Cleaning and Painting New Steel Structures Art. 506.03
505.13 Basis of Payment. Structural steel furnished and erected in place will
be paid for at the lump sum price for FURNISHING AND ERECTING STRUCTURAL STEEL. Fabricated structural steel furnished and delivered will be paid for at the lump sum price for FURNISHING STRUCTURAL STEEL. Storage and care of the fabricated steel by the fabrication Contractor beyond the specified storage period, will be paid for at the contract unit price per calendar day for STORAGE OF STRUCTURAL STEEL if a pay item is provided for in the contract, or will be paid for according to Article 109.04 if a pay item is not provided in the contract. Erected structural steel and other materials fabricated under this item will be paid for at the lump sum price for ERECTING STRUCTURAL STEEL. If alterations or deductions to the work specified in the aforementioned lump sum items are ordered by the Engineer, the Contractor shall accept payment for any increase or decrease in the amount of structural steel and other materials according to Article 104.02(a). The unit price used for the adjusted work will be determined by dividing the lump sum price bid for the item by the Engineer’s calculated weight as shown on the contract plans. No adjustment in this plan weight will be allowed in calculation of the unit price for the adjusted work. If the weight (Mass) in pounds (kilograms) for the increased or decreased amounts of structural metals ordered by the Engineer amounts to a change exceeding 0.5 percent of the Engineer’s calculated weight as shown on the contract plans or 3000 lb (1360 kg), whichever is larger, the unit price used for the increased or decreased amount of structural steel shall be agreed upon by the Contractor and Engineer. When specified, minor items of structural steel furnished and erected complete in-place will be paid for at the contract unit price per pound (kilogram) for FURNISHING AND ERECTING STRUCTURAL STEEL. Stud shear connectors that are to be field welded to the top flanges of beams or girders will be paid for at the contract unit price per each for STUD SHEAR CONNECTORS. SECTION 506. CLEANING AND PAINTING NEW STEEL STRUCTURES
506.01 Description. This work shall consist of the cleaning and preparation
of new steel surfaces, and the furnishing, application, and protection of the paint coatings. The paint system shall be as shown on the plans and as specified herein.
506.02 Materials. Structural steel coatings shall be according to
Section 1008. All coating materials to be used on an individual structure shall be produced by the same manufacturer.
506.03 Submittals . A minimum of 30 days prior to shop or field painting, the
Contractor shall submit the following for the Engineer’s review and acceptance: applicable plans, certifications, and information. Painting shall not commence until the submittals are accepted by the Engineer. Art. 506.03 Cleaning and Painting New Steel Structures
a.Shop Qualifications. The shop painting Contractor shall possess AISC Sophisticated Paint Endorsement or SSPC-QP3 certification, except for shops that only fabricate miscellaneous steel items such as bearings, side retainers, or expansion joint devices. Evidence of current qualifications shall be provided.
b.Field Qualifications. The field painting Contractor shall possess SSPC-QP1 certification. Evidence of current certification shall be provided. The Contractor shall maintain certified status throughout the duration of the painting work under the contract. For projects with less than 200 tons (180 metric tons) of fabricated steel, the Department will accept Contractors documented to be currently enrolled in the SSPC-QP7, Painting Contractor Introductory Program, in lieu of the QP certification noted above.
c.Quality Control (QC) Personnel Qualifications. Personnel managing the shop and field QC program(s) for this work shall possess a minimum classification of Society of Protective Coatings (SSPC) BCI certified, National Association of Corrosion Engineers (NACE) Coating Inspector Level 2-Certified, or shall provide evidence of successful inspection of three projects of similar or greater complexity and scope that have been completed in the last two years. Copies of the certification and/or experience shall be provided, including names, addresses, and telephone numbers of contact persons employed by the bridge owner. The personnel performing the QC tests for this work shall be trained in coatings inspection and the use of the testing instruments. Documentation of training shall be provided. The QC personnel shall not perform hands on surface preparation or paint activities. Painters shall perform wet film thickness measurements, with QC personnel conducting random spot checks of the wet film. The Contractor shall not replace the QC personnel assigned to the project without advance notice to the Engineer, and acceptance of the replacement(s), by the Engineer.
d.Quality Control (QC) Program. The shop and field QC Programs shall identify the following: the instrumentation that will be used, a schedule of required measurements and observations, procedures for correcting unacceptable work, and procedures for improving surface preparation and painting quality as a result of quality control findings. The shop program shall include a copy of the QC form(s) that will be completed daily. The field program shall incorporate the IDOT Quality Control Daily Report form, as supplied by the Engineer.
