909PAINT AND LIQUID EPOXY

909.01General Requirements

All necessary facilities for inspection of materials and manufacture of coatings, paints, and ingredients shall be granted. Free access to all parts of the premises where any or all of these products are being prepared shall be allowed. SDSs shall be provided.

Paints and coatings shall be furnished ready for use without modification and shall not settle, cake, curdle, liver, gel, or develop excessive change in viscosity between 10 time of manufacture and time of use. It shall remain capable of being readily dispersed with a paddle, or other approved methods, to a consistency appropriate for the intended use. Paints and coatings may be sampled and tested at any time prior to use. Paints and coatings that are part of a steel coating sy stem listed on the QPL of Structural Steel Coating Systems shall be submitted in an unopened, full, and complete kit for testing.

Individual batches of organic zinc primer and waterborne finish paint listed on the QPL of Coating Formulations shall be submitted in an unopened, full, and complete kit for testing.

If, for any reason, re-sampling and re-testing following initial or prior acceptance is indicated, the latest test results shall prevail over all previous tests for material that has not been used. Previously accepted paint or coating that are stored for future use may be re-sampled and re-tested.

Paints and coatings shall be delivered in new containers of such strength, durability, design, fabrication, and material that the paint shall be suitably protected in transit and in storage against any change in characteristics which would cause rejection based on laboratory or field evaluation. Each container shall bear a label which shows the name and address of the manufacturer, kind of paint or coating, formula 30 identification, date of manufacture, and lot or batch number. The container shall be filled so the net weight of the material in the container equals the product of the weight per gallon at 77°F and the stated number of gallons in the container.

All containers shall be labeled in accordance with the OSHA requirements for labeling of hazardous chemicals as described in the Hazardous Communications Standard. 909.01

909.02For Metal

Paints for metal surfaces shall be in accordance with the requirements shown 40 below.

Both inorganic zinc primer and organic zinc primer for use on faying surfaces at all slip-critical structural bolted connections using ASTM F3125, grade A325 or grade A490, high strength heavy hex bolts in primary members shall meet class B slip coefficient in accordance with Test Method to Determin e the Slip Coefficient for Coatings Used in Bolted Joints as adopted by the Research Council on Structural Connections.

Inorganic zinc primers shall be multi-com ponent and of the self-cure type which, when mixed and applied in accordance with these specifications, shall cure without the use of a separate curing solution. Multi-component inorganic zinc silicate primers shall have a maximum of three components. The components of each primer shall be packaged in such proportions that when the full quantity of each component is mixed together, the specified mixed primer shall be yielded.

Inorganic zinc primers shall be in accordance with AASHTO M 300.

Organic zinc primer shall be a self-curing primer. It shall be in accordance with SSPC Paint Specification No. 20, Type II. The organic zinc primer shall be compatible with inorganic zinc and finish coat paints already on the bridge. The color shall be able to produce a distinct contrast with blast cleaned metal surface and the finish coat. The cured organic zinc film shall be compatible with a top coating of waterborne finish coat paint.

The organic zinc primer shall also be in accordance with the following requirements: 70

Viscosity, ASTM D562, Krebs Units ......................................... 70 – 100 Viscosity variation from the initially approved formulation, ASTM D562, Krebs Units, max. .................... ±10 Volatile organic compounds, ASTM D3960, max. .................... 419 g/L Weight/volume, ASTM D1475, 25°C, min. ............................... 2.040 kg/L Weight/volume variation from the initially approved formulation, max. ................................................................ ±0.048 kg/L Dry time, ASTM D1640, 6 mils wet film thickness on a tin coated steel panel, max.: 80 Set-to-touch ............................................................ 1 h Dry hard ................................................................. 24 h Total solids of sample , ASTM D2369 ........................................ 70 – 100% 909.02

Total solids variation from the initially approved formulation, ASTM D2369, %, max. .................................. ±2.0 Pigment by mass of total solids A, min. ....................................... 83 % Metallic zinc in zinc dust, ASTM D521, min. ............................ 94 % Metallic zinc by mass of pigment, ASTM D521, min. ............... 84 % Metallic zinc by mass of total solids B, min. ................................ 72 % A The pigment by mass of total solids shall be calculated as follows: 90

Pigment by mass of total solids, % = A B x 100%

where: A = % pigment extracted from sample B = % total solids of mixed sample

B The metallic zinc by mass of total solids shall be calculated as follows:

Metallic zinc by mass of total solids, % = (C x D) ୉ 100

where: C = % metallic zinc in pigment D = % pigment extracted from sample E = % total solids of mixed sample

The infrared spectrum of the vehicle when extracted from the organic zinc primer, in accordance with ASTM D3168, shall match the infrared spectrum of the vehicle of the sample submitted for formulation approval.

