542 Epoxy Intermedia te Paint ............................................ 909.02(b) Finish Coat for Weathering Steel ................................ 909.02(e) Multi-Component Inorganic Zinc Silicate Primer ....... 909.02(a)1 Organic Zinc Primer .................................................... 909.02(a)2 Polyurethane Finish Coat ............................................ 909.02(c) Structural Steel Coating Systems ................................ 909.03 Waterborne Finish Paint .............................................. 909.02(d) Safety data sheets shall be provided in the QCP for all materials to be delivered to the project site. 20 Caulk used to form the drip bead on weathering steel shall be a clear, 100% silicone caulk. Caulk used on joints of lapping members shall be compatible with either the structural steel paint system or the partial paint system, and in accordance with the paint manufacturer’s recommendations. CONSTRUCTION REQUIREMENTS
619.03 Quality Control and Quality Assurance
The Contractor shall be responsible for the quality of work on the contract and shall ensure that all work has been performed by accepted quality control methods. A QCP shall be prepared and submitted by the Contractor in accordance with ITM 803. No work may begin until written notice ha s been received that the QCP was accepted by the Engineer. The QC manager shall furnish the current referenced SSPC Standards at the project site. Cleaning and painting shall be done by a Contractor certified as SSPC-QP 2 for cleaning and painting existing bridge steel on steel structures shown in the contract 40 documents as being built before 1995. Cleaning and painting shall be done by a Contractor that at a minimum is certified as SSPC-QP 1 for cleaning and painting new bridge steel or for cleaning and painting existing bridge steel on steel structures shown in the contract documents as being built after 1994. The Department will accept work performed on the project through quality assurance inspections and testing. Acceptance testing will be performed and will be the basis for which acceptance will be made.
a.Test Method s and Procedures 50 The current version of the following test methods and procedures shall be performed as a minimum for quality control by the Contractor. These and other tests may be performed for acceptance testing by th e Engineer. The results of the following tests and procedures shall be compiled and submitted to the Engineer on a daily basis. 619.03 543 Test/Procedure Method and Procedure Clean Compressed Air ASTM D4285 Cleaning of Steel SSPC-Vis 1, Vis 3 Cleanliness of Recycled Ferrous Metallic Abrasives SSPC-AB 2 Dry Film Thickness SSPC-PA 2 Relative Humidity ASTM E337 State of Cure of Inorganic Zinc Primers ASTM D4752 Surface Profile ASTM D4417, Method B or C Relative humidity, dew point, and surface te mperature shall be recorded before the application of any coating and at least once per hour during the application of any coating. 60 Air compressor output and blasting abrasives shall be inspected at least once every four hours for contamination. Visual inspections for cleaning shall be performed after each phase of the applicable cleaning operations for compliance with the speci fied requirements for each lot. The surface shall be wiped with a white glove or white rag to ensure the surface is free of dust and other contaminants. The blast cleaned surface shall be inspect ed for surface profile, oil contamination, 70 dust, and blasting residue, and accepted prior to the application of the primer. The required number of surface profile measurements and dry film thickness measurements shall be in accordance with SSPC-PA 2. If a lot is non-conforming, corrective action shall be taken to make the lot acceptable. Corrective action shall be submitted in writing and performed as approved. A phase shall not be covered until the whole lot has been accepted.
b.Acceptance Testing 80 Acceptance testing of painting steel bridge work will be in accordance with ITM 803. The results of the acceptance testi ng will be compared to the specific requirements for that phase of work. The Cont ractor shall not proceed to the next phase of work until written approval has been received from the Engineer that the current phase is accepted.
619.04 Prosecution of Work Prosecution of work shall be in accordan ce with the applicable requirements of
108.04 Once the cleaning and painting operations have begun, it shall be performed on all work days without stoppage until all work has been completed. If the contract 90
contains more than one bridge, a schedule shall be included in the QCP which provides the sequence of work on the bridges. Once work has begun on a bridge, it shall be 619.04 544 performed until complete, including all cleanup. When cleaning and painting beam ends for encasement in concrete is specified, that work may be performed as a separate operation. Permission shall be obtained in writing to start or continue work at the hold points as follows: (a) prior to the acceptance of the QCP and start of work; 100
b.immediately following each phase of surface preparation;
c.immediately before the application of the first coat; (d) prior to the application of each succeeding coat; and (e) after the final coat has cured. A minimum of one day’s notice shall be given in advance of each of the hold points.
619.05 Inspection Access to Bridges Safe and reasonable access to all points of the bridge shall be provided for the 110
Engineer’s inspections immediately upon request.
619.06 Maintaining Traffic
The traffic lanes may be restricted wh en surface preparation or painting phases are being performed on a portion of the bridge over the traveled roadway, or as directed, when the need exists. Construction signs in accordance with 801.04 shall be furnished and placement at each project site shall be as shown in th e QCP. However, a “Bridge Painting Ahead” sign may be used in place of the “Road Construction Ahead” sign. 120 The traffic maintenance plan shall include a type of barrier system which shall protect against blasting of vehicles or pedestrians, eliminate abrasive materials and debris from falling onto the traveled portion of the pavement, and prevent the spreading of abrasive materials and debr is in the area which may create a traffic hazard. If the intended purpose of the pr otective devices has not been accomplished, work shall stop until adequate corrections have been made. All abrasive material or debris shall be removed by the end of each day’s work in accordance with 619.07.