e.Field Cleaning and Painting Inspection Access Plan. The plan shall identify the means of access that will be used by the Contractor QC personnel for ongoing inspections and by the Engineer during Quality Assurance (QA) observations.
f.Surface Preparation/Painting Plan. The surface preparation/painting plan shall include the methods of surface preparation and type of equipment to be utilized for solvent cleaning, abrasive blast cleaning, pressure washing, and power tool cleaning. The plan shall include the manufacturer’s names Cleaning and Painting New Steel Structures Art. 506.04 of the materials that will be used, including product data sheets and Safety Data Sheets (SDS). A letter or written instructions from the coating manufacturer shall be included, indicating the required drying time for each coat at the minimum, normal, and maximum application temperatures before the coating can be exposed to temperatures or moisture conditions that are outside of the published application parameters. The paint used for erection marks shall be identified together with a letter from the coating manufacturer indicating that the marking material is compatible with the coating system. The coating manufacturer shall provide a letter that stipulates the thickness of the primer to be applied in slip-critical connections and required drying times prior to bolting. All application shall be performed according to the coating manufacturer’s instructions.
g.Containment Plan. The Contractor shall evaluate project-specific conditions to determine the specific type and extent of containment needed to control the paint emissions and submit a plan for containing or controlling paint debris (droplets, spills, overspray, etc.).
h.Chloride Removal. Methods of chloride removal may include, but are not limited to, steam cleaning or pressure washing with or without the addition of a chemical soluble salt remover as approved by the coating manufacturer, and scrubbing. The Contractor shall provide the proposed procedures for chloride remediation in the Surface Preparation/Painting Plan. The frequency of testing shall also be included. Note: Chloride remediation is only required when the erected steel is exposed through the winter prior to field painting.
506.04 Quality Control and Quality Assurance. Quality Control and Quality
Assurance shall be according to the following.
a.Quality Control (QC) Inspections. The Contractor shall perform first line, in- process, QC inspections of each phase of the work. The submitted and accepted QC Program(s) shall be used to ensure that the accomplished work complies with these specifications. The shop painting Contractor shall use their forms as supplied in their submittal. These shop reports shall be made available for review when requested by the Engineer. The field painting Contractor shall use the IDOT Quality Control Daily Report form supplied by the Engineer to record the results of quality control tests. These field reports shall be submitted to the Engineer before work resumes the following day. The Engineer will sign the report as an acknowledgment that the report has been received. The Contractor shall supply all necessary equipment to perform the QC inspections. Equipment shall include the following at a minimum.
1.Psychrometer or comparable equipment for the measurement of dew point and relative humidity, together with all necessary weather bureau tables or psychrometric charts. Art. 506.04 Cleaning and Painting New Steel Structures
2.Surface temperature thermometer.
3.Bresle Cell Kits or CHLOR*TEST kits for chloride determinations, or equivalent, when applicable.
4.Wet film thickness gauge.
5.Blotter paper for compressed air cleanliness checks.
6.Type 2 magnetic dry film thickness gauge per SSPC-PA2.
7.Calibration standards for dry film thickness gauge.
8.Light meter for measuring light intensity during cleaning, painting, and inspection activities.
9.All applicable ASTM and SSPC Standards used for the work.
10.Commercially available putty knife of a minimum thickness of 40 mils (1 mm) and a width between 1 and 3 in. (25 and 75 mm). (Only required in touch-up areas where the coating is being feathered and tested with a dull putty knife.) The instruments shall be calibrated by the Contractor's personnel according to the equipment manufacturer's recommendations and the Contractor’s QC Program. All inspection equipment shall be made available to the Engineer for QA observations on an as needed basis.
b.Quality Assurance (QA) Observations. The Engineer may conduct QA observations of any or all phases of the shop or field work.
506.05 Hold Point Notification for Field Painting. Specific inspection items
throughout this specification are designated as (HOLD POINTS). The Contractor shall provide the Engineer with a minimum four-hour notification before a hold point inspection will be reached. If the four-hour notification is provided and the work is ready for inspection at that time, the Engineer will conduct the necessary observations. If the work is not ready at the appointed time, unless other arrangements are made, an additional four-hour notification is required. Permission to proceed beyond a hold point without a QA inspection will be granted solely at the discretion of the Engineer. The Engineer has the right to reject work that was performed without adequate provision for QA observation.
506.06 Inspection Access and Lighting. Inspection access and lighting
shall be as follows.
a.Inspection Access. The Contractor shall facilitate the Engineer’s observations as required, including allowing ample time to view the work. The Contractor shall furnish, erect, and move scaffolding or other mechanical equipment to permit close observation of all surfaces to be cleaned and painted. This equipment shall be provided during all phases of the work. Examples of acceptable access structures include the following. Cleaning and Painting New Steel Structures Art. 506.07
1.Mechanical lifting equipment such as scissor trucks, hydraulic booms, etc.
