Blast Cleaning Note 1* Paint 870 Note 1* Use low dusting mineral abrasives which contain a minimum of ten percent (10%) by weight G-80 steel grit blended homogeneously throughout the blasting abrasive or 100% steel grit. Alternate abrasive mixtures proposed by the Contractor require approval by the Office of Materials and Research before use. Abrasives shall contain no more than 100 ppm of any corrosive compound such as sulfate or chloride. Abrasives shall not contain EPA characteristic compounds such as lead, chromium, or arsenic which can be detected by the EPA Toxicity Characteristic Leaching Procedure (TCLP). The mineral abrasive used to blend with steel grit will be listed in the Department's Qualified Products Manual. 535.2.01 Delivery, Storage, and Handling General Provisions 101 through 150. 846 846 846 846 846 846

535.3Construction Requirements

535.3.01 Personnel

Provide the Engineer with documentation to ensure that all Contractors or Subcontractors that perform surface preparation or coating application are currently certified by the Society for Protective Coatings (SSPC) to the requirements of SSPC QP-1. Provide the Engineer with documentation to ensure that all Contractors or Subcontractors that perform removal or disturbance of paint containing lead or other hazardous material are currently certified to the requirements of SSPC QP-2, Category A. The painting Contractors and painting Subcontractors must remain so certified for the duration of the project. If a Contractor's or Subcontractor's certification expires, the company will not be allowed to perform any work until the certification is reissued. Notify the Engineer of any change in Contractor certification status, including certification expiration or certification renewal. Requests for extension of time for any delay to the completion of the project due to an inactive certification will not be considered and liquidated damages will apply. 535.3.02 Equipment

Preferably, use brushes with round or oval cross sections. If using flat brushes, ensure that the maximum width is 4 in. (100 mm). For surfaces inaccessible to brushes, apply paint with sheepskin daubers made for painting. Application of inorganic zinc by brush is prohibited except for small areas and touch up work.

If spraying paint, use air, cold airless, or hot circulating airless equipment. Spray equipment is subject to the Engineer’s approval. Use spray equipment that can constantly agitate the paint. Also, use equipment with a device that thoroughly mixes paints in their shipping containers before the paints are removed. Water traps are required as follows: • When using air spray equipment, ensure that the air lines in the system have suitable water traps. • For cold airless spray equipment, water traps are not required in the air lines; use them if desired.

Rollers are subject to the Engineer’s approval. Use rollers suitable to the type of paint applied and the work areas involved. Provide pans for dipping the rollers into the paint. Follow these restrictions: • Do not use worn rollers. • Do not use rollers to apply special protective coatings or paints to piling and swaybracing. • If a surface is inaccessible to rollers, apply the paint with sheepskin daubers made for painting. 847 847 847 847 847 847

Ensure that the system applicator has the following: • Wet-film gauge • Dry-film gauge • Surface thermometer • Sling psychrometer • Abrasive blasting finish gauge During and after field cleaning and painting, furnish a safety belt and a lift truck, bucket truck, or snooper truck to the Engineer’s satisfaction to inspect the cleaning and painting operation.

Furnish signs, warning lights, barricades, enclosures, and watchmen as required by the Manual on Uniform Traffic Control Devices or by the Engineer. 535.3.03 Preparation Refer to Subsection 535.3.05B.1, Weather Conditions before performing any cleaning operations.

Before painting, clean new steel structures as follows:

or special protective coatings by field blasting. The extent of cleaning shall be SSPC-SP6, Commercial Blast Cleaning.

be SSPC-SP6, Commercial Blast Cleaning.

Straightening Material.

in Subsection 535.3.03.A, Clean New Steel Structures, step 1 and step 2.

If desired, delay cleaning the rest of the structural steel until concrete work is complete and the main

painting operation is ready to begin.

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Ensure that no work is performed before a Project Bridge Painting /Repainting Pre-Construction Conference

is held.

Clean only as much metal as can be painted before it rusts. If surfaces rust after cleaning, clean them again before

painting them.

Blast clean existing steel structures as follows:

cleaning operations.

Protect the following from blast-cleaning hazards:

• Portions of the structure (superstructure, substructure, and highway appurtenances) that could

be damaged by the blast cleaning

• Existing pedestrian, vehicular, and other traffic on, underneath, or adjacent to the structure

Construct protection devices as follows:

from spreading and creating a traffic hazard.