The cured film shall not contain any toxic heavy metals above the limits of the regulatory levels of 40 CFR 261.24, Table 1. The cured paint shall not contain any other material which will require characterization as a hazardous waste for the disposal of the dried film.

Only zinc primers from the QPL of Coating Formulations shall be used. Zinc primers will be placed and maintained on the QPL of Coating Formulations in accordance with ITM 606.

Epoxy intermediate paint shall be a two-component coating consisting of an epoxy resin and a curing agent, together wi th prime and filler pigments, colorants, gellant, leveling agents and solvents. When mixed, this coating shall be suitable for application over inorganic and organic zinc primers and shall be compatible with a polyurethane finish coat. The color of this coating shall contrast significantly from the other coatings within the coating system.

909.02

The mixed paint shall be in accordance with the following requirements:

Volatile organic compounds, ASTM D3960, max. ...................... 336 g/L Volume solids, ASTM D2697, min. ............................................. 60% Set-to-touch, ASTM D1640, 6 mils wet film thickness, max. ...... 4 h Weight/volume variation from the initially approved formulation, ASTM D1475, 25°C, max. ............................... 0.060 kg/L Total solids variation from the initially approved formulation, ASTM D2369, max. ......................................... 3.0%

The coating shall be applied within the pot life recommended by the paint manufacturer with no evidence of gelation. The coating shall be in a free-flowing 140 condition and easily sprayed.

The infrared spectrum of each component and of the mixed coating shall match the spectrums of the initially approved batch.

Polyurethane finish coat shall be a two-component polyester or acrylic aliphatic polyurethane suitable for use as a finish coat over epoxy intermediate paint.

The mixed paint shall be in accordance with the following requirements: 150

Volatile organic compounds, ASTM D3960, max. ...................... 336 g/L Volume solids, ASTM D2697, min. ............................................. 60% Set-to-touch, ASTM D1640, 5 mils we t film thickness, min. ....... 30 minutes Total solids ASTM D2369, min. .................................................. 70% Specular gloss, 60°, 10 ±0.5 mils wet film thickness on a tin coated steel panel, dr ied 48 h, ASTM D523, min. .... 75 Contrast ratio, ASTM D2805, 5 ±0.5 mils wet film thickness, dried 24 h on opacity chart 2A or 2C, min. ........................... 0.95 160 Dry hard, ASTM D1640, 5 mils wet film thickness, max. ........... 24 h

The infrared spectrum of each component and of the mixed coating shall match the spectrum of the initially approved batch.

The color of the dried paint film shall match the color number of SAE-AMS-STD-595 as follows:

Color No. Color 13538 Yellow 13711 Buff 14260 Green 15450 Light Blue 17038 Black 17886 White 909.02

The waterborne finish coating shall be a single package, high build acrylic emulsion for use as a finish coat over inorganic and organic zinc primers. It shall be compatible with and adhere to the cured zinc primers.

The vehicle shall consist of an acrylic emulsion together with the necessary antifoamers, cosolvents, coales cing agent, preservatives, and antifreeze to produce a coating in accordance with this specification.

The active pigment shall consist of titanium dioxide in accordance with ASTM D476, Type IV, and non-reactive color rete ntive tinting pigments. The pigment shall contain extenders and additives as required for proper application.