619.07 Safety and Environmental Requirements 130
Safety requirements, pollution control, and disposal of existing paint waste and debris shall be in accordance with the following requirements.
a.Safety Requirements The containment system shall be in accordance with 619.07(b)1a or 619.07(b)1b, as applicable, based on the year the stru cture was built as shown in the contract. The Contractor shall follow OSHA rules and regulations and be responsible for 619.05 545 determining the level of hazards that are present in the containment during the removal of the existing bridge coating operation. Once the Contractor establishes the level of 140 hazard present, the Contractor shall be re sponsible for furnishi ng personal protective equipment to provide the degree of protection necessary for the established level of hazard. All Contractor and Department personnel on the project site shall wear personal protective equipment to the level of hazard as determined by the sampling and monitoring requirements performed by the Contractor. The protective equipment shall be furnished by the Contractor, including to Department personnel. Training shall be given to all personnel who are provided with personal protective equipment. Personal protective equipment shall include, but not be limited to, clean air supplied respirators, air purifying respirators, conventional hood as applicable, eye protection, and protective clothing. 150
b.Pollution Control Pollution control shall consist of two different operations. One shall be controlling and containing the atmosphere generated during the coating removal operation. The other shall be controlling and containing the solid waste stream generated as a result of the coating removal operation. 1. Pollution Control during Existing Coating Removal Operations During existing coating removal operations, the Contractor shall recognize that the environment created by removal of the existing coating from the structure may 160 create an atmosphere in which hazards to personnel on the jobsite are likely to be generated, and thus the Contractor shall be responsible for controlling and protecting the exposure of all workers and the surrounding environment from the hazards. The characterization of the level of hazard of the existin g coating that the Department considers to be present on the structure will be dictated by the year the structure was built as described below. The characterization of the level of hazard of the existing coating is not related to the results of the TCLP.
a.Containment for Structures Built Before 1995 170 For structures shown in the contract documents as being built before 1995, the Contractor shall provide a containment system in order to contain all blasting materials, scrapings, wire brushings, and paint particle s in accordance with SSPC- Guide 6, Class 2A or greater with met hod A, level 1 emission control capability. The Contractor shall take samples and monito r the work environmen t in accordance with IOSHA requirements and shall provide persona l protective equipment appropriate to the conditions present within the work environment. b. Containment for St ructures Built After 1994 For structures shown in the contract documents as being built after 1994, the 180 Contractor shall provide a containment system in order to contain all blasting materials, scrapings, wire brushings, and paint particle s in accordance with SSPC- Guide 6, Class 2A or greater with met hod A, level 3 emission control capability. The Contractor shall take samples and monito r the work environmen t in accordance with 619.07 546 IOSHA requirements and shall provide persona l protective equipment appropriate to the conditions present within the work environment. Regardless of the level of containment as listed above, if a spill, as defined in IDEM Regulation 327 IAC 2-6.1 does occur, all work shall stop and immediate action shall be taken to clean up the site. Spills of material, that enter or threaten to enter the 190 water, shall be handled in accordance with IDEM Regulation 327 IAC 2-6.1. The IDEM Emergency Response Branch, the local health department, and all water intake users within 500 ft of the bridge shall be immediately contacted and advised of the spill. Written documentation of all such c ontacts and actions shall be kept. All applicable Federal, State, and local rules and regulations described in 619.07(b)2b(1) shall be observed. 2. Pollution Control of the Generated Waste Stream
a.Waste Stream Sampling 200 Each bridge shall generate a separate waste stream and shall not be commingled with other materials. A sample of the waste stream from the bridge shall be obtained at the conclusion of the first day of the coating removal operation for that bridge. The sample will be shipped to be tested within 24 h in a manner agreed to by the Department and as described in the QCP. The Engineer will witness the extraction of the waste stream sample. The Department will maintain custody of the waste residue sample until it is shipped. The waste stream sample shall be taken by random method as described in the QCP which reflects repr esentation of the entire bridge. The samples shall be analyzed for all contaminants listed in ITM 803 by the TCLP. The remaining waste shall be placed in an approved containe r. Such containers shall be labeled and 210 maintained to comply with 40 CFR 264. None of the waste shall remain on the booms or on any water surface overnight. All blasting debris shall be cleaned up afte r each day’s work. All waste material shall be properly stored at the project site to prevent loss or pollution. If the waste stream sample analysis is returned with one or more of the contaminants meeting or exceeding the regulatory level for the respective contaminant, the entire waste st ream for that bridge shall be considered to exhibit the characteristic of toxicity and thus shall be characterized as and considered to be 220 hazardous. If the waste stream sample characteri zation is returned with none of the contaminants meeting or exceeding the regulatory level for the respective contaminant, the entire waste stream for that bridge shall be considered to not exhibit the characteristic of toxicity and thus shall be characterized as and considered to be non-hazardous. 619.07 547 Waste stream characteriza tion as either hazardous or non-hazardous for disposal shall be based only on the results of the TCLP. The results of the TCLP do not dictate 230 the level of the containment system required in accordance with 619.07(b)1. If hazardous materials are found to be pr esent in the waste sample of a structure shown in the contract documents as being built after 1994, the Contractor shall immediately notify the Engineer that hazardous materials have been found and, if not addressed in the QCP, the Contractor shall submit revisions to the QCP that detail the necessary changes due to the presence of h azardous materials. The Contractor shall not return to work until the revised QCP is approved in writing. b. Waste Disposal 240 Regardless of the waste characterizati on obtained from the waste stream sample, disposal of existing paint and debris shall be in accordance with SSPC-Guide 7 and the following requirements.