Do not begin work until effective corrections are made.

shoulders, or slope paving in the area.

be cleaned and painted.

The extent of cleaning shall be SSPC-SP6, Commercial Blast Cleaning, with an anchor pattern between

1.0 and 2.0 mils (0.025 and 0.051 mm). Anchor patterns greater than 2.0 mils (0.051 mm) will require that

the primer be applied at a thickness of at least 1 mil (0.025 mm) over the anchor pattern or that the steel be

re-blasted unless otherwise approved by the Engineer.

Deck

Piers

Railing

Other adjoining parts of the structure

Slope paving

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blasting as follows:

structure may be flexible or rigid.

least 3 ft. (1 m).

Verify pressure through the concave nature of the containment materials, taking into account

wind effects.

Observe air flow using smoke or other visible means inside or outside the containment.

approved method.

containment comply with OSHA Standard 29 CFR 1910.94.

Stretch a floating boom across the waterway at or before this 200 ft. (60 m) limit on the downstream and

downwind sides of the bridge to contain floating spent material.

and will require further containment measures.

will temporarily suspend the blast cleaning.

spent material.

spent material.

If desired, propose an alternate method for containing the dust and spent materials from blast cleaning the

structural steel.

The Department may reject a proposed alternate method that does not satisfy the Department’s concerns for

the safe removal and containment of lead-based paint from bridge structures.

Submit the proposal for evaluation and approval as follows:

and health.

conditional approval. 850850850850850850

blast cleaning on a trial basis.

1) The Department will evaluate the effectiveness of dust and spent material containment, worker safety

and health concerns, and noise levels.

2) If the Department finds the alternate method unacceptable, the Department may reject it and require

work according to this specification.

3) If the Department approves the alternate method, the Contractor will receive no additional payment

above the established Contract Unit Price.

Handle spent materials according to the following requirements:

potential hazard.

course, in standing water, nor on Department property. Ensure compliance with the requirements of EPA

40 CFR 264.14 and 40 CFR 264.18.

sampling plan referenced in Subsection 535.1.03.D.

Leaching Procedure (TCLP).

(40 CFR 240-299).

twenty percent Portland cement with the spent materials and solidify the mixture before disposing of it at

a licensed solid waste landfill. The cost of treatment and disposal of non-hazardous spent material is

considered incidental to the pay item.

Restriction standard of 0.75mg/l. The waste shall not be disposed of until authorized by the Engineer.

1) If the waste is to be treated on-site, submit a waste analysis plan to the regional EPA office in

accordance with 40 CFR 264.13 within 30 days of receipt of the TCLP results.

2) If the waste is to be treated off-site, submit TCLP results to the EPA permitted hazardous waste

treatment facility.

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Plan which could either be the sampling plan listed below or a similar plan that conforms to EPA SW 846,

Chapter 9 Test Methods for Evaluating Solid Waste Physical/Chemical Methods.

Ensure the plan includes the following:

1) Who will be responsible for the sampling

2) How often samples will be taken

3) How the samples will be obtained

4) Where the samples will be taken

5) How the samples will be handled

6) How the sample results will be tied back to the waste from which it was sampled.

samples will be taken. The Department will monitor the sampling procedure and the project personnel will

enter all pertinent information in a logbook. Information to be recorded is as follows:

1) Project and Contract ID numbers

2) Sampling points

3) Field contact personnel

4) Producer of waste

5) Type of process producing the waste

6) Type of waste

7) Total number of samples

8) Number of drums each sample will cover

9) Which bridge location and the drum number i.e. 1-10, 11-18 that the sample will cover.

the following:

• The Date

• The Project Number

• The Contract ID Number

• The Bridge Location

• Assign drums a series of consecutive numbers, i.e., 1-40.

thieving device to secure samples from each of the drums. The minimum sample size is 0.66 lb. (300 g)

which is about a cupful. 852852852852852852

1) Send the samples to a certified private testing lab.

2) Attach a Sampling Analysis Request (sample card) to the samples which includes:

3) Include this information on the test report and the manifest so that the waste on the manifest can be

keyed to the results on the TCLP report.

4) Ensure that a chain of custody form accompanies the sample and is returned with the test results.