2.Platforms suspended from the structure comprised of trusses or other stiff supporting members and including rails and kick boards.
3.Simple catenary supports are permitted only if independent life lines for attaching a fall arrest system according to OSHA regulations are provided. When the surface to be inspected is more than 6 ft (1.8 m) above the ground or water surface, and fall prevention is not provided (e.g. guardrails) the Contractor shall provide the Engineer with a safety harness and a lifeline. The lifeline and attachment shall not direct the fall into oncoming traffic. The Contractor shall provide a method of attaching the lifeline to the structure independent of the inspection facility. When the inspection facility is more than 30 in. (750 mm) above the ground, the Contractor shall provide an approved means of access.
b.Lighting. The field Contractor shall provide artificial lighting both inside and outside containment where natural light is inadequate, as determined by the Engineer, to allow proper cleaning, inspection, and painting. Illumination for inspection shall be at least 30 footcandles (325 lux). Illumination for cleaning and painting, including the working platforms, access, and entryways, shall be at least 20 footcandles (215 lux). General work area illumination outside the containment shall be employed at the discretion of the Engineer and shall be at least 5 footcandles (54 lux). The exterior lighting system shall be designed and operated so as to avoid glare that interferes with traffic, workers, and inspection personnel. CONSTRUCTION REQUIREMENTS
506.07 Shop Cleaning New Structures. After fabrication, all steel surfaces
except bolts, stainless steel, and sliding surfaces shall be blast cleaned in the shop. Rolled and thermal cut corners to be painted with zinc primer shall be broken if they are sharper than a 1/16 in. (1.5 mm) radius. Corners shall be broken by a single pass of a grinder or other suitable device at a 45 degree angle to each adjoining surface prior to final blast cleaning, so the resulting corner approximates a 1/16 in. (1.5 mm) or larger radius after blasting. Surface anomalies (burrs, fins, deformations) shall also be treated to meet this criteria before priming. Prior to blast cleaning, dirt, oil, and grease shall be removed according to the requirements of SSPC-SP1 for Solvent Cleaning. Blast cleaning of areas to be shop painted shall be accomplished according to the requirements of the SSPC Surface Preparation Specification SP10 for Near-White Blast Cleaning. Small areas may be cleaned according to SSPC Surface Preparation Specification SP11 for Power Tool Cleaning to Bare Metal. Areas of carbon steel to be blast cleaned but not shop painted shall satisfy the requirements of SSPC Surface Preparation Specification SP10 for Near-White Blast Cleaning. Art. 506.07 Cleaning and Painting New Steel Structures All areas of weathering steel that are not to be shop painted shall satisfy the requirements of SSPC Surface Preparation Specification SP6, Commercial Blast Cleaning. After the painted areas have cured, unpainted surfaces shall be sprayed with a stream of potable water to ensure uniform weathering. All blast cleaned surfaces to be shop painted shall have an anchor profile of 1.5 to 2.5 mils (35 to 65 µm). The anchor profile shall be measured according to ASTM D 4417 Method C. A profile measurement shall be made and recorded at the following intervals: One profile measurement minimum for every 1000 sq ft (90 sq m) of blast cleaned surface of primary member; one profile measurement minimum for each blast cleaned beam, girder or arch segment; one profile measurement for each five percent of splice plates and secondary members; and three profile measurements minimum each shift or 12 hour period, whichever is shorter. Test locations shall be 6 in. x 6 in. (150 mm x 150 mm). Profile measurements and test tapes shall be provided to the Engineer.
506.08 Painting Systems for New Structures . One of the following paint
systems shall be utilized as shown on the plans.
a.Inorganic Zinc-Rich/ Waterborne Acrylic Paint System. This system is designed for shop priming and field application of the intermediate and top coats. Shop application of the intermediate and top coats will not be allowed. In the shop, all structural steel designated to be painted shall be given one coat of inorganic zinc rich primer. In the field, the structural steel shall receive one full intermediate coat and one full topcoat of waterborne acrylic paint.
b.Organic Zinc-Rich/ Epoxy/ Urethane Paint System. This system is designed for full shop application of the coating system, except for contact surfaces of field connections and portions of the fascia girders when specified. In the shop, all structural steel designated to be painted shall be given one coat of organic zinc rich primer. Prior to application of the intermediate and top coats, all contact surfaces shall be masked off. Intermediate and top coats shall be shop applied to all designated surfaces. A stripe coat of the urethane topcoat shall be applied to crevices and outside edges prior to the application of the full topcoat. Field painting of this system shall be limited to all damaged areas, all installed fasteners, and any other areas left un-topcoated in the shop. When fabrication and erection of structural steel are accomplished under separate contracts, the entire paint system shall be shop applied according to
Article 506 — 08(b) as part of the fabrication contract.