1.Laws to be Observed Federal and State laws and regulations regulate the disposal of bridge painting debris. Bridge paint debris shall be manifested or certified and shall be disposed of at an appropriate disposal facility. The Contractor shall have direct knowledge regarding compliance with laws 250 pertaining to pollution control and waste management such as, but not limited to, the following.
a.subtitle C of the RCRA , 40 CFR 261, 262, 263, 265, and 268;
b.the Solid Waste Rule, 329 IAC 10; c. the Hazardous Waste Rule, 329 IAC 3.1;
d.the Air Pollution Rule 329 IAC 6-4; e. the Water Pollution Rule, 327 IAC 2-6.1; f. the United States Department of Transportation regulations 49 CFR 172.300; and
g.OSHA worker safety regulations 29 CFR 1926. (2) Time Limitations 270 The maximum time limit from the date the generated waste is placed in a container and the date the material is transported to a permitted treatment, storage, and disposal facility shall be 90 calendar days. 619.07 548 (3) Marking of Spent Material Containers Spent material containers shall be marked with the date that waste is first placed in the container. Until laboratory results described in 619.07(b)2a are received concerning the category of the waste stream , the containers shall be labeled “LEAD PAINT WASTE DEBRIS” or “ZINC PAINT WASTE DEBRIS”, as appropriate. The labeling shall include the contract number, bridge number, sample number, and sample 280 date. Labeling of containers as hazardous waste will not be required until the appropriate laboratory analysis determines the waste stream to be hazardous in accordance with the current RCRA hazard ous waste definitions . Immediately upon notice that the waste is hazardous, the contai ners shall be marked in accordance with 49 CFR 172, Subpart D. (4) Instruction for Disposal of Paint Waste If the waste stream is found to be hazardous, the Engineer will obtain an EPA identification number from IDEM. This number will be provided to the Contractor within 30 days of the start of waste generation for bridges having hazardous waste 290 paint debris. The waste from different bridges shall not be commingled. The Contractor shall be responsible for: a. determining the location for disposal, treatment, or recycling of the waste, obtaining the Engineer’s approval of the site, and arranging with th e approved site for acceptance of the materials;
b.preparing a hazardous waste manifest, as required by Federal and State requirements, for signature; 300
c.scheduling the shipment of waste to the permitted disposal site;
d.ensuring that the hazardou s waste manifest is carried in the transportation vehicle;
e.ensuring that all requir ed hazardous materials placards are properly displayed on the vehicle;
f.ensuring prompt movement of the vehicle to the disposal site; and
g.returning one copy of signed manifest documents to the Engineer. A copy of the chemical and physical analysis of the waste stream, all deposit receipts, manifests, and required paperwork for disposal shall be given to the Engineer and all waste disposed of before the waste disposal item will be paid. 320 619.07 549 If the waste stream is found to be non-hazardous in accord ance with current RCRA hazardous waste definitions, the waste shall be disposed of at an appropriate disposal facility.
5.Instructions for Disp osal of Other Project Generated Waste Other wastes that may be generated on the project include, but are not limited to, spent solvents from cleaning of equipment and empty or partially empty containers of paint, paint thinners, spent abrasives, and solvents. The Contractor shall recycle or dispose of all project generated waste materials. 330 If the waste stream is defined as a h azardous waste in accord ance with the current RCRA definitions, the waste shall be recycled or disposed of in accordance with 619.07(b)2b(4). All project generated waste and the method of recycling or disposal shall be identified in the QCP.
619.08 Surface Preparation of Concrete and Steel The tops of all concrete and steel pier caps, concrete abutment caps, and 2 ft down all sides of concrete pier and abutment caps shall be washed. The washing shall be accomplished by means of a pressure washer with potable water. The pressure shall 340
be between 800 and 1,500 psi. If detergents or other additives are added to the water, the surface shall be rinsed with potable water before the detergents dry. Cleaning of steel surfaces shall be performed by an SSPC certified contractor. This requirement will not apply to the following:
1.shop cleaning; or
2.sections of beams or other structural members less than 180 sq ft of total area to be painted for the contract where heat- 350 straightening or similar repairs have taken place. Surfaces to be painted shall be cleaned in accordance with the SSPC classification, unless otherwise specified. Compressed air shall pass through an oil and water extractor before entering another apparatus. Solvent cleaning in accordance with 619.08(a) shall be performed to remove all oils, soluble salts, visible grease, and any other surface contaminants before all other cleaning methods are started. 360 Field cleaned steel surfaces shall be pr imed the same day as cleaned, except for areas requiring a second abrasive blast cleani ng. Those areas shall be primed the same day as the second cleaning. If rust forms after cleaning, the surface shall be cleaned again before painting. Work shall be stopped when there is disagreement about whether a surface has been adequately cleaned. Written notification shall be provided specifically identifying the problem. 619.08 Cleaning shall be scheduled so that dust or other contaminants do not fall on wet, newly painted surfaces. A dust collector suitable for the containment type and size shall be used during all blast cleaning operations in preparation for all structural steel paint systems and as directed for a partial paint system. On existing bridges when abrasive blast cleaning is used, clean dry media in accordance with SSPC-AB 1 or SSPC-AB 3 sh all be used. The media shall produce a profile that is free of oil, soluble salts, gr eases, and other similar substances which can contaminate the blasted surface. If ferrous me tallic media is chosen and the Contractor elects to recycle the media by running th e media through recycling equipment, the recycling equipment shall be capable of separating the blasting media from the paint 380 debris and the cleanliness of the recycled ferrous metallic media shall be in accordance with SSPC-AB 2. The surface profile of cleaned new st eel surfaces and cleaned existing steel surfaces shall not be less than 1 mil and not greater than 3 mil. For structures shown in the contract documents as being built before 1995, the Contractor shall assume that mill scale is present on the existing steel. All mill scale shall be removed as a part of the cleaning operations. 390
a.Solvent Cleaning Solvent cleaning shall be performed in accordance with SSPC-SP 1. After the hold point for solvent cleaning has been released, one or more of the following cleaning methods shall be performed. (b) Hand Tool Cleaning Hand tool cleaning shall be in accordance with SSPC-SP 2.