1) If the results are 5 mg/l or greater leachable lead, the waste is to be declared hazardous and no

further testing is needed until the waste has been treated. After treatment, the waste shall be re-

sampled and re-tested in accordance with an approved sampling plan and shall be below 0.75 mg/l

before disposal.

2) If the results are below 5mg/l, the waste is to be declared non-hazardous, then the contractor or

his/her consultant shall uniformly blend twenty percent Portland cement with the spent material and

solidify the mixture before disposing of it at a licensed solid waste landfill.

action and send them to the lab files at the Office of Materials and Research. Send an extra copy of each

to the Office of Materials and Research/Independent Assurance.

If the TCLP toxicity test results classify the spent materials as a hazardous waste, treat the waste either

on-site or off-site to the Land Disposal Restriction Standard of 0.75 mg/l. Do not dispose of the waste

until authorized by the Engineer. Hazardous waste material may be treated off-site if the treatment is

performed by a licensed hazardous waste treatment facility in accordance with EPA and EPD guidelines.

Forward a copy of all manifests and other pertinent documents to the Engineer and to OMR. These

documents will be maintained in the project file for three years.

If after treatment, the spent material is classified as a hazardous waste by the TCLP test, retreat it until the

Universal Treatment Standard is met. Hazardous waste disposal shall be paid for as specified under

Subsection 535.5 Payment, of this specification.

hazardous waste laws when performing the Work. Obtain a separate United States Environmental

Protection Agency, Generator I.D. Number for each project where the spent material is hazardous waste

according to the Toxicity Characteristic Leaching Procedure (TCLP) results.

Management, (404) 656-2833.

number to the Project Engineer and the Office of Maintenance, Bridge Inspection Unit, 600 West

Peachtree Street, NW., Atlanta, GA 30308. 853853853853853853

the shipment.

treated hazardous spent abrasives. Include the following:

• Name and address of facility receiving the shipment Description of the waste as initially generated,

including the applicable EPA Hazardous Waste Number(s) and treatability group(s)

• Treatment standards applicable to the waste at the initial generation point

• Signature of an authorized Contractor representative on the certification

When cleaning and painting steel structures involves work on, over, or below the railroad right-of-way or the

property of a railroad company (Railroad), comply with the following:

• The additional requirements, including railroad flagging and insurance coverage, listed in the Special

Provision for Protection of Railway Interests

• The Railroad’s general rules, regulations, and requirements including those on safety, fall protection,

and personal protective equipment

Coordinate the work with the Railroad and ensure that there will be no interference with or delay to Railroad

operations, including train, signal, and communication services.

The Contractor is responsible for damages to vehicles, persons, or property resulting from

cleaning operations.

Ensure that the facilities and property of the Railroad or any tenants remain undamaged.

Comply with the following:

• Traffic (pedestrian, vehicular, rail, train, and other kinds of traffic) on, under, or next to the structure

• Portions of the structure (superstructure, substructure, and highway appurtenances) that could

be damaged

otherwise infringe on the clearances around an active track (see Subsection 535.3.03.C.2, Railroad

Construction Clearance Limits, below). Account for the following:

• Wind billowing of draped tarpaulins

• Sag from the weight of collected spent materials 854854854854854854

Comply with the Railroad Construction Clearance Limits:

Railroad Construction Clearance Limits

Track Type Horizontal Limits Vertical Limits

Single Track 25 ft. (8 m) from the center line The existing vertical clearance from the top of the rail

to the underside of the bridge

Multiple Tracks 25 ft. (8 m) from the center lines of the

outermost tracks

The existing vertical clearance from the top of the rail

to the underside of the bridge

When work is required within the Railroad Construction Clearance Limits, ensure that the following can be

moved outside the clearance limits when the Railroad flagman notifies you to clear the track for rail traffic.

• Working platforms

• Scaffolding

• Containment systems

• Other equipment necessary to complete the Work

While the track is open to rail traffic, do not allow ropes, hoses, tarps, booms, or other equipment or items to

hang from the bridge or infringe on the clearance limits.

When work is required on the Railroad bridge, ensure that the following can be moved completely off the

bridge when the Railroad flagman notifies you to clear the track for rail traffic.

• Working platforms

• Scaffolding

• Containment systems

• Other equipment necessary to complete the Work

• Spent material

Do not attach rigging or other items to the bridge rails or barriers at the sides of the bridge.