The color of the topcoat shall be as specified elsewhere in the contract. For weathering steel the color of the topcoat shall match the Aerospace Material Specification Standard 595 20045. Cleaning and Painting New Steel Structures Art. 506.09
506.09 Shop Painting New Structures . Before painting, all blast products
shall be removed from the surfaces. The blast-cleaned surfaces to be painted shall be given a prime coat within 24 hours after cleaning. If rust forms on the surface, all areas of rusting shall be recleaned prior to application of the primer. Surfaces shall comply with SSPC-SP10, Near-White Blast Cleaning at the time of painting, or SSPC- SP6, Commercial Blast Cleaning, for weathering steel. If slivers or laminations are found on the steel after blast cleaning, they shall be removed by grinding the surface prepared by abrasive blast cleaning to the specified degrees of cleaning, or by power tool cleaning according to SSPC-SP11, Power Tool Cleaning to Bare Metal. The quality of cleaning shall be accepted by the shop QC inspector and the Engineer prior to painting. At the Contractor’s option, hot-dip galvanizing may be substituted for shop priming of bearings, typical cross frames, or diaphragms on non-curved structures; expansion joint assemblies; and other elements not carrying calculated stress. Galvanized surfaces which will have concrete poured against them shall be chemically passivated or otherwise protected by a method approved by the Engineer. Galvanized bearings for exterior members and elements readily visible after erection shall be prepared for field painting, but galvanized items obscured from public view will not require field painting. If the Contractor elects to utilize galvanizing, a proposal shall be submitted to the Engineer, showing items to be galvanized with applicable provisions of AASHTO M 111, drain/vent holes, and any other necessary modifications. For galvanized items to be painted, the proposed method of surface preparation, and the coats to be applied shall also be addressed. Passivating treatments shall not be used on galvanized surfaces that will be painted. The fabricated steel shall not be loaded for shipment to the job-site until the shop paint is cured for handling, and the steel and coating has been inspected and approved by the Engineer. No painting shall be done after the material has been loaded for shipment. The shop painting of steel structures shall be according to the following requirements.
a.Paint. The shop applied portion of the paint system shall be according to
Article 506 — 08(a) or (b), as specified on the plans.
b.Storage Temperature. The paint shall be stored at temperatures between 40 and 110 °F (5 and 43 °C) or the manufacturer’s recommended limits, whichever are more restrictive. A permanent, automated record of storage temperatures shall be maintained and be available for the Engineer’s review.
c.Mixing of Paint. The paint shall be thoroughly mixed with a power mixer before being applied and the pigments shall be kept in suspension. Records shall be maintained for every batch or kit of coating applied in the shop showing when the activator was added, when the last of each product was either applied or discarded, and what items were coated with each material. Inorganic zinc-rich primer, after initial mixing, shall be strained through a metal screen not coarser than 30 mesh (600 µm) or finer than 60 mesh (250 µm), before application. Art. 506.09 Cleaning and Painting New Steel Structures Thinning will be permitted when required for proper application. The type of thinner used and the amount used shall be as recommended by the paint manufacturer for the ambient conditions. Any thinner additions (quantity and type) shall be documented on the record for each batch of coating. The manufacturer’s recommended pot life times shall not be exceeded, and coating applied after that limit shall be removed. Pot life and dry film thickness limits shall apply to spray, brush, or dauber application.
d.Weather Conditions. Coatings shall be applied within the temperature and relative humidity limits specified by the coating manufacturer’s product data sheet. Work may be performed outside when the air speed is less than 5 mph (8 km/hr) and surface temperature is more than 5 °F (3 °C) above dew point. For indoor painting, adequate ventilation shall be provided. The surface of the steel shall be dry when the paint is applied. The relative humidity and ambient temperature ranges specified by the coating manufacturer for coating application shall be maintained for at least ten hours where steel is stored after painting is complete, or longer if stipulated by the manufacturer in the submittals provided in Article 506.03(f). If the relative humidity for inorganic zinc-rich primer cannot be maintained above the manufacturer’s recommended lower limit due to ambient conditions, alternate methods of ensuring proper cure may be proposed by the Contractor, accompanied by supporting recommendations from the coating manufacturer, for the Engineer’s consideration. Documented records correlating the items coated, temperatures of paint and material during application, and the ambient temperature and relative humidity for painting and storage areas shall be maintained by the painting facility.