The mixed paint shall be in accordance with the following requirements:

Viscosity, ASTM D562, Krebs Units ........................................... 80 – 110 Weight/volume, ASTM D1475, variation from the initially approved formulation, 25°C, max. ..................... 0.024 kg/L 190 Dry time, ASTM D1640, 3 mils wet film thickness on a tin coated steel panel, max.: Set-to-touch .................................................................... 1 h Dry hard 24 h Contrast ratio, ASTM D2805, 5 ±0.5 mils wet film thickness dried 24 h on opacity chart 2A or 2C, min. ........................... 0.97 Specular gloss, 60°, 10 ±0.5 mils wet film thickness on a tin coated steel panel, dr ied 48 h, ASTM D523, max. ... 30 200 pH, ASTM E70 .............................................................................. 7.0 – 9.5 Volatile organic compounds, ASTM D3960, max. ...................... 180 g/L

The infrared spectrum of the vehicle wh en extracted from the mixed paint in accordance with ASTM D3168 shall match th e infrared spectrum of the sample submitted for formulation approval.

The mixed paint shall be in accordance with the requirements of Sections 5.4 through 5.17 of SSPC Paint Specification No. 24.

The cured waterborne finish paint shall not contain any toxic heavy metals above the limits of the regulatory levels of 40 CFR 261.24, Table 1. The cured paint shall not contain any other material which will require characterization as a hazardous waste for the disposal of the dried film. 909.02

The color of the dried paint film shall match the color number of SAE-AMS-STD-595 as follows:

Color No. Color 23538 Yellow 23717 Buff 24227 Green 24466 Light Green 25526 Light Blue 27038 Black 27780 White

Only waterborne finish paint from the QPL of Coating Formulations shall be used. Waterborne finish paint formulations will be placed and maintained on the QPL of Coating Formulations in accordance with ITM 606.

The finish coat shall be an aliphatic polyurethane or a waterborne acrylic paint, and the dried paint film shall match color No. 20045 of SAE-AMS-STD-595. It shall be suitable for use as a finish coat over epoxy intermediate paint. The mixed paint shall be in accordance with the following requirements: 230

For aliphatic polyurethane paint:

Weight/volume, ASTM D1475, 25°C, min. ................................. 1.200 kg/L Volatile Organic Compounds, ASTM D3960, max. ..................... 336 g/L Specular gloss, 60°, 10 ±0.5 mils wet film thickness on a tin coated steel panel, dried 48 h, ASTM D523, max. ... 30

For waterborne acrylic paint: 240

Weight/volume, ASTM D1475, 25°C, min. ................................. 1.200 kg/L Volatile Organic Compounds, ASTM D3960, max. ..................... 180 g/L Specular gloss, 60°, 10 ±0.5 mils wet film thickness on a tin coated steel panel, dried 48 h, ASTM D523, max. ... 30

909.03Structural Steel Coating System

This coating system shall consist of an inorganic zinc primer, an epoxy intermediate paint, and a polyurethane finish coat for the painting of steel bridges and 250 other structural steel. All coatings within any coating system shall be manufactured by 909.03

the same manufacturer and shall be compatible with one another. All coatings shall be in accordance with 909.02.

The cured film of each coating within th e structural steel coating system shall not contain any toxic heavy metals above the limits of the regulatory levels of 40 CFR

261.24, Table 1 or contain any other material which will require characterization as a

hazardous waste for the disposal of the dried film.

The coating system shall be evaluated by the PEAS Structural Steel Coatings Program. The certified report from PEAS shall include specific identification of the formulation or system being submitted for consideration. It shall also include all test results for the specific coating formulation or coating system. The certified report from PEAS will be accepted as the certified test report required for approval. The coating system shall be in accordance with all applicable acceptance criteria contained within

. In addition, the finish coat shall maintain a minimum of 60% specular gloss

retention relative to the initial gloss and a maximum color change of 6 ǻ(IRU7HVW1R 3, Cyclic Weathering Resistance. 270

Only structural steel coating systems from the QPL of Struct ural Steel Coating Systems shall be used. Structural steel coating systems will be placed and maintained on the QPL of Structural Steel Coating Systems in accordance with ITM 606.

909.04Field Paint for Wood or Metal

The primers for field paint shall be fo rmulated for minimal surface preparation, provide adhesion to the substrate and be compatible with the finish coat. The primers shall not contain lead, chromium, or other heavy metals which would require 280 classification as a hazardous waste upon removal. The primers shall comply with the current IDEM VOC regulations and shall be used as follows:

one coat of a zinc dust-zinc oxide pigmented primer.

for use on non-ferrous metals.