While the track is open to rail traffic, do not allow ropes, hoses, tarps, booms, or other equipment or items to

remain on the bridge.

Prepare surfaces and material for special protective coatings according to the manufacturer’s recommendations.

For a list of sources, see QPL 18.

535.3.04 Fabrication

General Provisions 101 through 150.

535.3.05 Construction

Protect the structure, adjoining property, and the public from the dangers and damages of cleaning and painting.

Protect the following:

• Pedestrian, vehicular, and marine traffic on or underneath the structures being painted

• Structures

• Slope paving

Clean slope paving stained during painting to the Engineer’s satisfaction. 855855855855855855

Follow these requirements when painting new and existing steel structures:

Cleaning or Painting shall not take place during windy or gusty conditions unless the contractor can demonstrate to

the satisfaction of the Engineer that containment is sufficient to prevent the escape of paint overspray or spent

material. If any paint overspray or spent material is detected outside containment areas, cease all operations until

cleanup has been completed. Do not recommence cleaning or painting operations until additional measures have

been taken to prevent any future escape of spent material and/or paint overspray.

When the Plans specify System VI (waterborne), ensure that the minimum air and surface temperature is 50 °F

(10 °C). Comply with the other weather requirements listed below.

When the Plans specify System VII, ensure that the minimum air and surface temperatures are above 35 o

F (2 o

C)

and the relative humidity is greater than 50% when applying the inorganic zinc primer. Apply System VII waterborne

intermediate and top coats only when the temperatures of both the air and surface are above 50 o

F (10 °C).

For Systems IV and V (alkyd), apply paint only when the air and surface temperatures are both above 40 o

F (4 °C).

Weather Requirements for Painting All Systems

Maximum surface temperature 140 °F (60 °C)

Relative humidity Below 85%

Minimum surface temperature 5 °F (3 °C) above dew point

Follow these weather restrictions:

• Do not apply paint to surfaces that are damp or otherwise unsatisfactory as determined by

the Engineer.

• Do not paint in open yards or on erected structures when the metal is hot enough to cause the paint

to blister or produce a porous film.

• Do not paint metal hot enough to cause oil separation in the alkyd paint.

• Do not paint metal when freezing weather 32 o F (0 o

C) is forecast or expected before the paint

can dry.

• Do not store at temperatures below 32 o

F (0 o

C)or above 100 o

F (38 o

C). When outdoor temperatures

exceed these limits, paint shall be stored in an appropriate indoor location.

If a prime coat on structural steel fades or chalks because of oxidation, thoroughly remove the oxidation by

brushing or by washing with water until the sound prime coat is visible.

Do not thin or dilute paints.

Thoroughly mix paints in their shipping containers using mechanical devices before removing the paint.

For inorganic zinc primers, add the powder component to the liquid component with thorough stirring, and

continue stirring until the powder is well dispersed. Strain the mixture through a 30-60 mesh sieve to remove

large particles. Use pressure pots equipped with a mechanical agitator, which will remain in motion

throughout the application.

Ensure that the paint formulation matches the application method (brush, roller, airless spray, or air spray).

Apply paint neatly by brushing, spraying, or rolling. Use rollers only as specified in Subsection 535.3.02.C, Rollers.

When using brushes or rollers, apply the paint as follows:

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Use the paint numbers shown in the Table of Application Methods, below.

Table of Application Methods

Brush Roller Airless Spray Hydraulic Air Spray

Ordinary Exposure Green System IV (Lead Free Alkyd)

1A 1A 1A X

1A 1A 1A X

2A 2A 2A X

3B 3B 3B X

X X X X

Heavy Exposure Green System V (Lead Free Alkyd)

1A 1A 1A X

1A 1A 1A X

1A 1A 1A X

2A 2A 2A X

3B 3B 3B X

Ordinary Exposure Green System VI (Waterborne)

1W 1W 1W 1W

1W 1W 1W 1W

2W 2W 2W 2W

3W 3W 3W 3W

Ordinary exposure Green System VII (Zinc Primer)

X X Inorganic Zinc Primer X

2W 2W 2W 2W

3W 3W 3W 3W

Apply the minimum required dry film thickness and the additional coats according to the paint system

required on the Plans.