e.Application. Paints shall be applied by either airless or conventional spray methods, except areas inaccessible to spray and small touch-up areas may be painted by brush or dauber. When inorganic zinc primers are applied by brush or dauber, the size of the areas shall be minimized and the thickness carefully controlled to avoid mudcracking. When inorganic or organic zinc- rich primer is being spray applied, the material shall be kept under constant agitation with a power mixer to avoid settling. The applicable recommendations of the coating and spray equipment manufacturers as well as those of the SSPC-PA1, Shop, Field, and Maintenance Painting of Steel shall be followed for all shop painting.
f.Dry Film Thickness. The dry film thickness of each coat applied in the shop shall be measured according to SSPC-PA2, and comply with the ranges specified below. Areas of insufficient thickness shall receive additional coating, applied according to the manufacturer’s written instructions. Excessive coating thickness shall be removed and repaired according to the manufacturer’s written instructions. Methods proposed for the repair of insufficient or excessive thickness shall be accepted by the Engineer prior to implementation. Cleaning and Painting New Steel Structures Art. 506.09
1.Inorganic Zinc/Acrylic System Dry Film Thicknesses: Inorganic Zinc/Acrylic System Dry Film Thickness Coating Minimum Thickness Maximum Thickness Inorganic Zinc Primer (shop) 3 mils (75 µm) 6 mils (150 µm) Aluminum Epoxy Mastic (field spot coat) 5 mils (125 µm) 7 mils (175 µm) Acrylic Intermediate (field) 2 mils (50 µm) 4 mils (100 µm) Acrylic Topcoat (field) 1/ 2 mils (50 µm) 4 mils (100 µm ) Total Thickness2/ 7 mils (175 µm) 14 mils (350 µm) 1/ Stripe coat not measured. 2/ The total dry film thickness, excluding the spot areas touched up with aluminum epoxy mastic and stripe coat areas.
2.Organic Zinc/Epoxy/Urethane System Dry Film Thicknesses: Organic Zinc/Epoxy/Urethane System Dry Film Thickness Coating Minimum Thickness Maximum Thickness Organic Zinc Primer (shop) 3 mils (75 µm) 5 mils (125 µm) Epoxy Intermediate (shop or field spot coat as specified) 3 mils (75 µm) 6 mils (150 µm) Aluminum Epoxy Mastic (field spot coat) 5 mils (125 µm) 7 mils (175 µm) Aliphatic Urethane Topcoat (shop or field as specified)1/ 2.5 mils (63 µm) 4 mils (100 µm) Total Thickness2/ 8.5 mils (213 µm) 15 mils (375 µm) 1/ Stripe coat not measured. 2/ The total dry film thickness, excluding the spot areas touched up with aluminum epoxy mastic and stripe coat areas.
g.Field Connections and Faying, Contact, and Inaccessible Surfaces,
1.All faying surfaces of field connections shall be masked off after priming and shall not receive the intermediate or top coats in the shop. The intermediate and top coats for field connections shall be applied in the field, after erection of the structural steel is completed.
2.Surfaces in contact with each other at shop-bolted connections shall be cleaned and primed before bolting.
3.Surfaces not in contact, but which will be inaccessible after assembly and erection, shall be shop primed.
h.Film Continuity. The shop coating shall be smooth and free of skips, misses, shadow-through, overspray, dryspray, runs, sags, and other film defects. Art. 506.10 Cleaning and Painting New Steel Structures Defective areas shall be repaired according to the manufacturer’s written instructions, as accepted by the Engineer.
i.Removal of Unsatisfactory Paint. If all or a portion of the coating shows significant or widespread defects, evidence of having been applied under unfavorable conditions, or poor workmanship, the Engineer may order it removed and steel cleaned and repainted. Where “mud cracking” occurs in inorganic zinc-rich primer, it shall be removed to soundly bonded paint and re-coated if necessary for adequate dry film thickness. Areas adjacent to the removal of unsatisfactory paint shall be feathered to provide a smooth transition between original and re-applied paint. Recoating shall be according to the manufacturer’s written instructions, as accepted by the Engineer.
j.Surfaces in Contact with Concrete. Top surfaces of painted beams and girders shall be given one shop coat of primer, except that portions where stud shear connectors are field installed shall not be painted. Unless hot dip galvanized, all portions of expansion guards (except anchor studs or bars), that are to be in contact with or partially embedded in concrete, shall be shop primed. When beam ends of weathering steel are embedded in concrete, only the shop primer shall be applied. Intermediate or topcoats shall not be applied.
