619PAINTING BRIDGE STEEL

619.01Description

This work shall consist of preparing surfaces, disposing of waste, and applying paint or another coating to steel bridges, steel piling, bearing assemblies, or other steel items in accordance with 105.03.

619.02Materials

Materials shall be in acco rdance with the following:

619.02

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

619.03Quality 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 has 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.

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 the Engineer. The results of the following tests and procedures shall be compiled and submitted to the Engineer on a daily basis.

619.03

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 specified 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 inspected 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.

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 Contractor shall not proceed to the next phase of work until written approval has been received from the Engineer that the current phase is accepted.

619.04Prosecution of Work

Prosecution of work shall be in accordance 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

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 minimum of one day’s notice shall be given in advance of each of the hold points.

619.05Inspection 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.

619.06Maintaining 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.

619.07Safety and Environmental Requirements 130

Safety requirements, pollution control, and disposal of existing paint waste and debris shall be in accordance with the following 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 structure was built as shown in the contract.

The Contractor shall follow OSHA rules and regulations and be responsible for 619.05

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 furnishing 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

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.

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.

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 particles 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.

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 particles 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

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.

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 representation 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 container. Such containers shall be labeled and210

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 after 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 stream for that bridge shall be considered to exhibit the

characteristic of toxicity and thus shall be characterized as and considered to be220

hazardous.

If the waste stream sample characterization 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 characterization 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 dictate230

the level of the containment system required in accordance with 619.07(b)1.

If hazardous materials are found to be present 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 hazardous materials. The Contractor shall

not return to work until the revised QCP is approved in writing.

Regardless of the waste characterization obtained from the waste stream sample,

disposal of existing paint and debris shall be in accordance with SSPC-Guide 7 and

the following requirements.

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 laws250

pertaining to pollution control and waste management such as, but not limited to, the

following.

268;

260

49 CFR 172.300; and

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

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 sample280

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 hazardous waste definitions. Immediately upon

notice that the waste is hazardous, the containers shall be marked in accordance with

49 CFR 172, Subpart D.

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 waste290

paint debris. The waste from different bridges shall not be commingled. The

Contractor shall be responsible for:

recycling of the waste, obtaining the Engineer’s approval of

the site, and arranging with the approved site for acceptance

of the materials;

Federal and State requirements, for signature;300

site;

transportation vehicle;

properly displayed on the vehicle;

310

site; and

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 accordance with current

RCRA hazardous waste definitions, the waste shall be disposed of at an appropriate

disposal facility.

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 hazardous waste in accordance with the current

RCRA definitions, the waste shall be recycled or disposed of in accordance with

(b)2b(4). All project generated waste and the method of recycling or disposal

shall be identified in the QCP.

619.08Surface 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 shall340

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:

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 primed the same day as cleaned, except for

areas requiring a second abrasive blast cleaning. 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

550

Cleaning shall be scheduled so that dust or other contaminants do not fall on wet,

newly painted surfaces.

370

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 shall be used. The media shall produce a

profile that is free of oil, soluble salts, greases, and other similar substances which can

contaminate the blasted surface. If ferrous metallic media is chosen and the Contractor

elects to recycle the media by running the media through recycling equipment, the

recycling equipment shall be capable of separating the blasting media from the paint380

debris and the cleanliness of the recycled ferrous metallic media shall be in accordance

with SSPC-AB 2.

The surface profile of cleaned new steel 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

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.

Hand tool cleaning shall be in accordance with SSPC-SP 2.

Brush-off blast cleaning shall be in accordance with SSPC-SP 7/NACE No. 4.

Commercial blast cleaning shall be in accordance with SSPC-SP 6/NACE No. 3.

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, as410

determined by the Engineer, shall be abrasive 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.

White metal blast cleaning shall be in accordance with SSPC-SP 5/NACE No. 1.

420

Power tool cleaning shall be in accordance with SSPC-SP 3.

Commercial grade power tool cleaning shall be in accordance with SSPC-SP 15.

Power tool cleaning to bare metal shall be in accordance with SSPC-SP 11.

Upon completion of cleaning operations, the Contractor shall vacuum or blow off430

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.

619.09Paint 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

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.

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 partial450

painting of steel bridges and other structural steel.

619.10Painting

Painting shall be performed by a SSPC certified contractor, except as noted in

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 the470

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.

along the top and sides. The bottom shall remain open for

drainage.

leading edge and sides of steel members facing toward

oncoming traffic or facing toward the prevailing wind direction.480

of steel members facing away from oncoming traffic or

prevailing wind direction.