Table of Paint Systems and Minimum Required Dry Film Thickness

No. of Coats Color of Coats Thickness, mils (mm)

Ordinary Exposure Green System IV (Lead Free Alkyd)

Primer Red 2.0 (0.051) to 5.0 (0.127)

Touch-Up Red * 857857857857857857

Table of Paint Systems and Minimum Required Dry Film Thickness

2nd Coat Buff 2.0 (0.051) to 5.0 (0.127)

3rd Coat Green 1.0 (0.025) to 3.0 (0.076)

4th Coat None X

Heavy Exposure Green System V (Lead Free Alkyd)

Primer Red(T) 2.0 (0.051) to 5.0 (0.127)

Touch-Up Red *

2nd Coat Red 2.0 (0.051) to 5.0 (0.127)

3rd Coat Buff 1.5 (0.038) to 5.0 (0.127)

4th Coat Green 1.0 (0.025) to 3.0 (0.076)

Ordinary Exposure Green System VI (Waterborne)

Primer Brown 3.0 (0.076) to 5.0 (0.127)

Touch-Up Brown *

2nd Coat Buff or White 3.0 (0.076) to 5.0 (0.127)

3rd Coat Green 3.0 (0.076) to 5.0 (0.127)

4th Coat None X

Ordinary Exposure Green System VII (Zinc Primer)

Primer Gray 3.0 (0.076) to 5.0 (0.127)

2nd Coat Buff or White 2.0 (.0.051) to 5.0 (0.127)

3rd Coat Green 2.0 (0.051) to 5.0 (0.127)

4th Coat None X

* = 2.0 (0.051) for touch-up coats

Ensure that each coat is thoroughly dry and cured before applying the next coat. Allow at least 24 hours

between coats.

If weather conditions and paint type require, allow longer periods between coats.

Before applying the second field coat, fill small cracks and cavities that are not sealed watertight by the first

field coat using the following

Plan-Required Paint System Fill Mixture

IV or V Pasty mixture of zinc hydroxy phosphite and linseed oil

VI Pasty mixture recommended and supplied by the manufacturer

VII Pasty mixture recommended and supplied by the manufacturer 858858858858858858

Paint new steel structures as follows:

and Minimum Required Dry Film Thickness. If the Plans do not specify a paint system, use System VI.

If the structure is located in the 13-county ozone non-attainment region, use only Waterborne coatings for any

painting operation conducted between May 1 and September 30. The 13 metro Atlanta counties that

comprise the non-attainment region are: Cherokee, Clayton, Cobb, Coweta, DeKalb, Douglas, Fayette,

Forsyth, Fulton, Gwinnett, Henry, Paulding, and Rockdale. Do not apply Alkyd coatings and the System VII

inorganic zinc primer under the above conditions. System VI and the System VII waterborne intermediate and

top coats may be applied.

When severe exposure conditions require, apply one additional prime coat. Once painting has commenced,

(including shop coat) succeeding coats of paint are to be the same paint system and from the same

paint manufacturer.

If succeeding coats are the same type and color, tint one of the underlying coats as required by

Subsection 870.2.01.B.1.d and Subsection 870.2.06.A.6.

If the following surfaces will touch previously poured and hardened concrete, apply two coats of primer

to them:

• Steel surfaces

• Nongalvanized handrail posts

• Nonembedded armored joints

Unless otherwise specified on the Shop Drawings, do not shop paint surfaces that will touch plastic

concrete.

Before assembly, paint surfaces that will be inaccessible after assembly or installation with two coats of

primer.

Do not shop paint the following connection areas:

• Surfaces that will touch after welding or bolting

• Areas next to field welds

Using the materials specified, either shop paint or coat the machine-finished surfaces according to

Subsection 501.3.04.D.9, Coating Machine-Finished Steel Surfaces.

Apply one coat of the shop primer specified on the Plans to plates that will touch elastomeric

bearing pads.

1) Paint surfaces and edges that will be exposed after components are erected.

2) Do not apply the primer paint to areas that will be welded.

3) Do not apply the primer paint to the area that will bear against the elastomeric pad.

4) Dimension and locate the blocked-out, no-paint areas to within plus or minus 1/2 in. (13 mm) of the

theoretical location and size of the elastomeric pad.

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If the following surfaces will touch previously poured and hardened concrete, touch them up as required

with primer (or apply two coats of primer if the item was not shop painted) before installing them:

• Steel surfaces

• Nongalvanized handrail posts

• Nonembedded armored joints

Do not install until the paint is thoroughly dry.