The field paint finish coat shall be an exterior type coating. It shall be chalk 290 resistant, gloss retentive, and suitable for application by brush, roller, or spray. This coating shall comply with the current IDEM VOC regulations and shall not contain lead, chromium, or other heavy metals which would require classification as a hazardous waste upon removal. The color of this coating shall be as specified.

909.05White and Yellow Waterborne Traffic Paint

White and yellow waterborne traffic paints shall consist of an emulsion of pigmented binder. 909.05

When glass beads are induced into the paint lines, the paint shall provide capillary 300 action in the interstices and voids between the glass beads sufficient to cause the level of paint to raise approximately 2/3 the diameter of the glass beads. This capillary action shall not cause complete envelopment of the glass beads. The paint as furnished shall not contain glass beads. The paint shall be ground to a uniform consistency, and it shall enable satisfactory application by the pressure-spray type of painting equipment. The painting equipment shall use a pressurized bead application method that is designed to apply 4 to 6 in. reflectorized paint lines at paint temperature up to 150°F. The paint shall be capable of being applied at speeds of 10 to 15 mph.

The paint shall not darken under the heating conditions of application or show 310 appreciable discoloration due to sunlight exposure and aging of the paint lines. The paint shall be furnished ready for use without thinning, screening, or other modifications and shall not settle, cake, curdle, liver, gel, or have an excessive change in viscosity in the container during a period of one year after manufacture. The paint shall be capable of being stirred to a uniform consistency. The paint shall be able to withstand variations of temperatures when stored outside in the containers as delivered, and in an environment above 40°F. All paint furnished under these specifications will be rejected if it contains skins, thickened or jelly-like layers, lumps, coarse particles, dirt, or other foreign materials which prevent the proper application of the paint, or produces a non-uniform paint line. All paint which cannot be 320 transferred by pumps on the paint equipment from the shipping containers and through the paint equipment due to excessive clogging of screens, filters, or paint guns will be rejected.

The paint shall dry to a no-tracking condition in less than 60 s. The no tracking condition shall be determined by actual application of the paint on the pavement at a wet film thickness of 15 mils with glass beads at a rate of 6 lb/gal. The paint lines for the determination of no-tracking condition shall be applied with the specialized painting equipment operated to have the paint at application temperatures up to 140°F at the spray guns. This maximum no tracking time shall not be exceeded when the 330 pavement temperature varies from 50 to 120°F, and with all relative humidity conditions providing that the pavement is dry. The no tracking time shall be determined by passing over the paint line 60 s after the paint application, in a simulated passing maneuver at a constant speed of 30 to 40 mph with a passenger car. A paint line with no visual deposition of the paint to the pavement surface when viewed from approximately 50 ft from the point where the vehicle crossed the paint line shall be considered as showing a condition of no tracking and being in accordance with the requirement.

The exact composition of the waterborne traffic paint shall be left to the discretion of the manufacturer, provided that the finished product is in accordance with the specification requirements.

909.05

The pigment portion of these paints shall be a combination of prime and extender pigments as required to produce either white or yellow waterborne traffic paint in accordance with the color and other requirements of the finished product. The yellow waterborne traffic paint pigment shall contain pigment yellow Color Index No. 65, or 74, or 75 or a combination of each. The white waterborne traffic paint pigment shall contain titanium dioxide in accordance with ASTM D476. The non-volatile portion of 350 the vehicle shall be composed of a 100% acrylic polymer.

The cured film of waterborne traffic paint shall not contain any toxic heavy metals above the limits of the regulatory levels of 40 CFR 261.24, Table 1 or contain any other material which will require characterization as a hazardous waste for the disposal of the dried film.