k.Machine-Finished Surfaces. Machine-finished surfaces of pins, pin holes, or other sliding surfaces, except stainless steel, not to be painted shall be coated as soon as practicable after being approved, with lacquer or an anti- rust compound. When anti-rust compound is used, it shall be removed at the time of erection and a coating of a suitable lubricant approved by the Engineer shall be provided and applied by the erection Contractor before installation. Except for stainless steel which shall not be painted, machine- finished surfaces, and the ends, threaded parts, and nuts of pins exposed after erection shall be cleaned according to SSPC-SP1, Solvent Cleaning, painted with one coat of the paint used for spot painting, and then painted with the topcoat specified for field painting the structure.
l.Bearing Surfaces. All surfaces of rockers, bolsters, masonry (base) plates, and shims placed under masonry plates shall be given one coat of primer. Sole (top bearing) plates welded or bolted to members shall receive the same treatment as the member at that location.
m.Erection Marks. Erection match marks and member piece marks shall be legible when delivered to the jobsite. Contrasting paint may be used on areas that have received shop coating to identify locations of stamped marks or to duplicate their information. The paint used shall be the same as, or compatible with, the field topcoat. Paint marks used on unpainted steel shall not be in locations readily visible on the finished structure, such as the outside face of exterior members or the underside of bottom flanges. Marks in areas readily visible after erection shall be removed.
506.10 Field Cleaning and Painting New Structures. The requirements of
Article 506 — 09, paragraphs (a) to (i), inclusive, together with the following shall also
Cleaning and Painting New Steel Structures Art. 506.10 pertain when field-applying intermediate or final coats of paint on new steel, hereinafter referred to as “field painting.”
a.Seasonal Restrictions on Field Cleaning and Painting. Field cleaning and painting work shall be accomplished between April 15 and October 31 unless authorized otherwise by the Engineer in writing.
b.Protection. Stainless steel and other surfaces designated in the plans or by the Engineer shall be protected from cleaning and painting. Paint drips, spills, and overspray are not permitted to escape into the air or onto any other surfaces or surrounding property not intended to be painted. Containment shall be used to control paint drips, spills, and overspray, and shall be dropped and all equipment secured when sustained wind speeds of 40 mph (64 kph) or greater occur, unless the containment design necessitates action at lower wind speeds. When the containment needs to be attached to the structure, it shall be attached by clamping or similar means. Welding or drilling into the structure shall be prohibited unless otherwise approved by the Engineer in writing.
c.Field Surface Preparation (HOLD POINT). Before the application of the field coats, the shop coats and any newly installed fasteners shall be pressure washed as specified below to remove dirt, oil, lubricants, oxidation products, and foreign substances, followed by solvent cleaning per SSPC-SP1 as required. All damaged shop coated areas and newly installed fasteners shall then be spot cleaned per SSPC-SP3. The surrounding coating at each repair location shall be feathered for a minimum distance of 1 1/2 in. (40 mm) to achieve a smooth transition between the prepared areas and the existing coating. The existing coating in the feathered area shall be roughened to ensure proper adhesion of the repair. The following processes shall be used to prepare the shop-coated steel surfaces for field painting. The Contractor shall notify the Engineer 24 hours in advance of beginning surface preparation operations.
1.Low Pressure Water Cleaning and Solvent Cleaning. Pressure washing shall involve the use of potable water at a minimum of 1000 psi (7 MPa) and less than 5000 psi (34 MPa) according to “Low Pressure Water Cleaning” of SSPC-SP12. Paint spray equipment shall not be used to perform the pressure washing. The cleaning shall be performed in such a manner as to remove dust, dirt, chalk, insect and animal nests, bird droppings, and other foreign matter prior to solvent cleaning. When detergents or additives are used, the surface shall be rinsed with potable water before the detergent water dries. Pressure washing shall be completed no more than two weeks prior to painting. After pressure washing has been accepted by the Engineer, all traces of asphaltic cement, oil, grease, diesel fuel deposits, and other soluble contaminants which remain on the steel surfaces to be painted shall be Art. 506.10 Cleaning and Painting New Steel Structures removed according to SSPC-SP1 Solvent Cleaning, supplemented with scraping (e.g., to remove large deposits of asphaltic cement) as required. All fasteners shall be thoroughly solvent cleaned. The solvent(s) used for cleaning shall be compatible with the applied coating. The Contractor shall identify the proposed solvent(s) in the submittals. If the coating is softened, wrinkled, or shows other signs of attack from the solvents, the Contractor shall immediately discontinue their use. If solvent cleaning/scraping is not successful in removing the foreign matter, the Contractor shall use other methods identified in SSPC-SP1, such as steam cleaning as necessary.