After completing steel erection, clean unprimed surfaces of connection areas requiring paint as specified

in Subsection 535.3.03.A, Clean New Steel Structures, step 3.

Connection areas include welded or bolted splices, beam and diaphragm connections, and bracing

connections.

Prime connection areas with the paint specified in the system number shown on the Plans.

Do not prime welded connections until the following occurs:

• Weld metal is cleaned according to Subsection 501.3.04.I.2, Paragraph 3.10.1, and

Subsection 501.3.04.I.3, Paragraph 4.30.1.

• Radiographic or magnetic particle inspection work, if specified, is complete and the welds

are approved.

After completing concreting work, clean surfaces as specified in Subsection 535.3.03.A, Clean New Steel

Structures, and field paint as follows:

1) Cover the following with one coat of touch-up primer paint and allow it to dry:

• Shipping and erection marks

• Bolt heads

• Other surfaces with worn off or defective prime coat

2) During touch up, stripe or paint the following with an additional coat of primer:

• Exposed edges of flanges on rolled beams and built-up girders

• Edges of angles and stiffeners

• Exposed edges of gusset plates, splice plates, and cover plates

3) Ensure that sharp, exposed edges have two full coats of primer paint, including the shop coat.

4) If removing oxidation as described in Subsection 535.3.05.B.2, Oxidation, damages the prime coat so

that bare metal is exposed after cleaning, prime the exposed bare metal with an additional coat at no

expense to the Department.

5) If removing oxidation reduces the prime thickness, use two field weather coats, if desired, to obtain

the total thickness required for the paint system.

However, when the two field weather coats are different types of paint, use additional prime paint to

obtain the prime thickness.

Paint existing steel structures as follows:

existing steel structures.

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conforming to SSPC SP-6 may be coated with System VI.

Provisions or plans. If succeeding coats are of the same type and color, tint one of the underlying coats as

required by the Specifications.

The drying requirements of Subsection 535.3.05.B.6 specified for new steel structures shall apply to existing

steel structures.

existing steel structures.

structures shall apply to existing steel structures.

shall apply to existing steel structures.

additional coats specified in Subsection 535.3.05.B.5 for new steel structures shall apply to existing steel

structures. However, when new paint is applied over existing sound paint, the required wet film thickness

of the new coats shall be that required by the Special Provisions or plans.

Systems and Minimum Required Dry Film Thickness.

However, when applying new paint over existing sound paint, comply with the required wet film thickness

specified by the Special Provisions or Plans for new coats.

described in Subsection 535.3.03.B, Clean Existing Steel Structures step 2.a) to the Engineer’s satisfaction.

Paint this material as follows:

Except as specified below, apply paint in the weather conditions specified in Subsection 535.3.05.B.1,

Weather Conditions.

cause the paint to blister or produce a porous film.

o F (0 o

C)] is forecast or expected in the time that

would occur before the paint has dried.

Do not thin or dilute pile paints.

Unless the Plans require a No. 1P or 2P system, described in Subsection 870.2.05.A.1, Paint for Steel Piling and

Swaybracing, paint steel H-piling, metal shell piling, and steel swaybracing with a System VII paint system.

Apply a No. 1P system as follows:

that containers are clearly labeled as primer or finish coat.

861861861861861861

Apply the black paints noted in Subsection 535.3.05.E.3, Number of Coats and Color using either brushes

or sprayers.

When using a brush, apply the paint as follows:

For each coat, apply at least 1 gal of paint type per 60 ft². (0.7 L/m ). Ensure that the total dry-film thickness of

paint coats is as specified in Subsection 535.3.05.E.6, Thickness of Paint, below.

Ensure that the final, dry-film thickness of the completed work is at least 25 mils (0.635 mm).

Apply additional coats to achieve the minimum dry-film thickness at no expense to the Department.

Paint to the following extent:

• Coat exposed piling with a System VII paint system unless a No. 1P orNo. 2P system is specified on

the plans.

• Coat piling in the stream bed and within 10 ft. (3 m) of the top of the stream bank with the System VII

from 5 ft. (1.5 m) below the stream bed to the bottom of the concrete cap.