c.Brush-Off Blast Cleaning 400 Brush-off blast cleaning shall be in accordance with SSPC-SP 7/NACE No. 4.
d.Commercial Blast Cleaning Commercial blast cleaning shall be in accordance with SSPC-SP 6/NACE No. 3.
e.Near-White Blast Cleaning Near-white blast cleaning shall be in accordance with SSPC-SP 10/NACE No. 2. In addition, all steel within a cross-sectional area measuring 5 ft longitudinally, on both sides of a bridge deck joint, as well as all areas of visible corrosion pitting, as 410 determined by the Engineer, shall be abrasi ve blast-cleaned two times. After the first cleaning, all dust shall be removed from the cleaned surfaces and the surfaces shall be wetted with potable water either by hand wiping or atomized low volume spray. The 619.08 551 volume of water used shall be low enough to preclude runoff. The surfaces shall be left undisturbed for a minimum of 24 h then cleaned a second time to the specified standard.
f.White Metal Blast Cleaning White metal blast cleaning shall be in accordance with SSPC-SP 5/NACE No. 1.
g.Power Tool Cleaning Power tool cleaning shall be in accordance with SSPC-SP 3.
h.Commercial Grade Power Tool Cleaning Commercial grade power tool cleaning shall be in accordance with SSPC-SP 15. (i) Power Tool Cleaning to Bare Metal Power tool cleaning to bare metal sh all be in accordance with SSPC-SP 11. Upon completion of cleaning operations, the Contractor shall vacuum or blow off 430 under full containment any residual dust remaining from the cleaning operation. The Engineer will check the prepared surface for dust prior to the Contractor beginning painting operations.
619.09 Paint Systems Paint systems shall be applied in accordance with the manufacturer’s
recommendations. The dry film thickness of a paint coating will be measured with a calibrated film thickness gauge in accordance with SSPC PA 2. All paint coatings shall have a dry film thickness not less than 80% of the required dry film thickness. 440
a.Structural Steel Paint System The coating system shall consist of an inorganic zinc primer with a dry film thickness of 3 mil, an epoxy intermediate coat with a dry film thickness of 4 mil, and a polyurethane finish coat with a dry film thickness of 3 mil for the painting of steel bridges and other structural steel. (b) Partial Paint System The coating system shall consist of organic zinc primer with a dry film thickness of 3 mil and a waterborne finish coat with a dry film thickness of 3 mil for partial 450 painting of steel bridges and other structural steel.
619.10 Painting Painting shall be performed by a SSPC certified contractor, except as noted in
619.08. Concrete at all junction points of concrete and steel shall be adequately shielded or otherwise protected so the application of paint on steel is full and complete, and that spraying onto the concrete is minimized. 619.10 552 460 If a blasted or painted surface is unsatisfactory, removal of the paint, thorough cleaning of the surface, and repainting or other correction will be required as directed. Where defects or damages occur in a film of any coating, all defective areas shall be removed to soundly bonded paint or bare steel and painted to the specified thickness. No lettering shall be painted on bare or painted steel surfaces, except marks required for erection and project information stenciled in accordance with 619.10(g). Joints of all lapping members shall be caulked after either the application of the epoxy intermediate coat of the structural steel paint system or the application of the 470 organic zinc primer of the partial paint system. The intermediate or primer coat shall be cured to the manufacturer’s recommended coating cure time prior to caulking.
1.All vertical and diagonal lapping members shall be caulked along the top and sides. The bottom shall remain open for drainage.
2.All horizontal lapping members shall be caulked along the leading edge and sides of steel members facing toward oncoming traffic or facing toward the prevailing wind direction. 480
3.All horizontal members shall remain uncaulked along the side of steel members facing away from oncoming traffic or prevailing wind direction.
a.Weather Limitations Field painting will not be allowed between November 15 and the following April 1 unless different date ranges are requested in the QCP and approved in writing. Painting shall begin only when the 24 h ambient temperature is to remain above 50°F after paint application, and the steel surf ace temperature is between 50°F and 100°F 490 unless different temperature ranges are requested in the QCP and approved in writing. Coating, painting, and curing shall be done only when the relative humidity is to remain between 30% and 80%. The pot life an d induction time shall be in accordance with the manufacturer’s recommendations for the existing temperature and humidity. Paint shall not be applied when the air is misty, or when conditions are otherwise unsuitable. The surface temperature of the steel to be painted shall not be within 5°F of the dew point. When painting in a protect ed area to eliminate the above conditions, the steel shall remain under cover until the pa int is dry. All wet paint which has been exposed to excessive humidity, rain, snow, or condensation shall be allowed to dry. 500 Damaged paint shall then be removed. The surface shall be re-cleaned and repainted as directed. The Engineer will be the sole authority to decide when work may begin or shall stop due to weather conditions. 619.10 553 (b) Storage Paint shall be stored in accordance w ith the manufacturer’s recommendations. If paint is allowed to remain in storage, the co ntainers shall be turned end for end at least once per week. The paint shall be used within the manufacturer’s recommended shelf life. 510
c.Mixing Paint shall be thoroughly mixed so that the pigment is completely in suspension and the consistency is uniform. Mechanical mixers shall be used in accordance with the manufacturer’s instructions. The paint shall remain in this condition during application to the steel surface. After initial mixing and before application, zinc primer shall be strained through a metal scr een not coarser than the No. 30 (600 μm) sieve. Partially empty containers of paint shall not be used. Partial mixing of containers will not be allowed. All paint containers shall remain closed until needed for mixing.