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 surface temperature is between 50°F and 100°F490

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 and 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 protected area to eliminate the above conditions,

the steel shall remain under cover until the paint 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

Paint shall be stored in accordance with the manufacturer’s recommendations. If

paint is allowed to remain in storage, the containers shall be turned end for end at least

once per week. The paint shall be used within the manufacturer’s recommended shelf

life.

510

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 screen 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.

520

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

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 airless or conventional spray method which has

been recommended by the paint manufacturer. 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 daubers. Epoxy intermediate and polyurethane540

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.

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 specified, the stripe coat shall be allowed to550

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 accordance with 619.09(b), 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 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 steel560

surfaces. Painting techniques shall minimize 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 stripe coat application

method to be changed.

570

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 manufacturer’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.

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

619.11Shop 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 profile600

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 the primer has been

allowed to cure for a minimum of 48 h.610

All structural steel shall be cleaned in accordance with 619.08(e).

All structural steel shall receive an inorganic zinc primer, including faying

surfaces of high strength bolted connections and areas in contact with concrete.

Surfaces, other than the contact surfaces described above, which are inaccessible after

erection shall be painted in the shop with the full paint system required on the

completed bridge.

620

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).

619.12Field Painting New Steel Bridge

All structural steel surfaces which are accessible after final erection shall be

painted with the remaining coatings specified for structural steel paint system in630

accordance with 619.09(a) in the 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

(d) or 619.08(i). Likewise, all bolt and field connections shall be cleaned in the

same manner. All the damaged areas, and bolt and field connections shall then be640

painted with the inorganic zinc primer applied 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). Structural 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

619.13Painting 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 bridge, 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 clean 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 frames, 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 contract670

also includes pay items for clean steel bridge and paint steel bridge, all exposed

structural steel shall be cleaned in accordance with 619.08(a) and either 619.08(e) or

(i), and painted in accordance with 619.09(a), from the face of concrete

encasement to opposite face of concrete encasement.

619.14Handling of Steel Bridge Superstructure to be Removed

If the Contractor elects to take ownership of the steel in accordance with 202.03,

a QCP shall be submitted in accordance with 619.03. The 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 be680

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.

619.15Drain 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.

619.16Clean 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 be700

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 assemblies 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 structure, the entire bearing assembly shall be

painted with the structural steel paint system that is being used on the rest of the bridge.710

.1 Clean and Paint Steel Piling

All exposed steel piling shall be cleaned in accordance with 619.08(a) and either

(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.

619.17Responsibility for Damage

Unless otherwise specified by the Engineer in writing, full containment shall be

provided when performing the surface preparation operation and when applying all720

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 the bridge superstructure and substructure,

and all adjacent property. The Contractor shall be responsible for damages in

accordance with 107.17.

619.18Top 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 structural 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 cleanliness 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 shall be sampled in accordance with 619.07740

and all other requirements of 619.07 shall be followed. Once the result from the waste

stream sampling is known and the waste stream is appropriately characterized as

hazardous or non-hazardous, all waste shall be disposed of in accordance with

619.19Method of Measurement

Cleaning and painting of steel structural members, cleaning the top of the top

flange of steel structural members, cleaning 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 will750

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 will 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 with770

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.

619.20Basis 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 of780

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 specified. 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 item 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 steel790

piling will be paid for at the contract lump sum price for clean and paint steel piling,

at the bridge number specified.

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 payment for all additional costs incurred.

800

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.

810

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

(d) shall apply. If agreed to in writing between the Contractor and the

Department, the work shall proceed with the Contractor assuming all risks for removal

of mill scale. An additional 55% of the clean steel bridge item as computed in

(b)1 in accordance with 109.05 will be paid as additional compensation for the820

removal and disposal of the hazardous materials, 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.

The following prices will be computed and used as the price for the pay item

identified below in all pre-established remedies to changed conditions referenced in

this section.

619.20

560

The price for the clean steel bridge item, per bridge, used in all pre-established830

remedies to changed conditions referenced in this section will be limited to the lesser

of the following:

bridge item for that bridge; or

shown in the Schedule of Pay Items.

Roadway drain casting extension pipe will be paid for in accordance with 715.14.

840

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 Flanges, QP-2, Br. No. ____ .............. LS

Disposal of Cleaning Waste, ______, Br. No.____ ................... LS

waste type860

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 brushing, 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 assemblies, clean and paint steel piling, or clean

steel bridge, top flanges. The cost of cleaning 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 shall900

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, labor, 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 measuring910

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 assemblies, 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 with cleaning and painting bearing assemblies,

except disposal of cleaning waste, shall be included 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 be920

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 shown930

on the plans, all costs associated 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 pay 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