2.Power Tool Cleaning of Shop-Coated Steel. Damaged and rusted areas shall be spot cleaned according to Power Tool Cleaning SSPC- SP3. Final power tool cleaning shall be performed no longer than 12 hours prior to painting. A power tool cleaned surface shall be free of all loose rust, loose and peeling paint, and loose rust that is bleeding through and/or penetrating the coating. All locations of visible corrosion and rust bleed, and lifting or loose paint shall be prepared using the power tools. Upon completion of the cleaning, rust, rust bleed, and surrounding paint are permitted to remain if they cannot be lifted using a dull putty knife.
3.Pressure Washing Between Coats. When foreign matter has accumulated on a newly applied coat, pressure washing shall be performed prior to the application of subsequent coats.
d.Field Soluble Salt Remediation (HOLD POINT). If the erected steel is exposed to winter weather prior to field painting, the Contractor shall implement surface preparation procedures and processes that will remove chloride from the surfaces prior to field painting. Surfaces that may be contaminated with chloride include, but are not limited to, expansion joints and all areas that are subject to roadway splash or runoff such as fascia beams and stringers. Upon completion of the chloride remediation steps, the Contractor shall use cell methods of field chloride extraction and test procedures (e.g., silver dichromate) accepted by the Engineer, to test representative surfaces for the presence of remaining chlorides. Test frequency shall be according to the approved submittals. Remaining chloride levels shall be no greater than 7 µg/sq cm as read directly from the surface without any multiplier applied to the results.
e.Surface and Weather Conditions (HOLD POINT). Surfaces to be painted shall be free of moisture and other contaminants. The Contractor shall control his/her operations to ensure that dust, dirt, or moisture does not come in contact with surfaces painted that day. Prepared surfaces shall meet the requirements of the respective degrees of cleaning immediately prior to painting, and shall be painted before rusting appears on the surface. If rust appears or bare steel remains unpainted for more than 12 hours, the affected area shall be prepared again. Cleaning and Painting New Steel Structures Art. 506.10 The surface temperature shall be at least 5 °F (3 °C) above the dew point during final surface preparation operations. The paint manufacturer’s published literature shall be followed for specific temperature, dew point, and humidity restrictions during the application of each coat, and for the minimum and maximum time between coats. The Contractor shall monitor temperature, dew point, and humidity every four hours during surface preparation and coating application in the specific areas where the work is being performed. The frequency of monitoring shall increase if weather conditions are changing.
f.Field Painting. Field painting shall be as follows. (HOLD POINT)
1.Field Painting for the Inorganic Zinc-Rich/Waterborne Acrylic Paint System. All damaged shop primed areas and all field installed fasteners shall be fully primed with epoxy mastic. The structural steel shall then receive one full intermediate coat and one full topcoat of waterborne acrylic. A stripe coat shall be applied to crevices and outside edges prior to the application of the full topcoat.
2.Field Painting for the Organic Zinc-Rich/Epoxy/Urethane Paint System. All damaged areas and newly installed fasteners shall be fully primed with epoxy mastic. One intermediate coat of epoxy shall be applied over the epoxy mastic and on exposed shop primer. One topcoat of aliphatic urethane shall be applied to all areas where the intermediate coat is visible, whether the intermediate coat was applied in the shop or in the field. The field applied coats shall only overlap onto the existing topcoat where sanding has been performed. Where the intermediate coat, but not the urethane topcoat, is applied in the shop, all damaged areas and all newly installed fasteners shall be fully primed with epoxy mastic. The maximum recoat time for the intermediate coat shall be observed when applying the urethane topcoat. If the recoat time for the intermediate coat is exceeded, the Contractor shall submit for approval by the Engineer, written recommendations from the coating manufacturer for the procedures necessary to extend that recoat window or otherwise prepare the intermediate coat to receive the topcoat. A stripe coat of the urethane topcoat shall be applied to crevices and outside edges prior to the application of the full topcoat. If either system is damaged after all coats are applied, damaged areas shall be prepared and feathered according to Article 506.10(c). The cleaned areas shall be spot painted with a penetrating sealer as recommended by the manufacturer, which shall overlap onto the existing topcoat in the feathered area. Then the aluminum epoxy mastic shall be spot applied not to go beyond the area painted with the sealer. The intermediate and topcoat shall be spot applied to the mastic.