d.Thinning When required for proper application, the thinning of field paint will be allowed. Only thinners recommended by the manufacturer and as approved shall be used. Thinners shall be added to paint in accordance with the manufacturer’s recommendations. The maximum quantity added shall not exceed the manufacturer’s recommendations. The thinned paint shall not exceed IDEM regulations for volatile organic compounds. The Contractor shall contact IDEM and the local air pollution control board for information about any volatile organic compound regulations or restrictions. 530
e.Application of Paint All paint coatings shall be of colors to produce a distinct contrast with adjacent coatings, including the color of a clean steel surface. Paint shall be applied by either an airl ess or conventional spray method which has been recommended by the paint manufactur er. The compressed air used for painting shall pass through an oil and water extractor before entering the paint pot. However, areas to be painted which are inaccessible to spray application or areas requiring touchup may be painted with brush or daube rs. Epoxy intermediate and polyurethane 540 finish paints may also be applied by brushes or rollers provided the coating cures to a smooth and uniform finish. Spray shall be adjusted to produce a uniform coating.
1.Stripe Coat If using the structural steel paint system in accordance with 619.09(a), a stripe coat in accordance with SSPC-PA Guide 11 shall be applied. All sharp edges, welds, outside corners, bolt heads, nuts, threads, crevices, plate seams, back-to-back angle seams, pitted steel, rivet heads, and other sharp discontinuities shall be striped on the second and third coats, and then repainted with the remaining steel surfaces. Striping shall extend at least 1 in. from edges. If sp ecified, the stripe coat shall be allowed to 550 619.10 554 dry to the manufacturer’s recommended recoat dry time prior to painting the second and third coats on the remaining steel surfaces. If using the partial paint system in acco rdance with 619.09(b), a stripe coat in accordance with SSPC-PA Guide 11 shall be a pplied. All sharp edges, welds, outside corners, bolt heads, nuts, th reads, crevices, plate seams, back-to-back angle seams, pitted steel, rivet heads, and other sharp discontinuities shall be striped on each of the coats, and then repainted with the remaining steel surfaces. Striping shall extend at least 1 in. from edges. If specified, the stripe coat shall be allowed to dry to the manufacturer’s recommended recoat dry time prior to painting the remaining steel 560 surfaces. Painting techniques shall minimi ze dry overspray. Dry overspray shall be removed prior to application of other coatings and after application of the finish coat. For both paint systems, the stripe coat may be applied with either a brush or a sprayer. If the Contractor-chosen method of applying the stripe coat is not producing results acceptable to the Engineer, the Engineer will require the stri pe coat application method to be changed. 2. Blank
f.Curing Time The minimum curing time between coatings shall be 24 h for inorganic zinc primers and 8 h for the epoxy intermediate coat. The curing time will vary depending on the temperature and humidity. The inorganic zinc primer shall be cured to a minimum solvent resistance rating of 4 in accordance with ASTM D4752 prior to the application of the epoxy intermediate coat. It shall be demonstrated that the inorganic zinc primer is in accordance with this requirement. The epoxy intermediate coat shall be cured in accordance with the manufact urer’s recommendations prior to the application of the polyurethane finish coat. The polyurethane finish coat shall be applied within 12 calendar days of application of the epoxy intermediate coat. 580 The curing time of all other paint systems or coatings shall be in accordance with the manufacturer’s recommendations. (g) Stencil Identification After the hold point for the finish coat has been released, project identification information shall be painted with a stencil in 2 in. black capital letters onto the outside of both fascia beams, at the right end of the beam and near the end bent, which reads as follows: _____________________ 590 bridge number ______________________ contract number PAINTED _____________ date 619.10 555 619.11 Shop Prime Coating The shop performing the cleaning and the application of the prime coat for structural steel shall have a valid AISC-420-10/SSPC-QP 3 certification. Abrasive used for cleaning steel in the shop shall be an abrasive that produces a surface profile 600 in accordance with 619.08. The inorganic zinc primer coat shall be applied to all structural steel in the shop. The remaining two coats shall be applied in the field after final erection. A structural steel paint system in accordance with 619.09(a) shall be used. When shear connectors have been specified, the top of the top flange shall not be primed. Erection marks may be painted on zinc painted surfaces. Machine finished surfaces for sliding contact shall be coated with heavy grease as soon as practicable after being accepted, but before removal from the shop. Shop primed beams shall not be loaded for shipment until th e primer has been allowed to cure for a minimum of 48 h. 610
a.Non-Weathering Steel All structural steel shall be clean ed in accordance with 619.08(e). All structural steel shall receive an inorganic zinc primer, including faying surfaces of high strength bolted connectio ns and areas in contact with concrete. Surfaces, other than the contact surfaces de scribed above, which are inaccessible after erection shall be painted in the shop with the full paint system required on the completed bridge. 620
b.Weathering Steel All structural steel shall be left unpainted, except as shown on the plans. All diaphragms, stiffeners, and other appurtenances located within the limits shown on the plans shall be included in the painting area. Surfaces to be painted shall be cleaned in accordance with 619.08(e). Surfaces shall be painted in accordance with 619.09(a), except the finish coat shall be in accordance with 909.02(e).