Min. Max. Volume solids, ASTM D2697, % 58.0 -- Total solids by mass, ASTM D2369, % 73.0 -- Pigment by mass, ASTM D3723, % 45.0 57.0 Vehicle solids by mass of the vehicle, % 44.0 -- Viscosity, ASTM D562, Krebs Units 75 95 Weight/volume, ASTM D1475, 25°C, kg/L 1.498 -- Weight/volume @ 25°C, variation from the manufacturer’s initially approved batch, ASTM D1475, kg/L. -- 0.024 Dry time, ASTM D711, 15 mils wet film thickness, airflow of less than 50 cu ft/min, without glass beads -- 10 min Reflectance Factor, Y, C.I.E. illuminant, C, 2° standard observer, ASTM E1349, 15 mils wet film thickness, air dried a minimum of 16 h, %

--

Color, yellow only, x - y C.I.E. Coordinates for the strong limits of FHWA color chart PR1, 15 mils wet film thickness, air dried a minimum of 16 h, measured on white background, C.I.E. illuminant, C, 2° standard observer, % deviation Match the strong limits ±6.00 Coarse material retained on a No. 30 sieve, ASTM D185, % -- 0.05 Bleeding ratio, Federal Specifications TT-P-1952B, except asphalt saturated felt paper shall be in accordance with ASTM D226, Type I 0.97 -- Contrast ratio, ASTM D2805, 10 mils wet film thickness on opacity chart 2A or 2C, air dried a minimum of 16 h 0.96 -- Volatile organic compounds, ASTM D3960 from May 1 thru September 30, g/L from October 1 thru April 30, g/L -- --

Abrasion resistance, Federal Specifications TT-P-1952B, L 190 -- (continued on next page)

909.05

(continued from previous page)

Min. Max. Freeze-thaw stability, Federal Specifications TT-P-1952B, change in consistency, Krebs Units -- 10 Heat stability, Federal Specifications TT-P-1952B, change in consistency, Krebs Units -- 10 Scrub resistance, ASTM D2486, with abrasive medium and shims, cycles 300 -- Water resistance, Federal Specification TT-P-1952B Film shall not soften, blister, wrinkle, or lose adhesion Flexibility, Federal Specifications TT-P-1952B No cracking or flaking of film Infrared spectrum of the vehicle ASTM D3168 Shall match spectrum of manufacturer’s previously submitted samples

Dilution test shall be capable of dilution with water at all levels without curdling or precipitation such that wet paint can be cleaned up with water only.

909.06Blank

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909.08Blank

909.09Blank 370

909.10Non-Epoxy PCC Sealers

Non-Epoxy PCC sealers shall be selected from the QPL of Non-Epoxy Portland Cement Concrete Sealers. A non-epoxy PCC sealer will be considered for inclusion on the QPL by completing the requirements in accordance with ITM 806, Procedure C.

The non-epoxy PCC sealer shall be in accordance with NCHRP 244, Series IV, Southern Climate Weathering Test and possess the following properties: 380

Property Requirement Reduction of ChlorideIon Content 90% of the Control Active Ingredients, minimum, Silane Based 40%

909.06

The testing shall be performed by a recognized laboratory in accordance with ITM 806.

The non-epoxy PCC sealers shall be delivered to the jobsite in unopened containers with the manufacturer’s numbered seal intact.

909.11Epoxy-Resin-Base System for Bonding Plastic Concrete to Hardened 390

Concrete Two-component, epoxy-resin bonding systems for use in bonding freshly mixed concrete to hardened concrete shall be in accordance with ASTM C881 for Type II, grade 2, and the class consistent with the ambient temperature as follows. Class A for use below 40°F, class B for use between 40°F and 60°F, and class C for use above 60°F. A Type C certification in accordance with 916 shall be provided for the epoxy- resin-base system.

909.12Epoxy Resin Additives for Injection into Concrete

The epoxy resin adhesive shall be of low enough viscosity so it flows to the next 400 open port in the surface seal material. The adhesive shall be capable of penetrating crack widths down to 0.005 in. The adhesi ve shall be capable of bonding to dry or damp surfaces. The adhesive shall exhibit a slant shear strength exceeding the concrete strength when tested fully cured in accordance with AASHTO T 237.

The surface seal material shall have adequa te strength to hold injection fittings in place and to resist injection pressures adequately to prevent leakage during injection.

A Type C certification in accordance with 916 shall be provided for the epoxy resin adhesive. 410