g.Methods and Sequence of Application. Paint may be applied by airless spray or with brushes. In addition, the use of rollers will be permitted in the Art. 506.10 Cleaning and Painting New Steel Structures application of paint coatings to flat surfaces, provided satisfactory results are obtained. If the structure includes a concrete deck, field painting at the job site shall be done after the deck is poured and the forms have been removed and the surface pressure washed. Painting shall only be done when dirt, dust, or other material from cleaning operations will not fall or blow onto the coating. The painted areas shall be kept within the manufacturer’s recommended temperature range and protected from moisture and contaminants until drying is achieved as stipulated by the manufacturer in the submittals. The sequence of the work shall permit each coat to properly cure according to the manufacturer’s requirements before the next coat is applied. In no case shall paint be applied until the previous coat has been inspected by the Engineer and its condition has been verified by the appropriate tests. Except as provided herein, field painting shall be done after the erection is completed. Surfaces that require field paint, but would be inaccessible after the erection is completed, shall be painted during either fabrication or erection as approved by the Engineer. Surfaces that will have concrete poured against them and contact surfaces of bolted connections shall be shop primed only.
h.Work Under Separate Contracts. When field painting of structural steel is not part of the erection contract, the erection Contractor shall still be responsible for repairing any damage to the shop applied paint system as a result of the steel erection process. Field painting under a contract that does not include the erection shall include the cleaning and spot preparation necessary at the time the work is performed, and the additional spot and field paint coatings required.
i.Painting Date/System Code. At the completion of the work, the Contractor shall stencil, using a contrasting colored paint, the date of painting the bridge, the painting Contractor’s name, and the paint type code from the Structure Information and Procedure Manual for the system used. The letters shall be capitals, not less than 2 in. (50 mm) and not more than 3 in. (75 mm) in height. When all coats are applied in the shop, the shop Contractor shall do the stenciling. When one or more coats are applied in the field, the field Contractor shall do the stenciling. The stencil shall contain the following wording "PAINTED BY (insert the name of the painting Contractor)" and shall show the month and year in which the painting was completed, followed by “CODE” and the appropriate code number for the paint system applied, all stenciled on successive lines. This information shall be stenciled on the cover plate of a truss end post near the top of the railing, or on the outside face of an outside stringer near both ends of the bridge facing traffic, or at some equally visible surface designated by the Engineer.
506.11 Method of Measurement. Shop cleaning and painting new steel
structures will not be measured for payment. Field cleaning and painting will not be measured for payment, except when performed under a contract that contains a separate pay item for this work. Timber Structures Art. 507.03 When paid for as a separate item, cleaning and painting of steel railings will be measured for payment in place in feet (meters). The length measured will be the overall length along the top longitudinal rail element through all posts and gaps.
506.12 Basis of Payment. Cleaning and painting in connection with the
fabrication and erection of steel structures will not be paid for separately but shall be considered as included in the contract unit price or prices for furnishing, fabricating and erecting, or installing the material. The field cleaning and painting of newly erected structural steel under a contract separate from the fabrication and erection will be paid for at the lump sum price for CLEANING AND PAINTING STRUCTURAL STEEL, at the location specified. The field cleaning and painting of steel railings which are fabricated and erected at the contract unit price per foot (meter) will be paid for at the contract unit price per foot (meter) for PAINTING STEEL RAILING when performed under a contract separate from the erection. SECTION 507. TIMBER STRUCTURES
507.01 Description. This work shall consist of timber construction required
for bridges and appurtenances, where the timber is incorporated in the completed structure. All lumber and timber for erection purposes, such as falsework, forms, sheeting, bracing, etc., are not subject to the requirements of this Section.
507.02 Materials. Materials shall be according to the following.
Item Article/Section
a.Structural Timber ................................................................................ 1007.03
b.Preservative Treatment ..................................................................... 1007.12
c.Fastenings for Timber Structures ....................................................... 1006.17
d.Structural Steel .................................................................................. 1006.04
e.Asphalt Binder (Note 1) ........................................................................... 1032
f.Fine Aggregate .................................................................................. 1003.03
g.Structural Steel Coatings ................................................... 1008.01 - 1008.02 Note 1. The asphalt binder shall be Grade PG 52-28, PG 58-28, or PG 58-22. Structural steel and other metals requiring fabrication shall be fabricated according to Section 505. CONSTRUCTION REQUIREMENTS
507.03 Storage of Materials. Untreated lumber at the site of the work shall
be open-stacked on supports at least 12 in. (300 mm) above the ground and shall be so stacked and stripped as to permit free circulation of air between the tiers and courses. When required by the Engineer, it shall be protected from the weather by suitable covering. Treated timber shall be close-stacked according to Article 1007.13.
Referenced in this section
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Source: Illinois Standard Specifications for Road and Bridge Construction, 2022 Edition. Pages 384–398 of 1,217. View official source ↗