619.12 Field Painting New Steel Bridge
All structural steel surfaces which ar e accessible after final erection shall be painted with the remaining coatings specified for structural steel paint system in 630 accordance with 619.09(a) in th e field after final erection. Portions of new structural steel, including cross frames, diaphragms, stiffeners, and all other appurtenances located within the limits of concrete end bent encasement as shown on the plans, will only require the inorganic zinc primer coat. Surface areas where the inorganic zinc primer was damaged during shipping, handling, and erection shall be cleaned in accordance with 619.08(a) and either 619.08(d) or 619.08(i). Likewise, all bolt and field connections shall be cleaned in the same manner. All the damaged areas, and bo lt and field connections shall then be 640 painted with the inorganic zinc primer app lied in the shop. This requirement will not apply to temporary steel bridges. 619.12 556 Where steel surfaces have been painted with the full paint system and the paint coatings have been damaged, the affected steel surface areas shall be cleaned in accordance with 619.08(i). Stru ctural steel paint system shall then be re-applied. For weathering steel girders, caulk shall be applied to act as a drip bead as shown on the plans. 650
619.13 Painting Existing Steel Bridges
The surfaces to be cleaned and painted shall include the surfaces of all steel members of the superstructure, substructure, floor beams, stringers, plates, castings, bearing assemblies, ornamental handrails, lattice work, and other steel appurtenances. When shear connectors have been specified, the top of the top flange shall not be painted. If the contract specifies clean steel brid ge, the bridge steel shall be cleaned in accordance with 619.08(a) and either 619.08(e) or 619.08(i). The structural steel paint system in accordance with 619.09(a) shall be used for painting. 660 If the contract specifies cl ean steel bridge, partial, the bridge steel shall be cleaned in accordance with 619.08(a) and either 619.08(e) or 619.08(h). The partial paint system in accordance with 619.09(b) shall be then used for painting. When the plans show encasing the ends of existing structural steel members in concrete, all beams and girders, cross fram es, diaphragms, stiffeners, and all other appurtenances located within the limits of the partial painting zone as shown on the plans shall be cleaned in accordance with 619.08(a) and either 619.08(e) or 619.08(h) and shall receive the partial paint system in accordance with 619.09(b). If the contract 670 also includes pay items for clean steel bridge and paint steel bridge, all exposed structural steel shall be cleaned in accordan ce with 619.08(a) and either 619.08(e) or 619.08(i), and painted in accordance with 619.09(a), from the face of concrete encasement to opposite face of concrete encasement.
619.14 Handling of Steel Bridge Superstructure to be Removed If the Contractor elects to take ownershi p of the steel in accordance with 202.03,
a QCP shall be submitted in accordance with 619.03. Th e entire surface area of the steel shall be cleaned in accordance with 619.08(d) prior to the steel leaving the construction limits and becoming the property of the Contractor. Mill scale shall be 680 assumed to be present on the existing steel . Cleaning in accordance with 619.08(a) shall not be performed. A level of containment in accordance with 619.07(a) shall be used. Testing of the waste stream and disposal of the waste produced by this cleaning shall be in accordance with 619.07.
619.15 Drain Castings Treatment Roadway drain castings located in a bridge deck shall be satisfactorily cleaned in 619.13
557 accordance with 619.08(c) or 619.08(g). The castings shall not be shot-blasted. 690 The roadway drain castings shall be painted with a black finish coat in accordance with 909.02(c). If a roadway drain casting extension pipe is damaged or missing, it shall be replaced. The extension pipe shall be in accordance with 715.
619.16 Clean and Paint Bearing Assemblies
When shown on the plans or a pay item is included in the schedule of pay items, all bearing assemblies including top and bottom plates of each assembly shall be 700 cleaned in accordance with 619.08(a) and 619.08(d). Pollution control shall be in accordance with 619.07. If the pay item clean and paint bearing asse mblies is listed in the schedule of pay items for a particular structure, the entire bearing assembly shall be painted with the structural steel paint system in accordance with 619.09(a). If the pay item, paint steel bridge, or paint steel bridge, partial, is listed in the schedule of pay items for a particular stru cture, the entire bearin g assembly shall be painted with the structural steel paint system that is being used on the rest of the bridge. 710
619.16.1 Clean and Paint Steel Piling
All exposed steel piling shall be cleaned in accordance with 619.08(a) and either 619.08(e) or 619.08(i). The structural steel paint system in accordance with 619.09(a) shall be applied. The color of the top coat shall be SAE-AMS-STD-595, color No. 13711. 619.17 Responsibility for Damage Unless otherwise specified by the Engineer in writing, full containment shall be provided when performing the surface prepar ation operation and when applying all 720 coats of paint, except primer coats, with spray equipment. All persons and property shall be protected from damage or injury from the surface preparation operations and painting operations by providing containment as described in the QCP. Persons and property shall include, but not be limited to, pedestrians, vehicles, and other traffic upon or underneath a bridge, all portions of th e bridge superstructure and substructure, and all adjacent property. The Contractor shall be responsible for damages in accordance with 107.17.