• Coat end bent piles 2 ft. (600 mm) below the bottom of the cap or concrete encased as defined in

Subsection 520.3.05.O, Coat and Paint Piling.

• For piling that will be encased according to Section 547, paint the piling with System VII to the extent

specified in Subsection 520.3.05.O, Coat and Paint Piling.

• Before driving, coat test piles located in permanent surface water with a System VII according to

Subsection 520.3.05.O, Coat and Paint Piling.

Paint enough of the test pile to ensure that the coated portion extends 5 ft. (1.5 m) below the stream

bed or bottom.

Ensure that each coat is thoroughly dry before the next coat is applied.

Unless the Plans require No. 1P or 2P system, apply a System VII coating. Apply the coating to the extent

specified in Subsection 520.3.05.O, Coat and Paint Piling.

Ensure that coverage, wet- and dry-film thicknesses, temperature considerations, primer use, and drying and

curing time comply with the manufacturer’s recommendations.

Apply the special protective coating as follows:

by the Engineer.

location and proceed as follows: 862862862862862862

535.3.06 Quality Acceptance

If applied paint does not meet the requirements of this specification, remove the paint or correct it using SSPC-

approved means.

Remove paint that is applied to improperly cleaned surfaces. Clean the surfaces and repaint them to the

Engineer’s satisfaction.

If the minimum required total dry-film thickness specified for the paint system is not reached after applying the

required number of coats and colors, apply additional coats at no expense to the Department until the required

thickness is obtained.

The Department considers the applied zinc primer deficient in thickness for measured dry thickness values less

than 3 mils (0.076 mm). If more than four deficient thickness values (one measurement per 25 ft. (2.32 m ) of

surface area) are found in any 200 ft. (18.6 m )of continuous metal section, blast clean the entire section to a

SSPC-SP6, Commercial Blast condition. Repaint the section with inorganic primer to achieve a dry film coating

thickness of 3.0 to 5.0 mils (0.076 to 0.127 mm).

Repair primed areas having excessive dry film coating thickness, coating dry spray, visible coating mudcracking,

visible surface hackles, handling abrasions, and missed paint in bolt holes. Repair in accordance with the written

recommendations of the paint manufacturer. Obtain the Engineer's approval for all repair recommendations.

Include current product data and application instruction sheets with the repair recommendations.

535.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150.

535.4Measurement

The cost of painting new steel structures shall be included in the Contract Price for structural steel. No separate

payment will be made.

Cleaning and painting existing steel bridge structures will be measured and paid for at the Contract Unit Price for

Painting Existing Steel Structure Station or Bridge I.D. No. _____. This includes payment for the following:

• Equipment (including a flotation device or temporary platform on waterway bridges)

• Work platform

• Bucket truck or snooper truck with safety belt

• TCLP testing

• Materials and work necessary to remove lead-based paint and contain the spent materials

• Collection and storage of spent materials, water, and slurry generated by abrasive blasting

535.4.01 Limits

Treatment of hazardous waste and subsequent disposal shall be paid for under a force account basis. The

Engineer will reimburse the Contractor based upon invoices from the licensed hauler and disposal facility.

An additional amount equal to 3 percent of the total invoices will be paid as administrative costs incurred by

the Contractor. 863863863863863863

The costs of collecting spent material, furnishing the containers, loading the material into containers, treating the

material onsite, and loading the containers into the licensed hauling unit will not be paid for separately. These

costs are considered incidental to the pay item.

The disposal of other spent materials collected is incidental to the Pay Item Painting Existing Steel Structures.

The cost of applying special protective coatings or paint to piling shall be included in the Contract Price for piling.

No separate payment will be made.

The cost of applying special protective coatings or paint to steel swaybracing shall be included in the Contract

Price for structural steel. No separate payment will be made.

535.5Payment

Payment is full compensation for the costs, direct and indirect, of complying with the requirements of this

Specification.

Payment will be made under:

Item No. 535 Painting existing steel structure, Station No. ____ Per lump sum

Item No. 535 Painting existing steel structure, Bridge I.D. No. ____ Per lump sum

Item No. 535 Painting existing steel structures, Railroad Special, Station No. _______ Per lump sum

Item No. 535 Painting existing steel structures, Railroad Special, Bridge I.D. No. _______ Per lump sum

535.5.01 Adjustments

General Provisions 101 through 150.. 864 864 864 864 864 864