619.18 Top of Top Flange of Steel Structural Members
When shown on the plans or a pay item is included in the schedule of pay items, 730 the top of the top flange of steel structur al members shall be cleaned in accordance with 619.08 by a contractor certified as SSPC-QP 2. The Contractor shall assume the existing coating on the top of the top flange contains hazardous materials and mill scale and shall use pollution control and containment in accordance with 619.07(b)1. A QCP shall be prepared and submitted in accordance with 619.03. The steel shall be 619.18 558 cleaned to a level of cleanlin ess in accordance with 619.08(e) or 619.08(h), however solvent cleaning in accordance with 619.08(a) shall not be performed. Each bridge shall generate a separate waste stream and shall not be commingled with other materials. The waste stream sh all be sampled in accordance with 619.07 740 and all other requirements of 619.07 shall be followed. Once the result from the waste stream sampling is known and the waste st ream is appropriately characterized as hazardous or non-hazardous, all waste sha ll be disposed of in accordance with 619.07(b).
619.19 Method of Measurement
Cleaning and painting of steel structural members, cleaning the top of the top flange of steel structural members, clean ing and painting of bearing assemblies, and cleaning and painting of steel piling will not be measured for payment. Cleaning areas around bridge joints and other areas with visible corrosion pitting a second time will 750 not be measured for payment. Disposal of the waste generated by the cleaning operation will not be measured for payment. Cleaning roadway drain castings, caulking joints of lapping members, and caulking on weathering steel will not be measured for payment. For steel that will become the property of the Contractor, cleaning existing steel, removal of mill scale, testing, disposal of the waste, containment, and all other items involved with this work will not be measured as per 202.13. 760 If a structure is shown in the contract documents as being built before 1995, no measurement will be made of the area covered by mill scale. Otherwise, the area of structural steel covered by mill scale wi ll be measured for payment after a proper cleaning of the entire containment area or an agreed large portion thereof and removing all other existing materials, including all paint and rust. The percentage of the area of structural steel covered by existing mill scale will be representative of this entire area. The pre-established remedies for this changed condition apply in accordance with 104.02(d) and 619.20. Roadway drain casting extension pipe will be measured in accordance with 770 715.13. The estimated weight, length, number of steel spans, surface area of steel, and type of primer shown on the plans or in the Proposal is incidental information. Such information is approximate only. The Department will not guarantee its accuracy. 619.20 Basis of Payment Existing steel bridges to be cleaned, or partially cleaned, whichever is specified, will be paid for at the contract lump sum price for clean steel bridge or clean steel bridge, partial, at the bridge number specified. Cleaning the top of the top flange of 780 existing steel bridges will be paid for at the contract lump sum price for clean steel 619.19 559 bridge, top flanges, at the bridge number spec ified. Existing steel bridges to be painted, or partially painted, whichever is specified, will be paid for at the contract lump sum price for paint steel bridge or paint steel bridge, partial, at the bridge number specified. When specified as a separate pay ite m in the contract, cleaning and painting bearing assemblies will be paid for at the contract lump sum price for clean and paint bearing assemblies, at the bridge number specified. When specified as a separate pay item in the contract, cleaning and painting steel 790 piling will be paid for at the contract lump sum price for clean and paint steel piling, at the bridge number specified. (a) Pre-Established Remedies for Changed Conditions
1.Discovery of Hazardous Materials but No Mill Scale on a Structure Shown in the Contract Documents as Being Built After 1994 The payment will be an additional 25% of the clean steel bridge item as computed in 619.20(b)1 in accordance with 109.05 as pa yment for all additi onal costs incurred.
2.Discovery of Mill Scale but No Hazardous Materials on a Structure Shown in the Contract Documents as Being Built After 1994 If, on a structure shown in the contract documents as being built after 1994 and the presence of hazardous materials has not been confirmed by laboratory analysis, the area of structural steel covered by mill scale comprises greater than 25% of the area of structural steel in accordance with 619.19, additional compensation for the removal of the mill scale will be made as an adjustment to the clean steel bridge item. The adjustment will be an additional payment of 30% of the clean steel bridge item as computed in accordance with 619.20(b)1 will be made.
3.Discovery of Hazardous Materials and Mill Scale on a Structure Shown in the Contract Documents as Being Built After 1994 If the laboratory analysis of a waste stream sample on a structure shown in the contract documents as being built after 1994 yields results indicating the presence of hazardous materials, the entire bridge shall be considered as having mill scale and the following pre-established remedy for this changed condition in accordance with 104.02(d) shall apply. If agreed to in writing between the Contractor and the Department, the work shall proceed with th e Contractor assuming all risks for removal of mill scale. An additional 55% of the clean steel bridge item as computed in 619.20(b)1 in accordance with 109.05 will be pa id as additional compensation for the 820 removal and disposal of the hazardous mate rials, the removal of the mill scale, the additional containment required, and all other incidental items associated with the removal of the hazardous materials and mill scale.
b.Prices used in Pre-Establis hed Remedies to Changed Conditions The following prices will be computed and used as the price for the pay item identified below in all pre-established reme dies to changed conditions referenced in this section. 619.20 The price for the clean steel bridge item, per bridge, used in all pre-established 830 remedies to changed conditions referenced in this section will be limited to the lesser of the following: 1. 70% of the sum of the clean steel bridge item and paint steel bridge item for that bridge; or
2.the actual amount for the clean steel bridge item for that bridge shown in the Schedule of Pay Items. Roadway drain casting extension pipe will be paid for in accordance with 715.14. For steel that will become the property of the Contractor, payment for cleaning existing steel, removal of mill scale, testing, disposal of the waste, containment, and all other costs involved this work will be in accordance with 202.14. The cost of transportation and disposal of waste materials, waste, waste containers, and all other debris generated from pollution control and cleaning that is disposed of will be paid for at the contract lump sum price for disposal of cleaning waste, hazardous or non-hazardous, at the bridge number specified. Payment will be made under: 850 Pay Item Pay Unit Symbol Clean and Paint Bearing Assemblies, Br. No. ____ .................. LS Clean and Paint Steel Piling, Br. No. ____ ................................ LS Clean Steel Bridge, Partial, QP- ____, Br. No. ____ ................ LS Clean Steel Bridge, QP- ____, Br. No. ___ ............................... LS Clean Steel Bridge, Top Flan ges, QP-2, Br. No. ____ .............. LS Disposal of Cleaning Waste, ______, Br. No.____ ................... LS waste type 860 Paint Steel Bridge, Br. No.____ ................................................ LS Paint Steel Bridge, Partial, Br. No.____ .................................... LS The cost to prepare a QCP shall be included in the cost of the pay items of this section. The cost of providing the Department with access to the bridge and seasonal or weather limitations shall be included in the cost of the pay items of this section. If a structure is shown in the contract documents as being built before 1995, no additional payment will be made for the removal of mill scale. The cost of the removal of mill scale shall be included in the cost of clean steel bridge, clean steel bridge, 870 partial, clean and paint bearing assemblies, clean and paint steel pilling, or clean steel bridge, top flanges. If a structure is shown in the contract documents as being built after 1994 and the 619.20 561 percentage of the area covered by mill scale is less than or equal to 25% of the total structural steel surface area of a bridge measured in accordance with 619.19 no additional payment will be made for the removal of mill scale. The cost of the removal of mill scale shall be included in the cost of clean steel bridge or clean steel bridge, partial. 880 The cost of furnishing all materials, equipment, and labor required for solvent cleaning, scraping, steel brus hing, or other acceptable methods for removing paint in the locations directed shall be included in the cost of clean steel bridge, clean steel bridge, partial, clean and paint bearing assemb lies, clean and paint steel piling, or clean steel bridge, top flanges. The cost of clea ning roadway drain castings shall be included in the cost of clean steel bridge or clean steel bridge, partial. The cost of providing containment in accordance with 619.07 and 619.17 and personal protective equipment shall be included in the cost of the pay items of this section. 890 The cost of furnishing all materials, equipment, and labor required to perform the quality control tasks outlined in 619.03 shall be included in the cost of clean steel bridge or clean steel bridge, partial, clean and paint bearing assemblies, clean and paint steel piling, or clean steel bridge, top flanges. The cost of furnishing all materials including caulk, equipment, and labor to perform caulking and painting, including the stripe coats, with the structural steel paint system or the partial paint system shall be included in the cost of paint steel bridge or paint steel bridge, partial. The cost of switching stripe coat application methods shall 900 be included in the cost of paint steel bridge or paint steel bridge, partial. The cost of furnishing all materials, equipment, and labor to perform painting of the roadway drain castings shall be included in the cost of paint steel bridge or paint steel bridge, partial. The cost of all equipment, material, la bor, testing, use of special cleaning methods, and shipping of waste stream samples shall be included in the cost of the clean steel bridge or clean steel bridge, partial, clean and paint bearing assemblies, clean and paint steel piling, or clean steel bridge, top flanges, pay items. The cost of dust removal, wetting, and within the cross-sectional area measuring 910 5 ft longitudinally on both sides of a bridge deck joint as well as all areas of visible corrosion pitting, a second time shall be included in the clean steel bridge, clean steel bridge, partial, clean and paint bearing asse mblies, or clean steel bridge, top flanges, pay items. When a pay item is included in the schedule of pay items for clean and paint bearing assemblies, all costs associated w ith cleaning and painting bearing assemblies, except disposal of cleaning waste, shall be in cluded in the cost of the pay item. If clean steel bridge, clean steel bridge, partial, paint steel bridge, or paint steel bridge, partial, are included as pay items in the schedule of pay items, no separate payment will be 920 619.20 562 made for cleaning and painting bearing assemblies on that bridge number. The cost of cleaning and painting bearing assemblies shall be included in the cost of the respective clean steel bridge, clean steel bridge, partial, paint steel bridge, or paint steel bridge, partial, pay items for that bridge number. When a pay item is included in the schedule of pay items for clean and paint steel piling, all costs associated with cleaning and painting steel piling, except disposal of cleaning waste, shall be included in the cost of the pay item. When encasing the ends of existing structural steel members in concrete is shown 930 on the plans, all costs associ ated with cleaning and painting all structural steel within the limits of the partial painting zone, including but not limited to, equipment, material, labor, testing, use of special cleaning methods, and shipping of waste stream samples, shall be included in the cost of clean steel bridge, partial, and paint steel bridge, partial, pay items. If the contract also includes pa y items for clean steel bridge and paint steel bridge, all costs associated with cleaning and painting all exposed structural steel, including but not limited to, equipment, material, labor, testing, use of special cleaning methods, and shipping of waste stream samples, shall be included in the cost of clean steel bridge and paint steel bridge pay items. 940
Source: Indiana Standard Specifications, 2024 Edition. Pages 540–562 of 1,248.