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700-66 The Engineer will permit paint thinning if required fo r proper application, but only as recommended by the
manufacturer. If thinner is used, add it to the paint during the mixing process. Do not add additional thinner after the paint is thinned to the proper consistency. Use thinner recommended by the manufacturer for inorganic zinc paints. Inorganic zinc paint should not require heating in cool weather, but is permitted provided ca re is taken that the paint is protected from all moisture.
4.Application of Paint. Apply the paint according to the manufact urer’s instructions. Provide the Field Engineer with a printed copy of the paint manufacturer’s application instructions. Apply the paint using either a conventional or an airless sprayer. Spray from a continuously agitated pot. Apply uniform coatings in tight contact with the metal. Work the coating into all corners and crevices. Apply a coating that is free of all defects. Allow ample time for each paint coati ng to dry. Do not apply the next co at of paint until the previous coat is inspected by the Engineer and found dry and hard throughout the entire film thickness. Remove and replace defective or unauthorized paint. Prepare the surfaces for repainting and repaint the areas according to the requirement s for painting structural steel. When the finish coat is complete, stencil (in black paint) the date the bridge was painted and the code representing the type of paint system used on the bridge. Stencil the legend on the right side of the outside face of the far right stringer near each end of the bridge. Use capital letters, 2 to 3 inches in height. The date stencil shall contain the word "PAINTED" and show the month and the year that the painting was completed. Make the paint system code selection from the following list: Inorganic Zinc/Acrylic IZ/A Inorganic Zinc/Polyurethane IZ/P Organic Zinc/Acrylic OZ/A Organic Zinc/Polyurethane OZ/P
5.Staging and Scaffolding. Use adequate staging an d scaffolding while painting the structural steel. Do not climb or work on the finished painted members. Provide the Engineer with safe means (such as scaffolding, snoopers or cherry pickers) to inspect any portion of th e structure during the cleaning and painting operations.
6.Protection of Pedestrians and Property. When painting on the project site, protect all pedestrians, vehicles (on or underneath the bridge), adjoining propert y along the right-of-way, pipes or ducts owned by utility companies, and portions of the bridge superstructure and substructure against damage or disfigurement from paint material. The Contractor is responsible for repairing any damage resulting from the painting operations.
7.Maintaining Traffic on Existing Bridges. Provid e traffic control as shown in Contract Documents and SECTION 805 . Unless traffic is detoured, maintain traffic on the existing bridge at all times during the work of cleaning and painting. At the option of the Contractor when work is being performed, ½ of the roadway on that span may be closed to traffic, with on e way traffic being maintained over the other half of the roadway. At all other times when work is not being performed, keep the entire bridge roadway open to traffic.
b.Shop Painting Structural Steel (Non-Weathering). The application of the prim e coat in the shop must comply with the general requirements for painting st ructural steel, with thes e additions and exceptions: Unless shown otherwise in the Contract Documents, apply 1 coat of inorganic zinc primer to the structural steel in the shop. Mask machin ed surfaces prior to painting. Use primer th at is tinted to contrasts (in color) with the blast-cleaned steel and with th e finish coat of paint. Apply 2 primer coats (not less than 6 mils total thickness) to surfaces that are not in contact with the concrete, but that will be inaccessible after assembly or erection. Apply the second coat between 4 and 24 hours after application of the first coat. Prime the welded stud shear connectors (including the underside of the stud head). Given the complexity, areas of thin primer and some shadows are permissible on the top 1 inch. Except where otherwise indicated, coat all blast clean ed surfaces of the structur al steel, including contact surfaces of high strength bolted connectio ns and areas in contact with concrete. The dry film thickness of the prime coat shall be 3 to 6 mils on flat areas. More thickness is allowed in fillet areas if there is no evidence of mud cracking, and if the coating is tight. The dry film thickness is measured from the peaks of the blast profile to the surface of the paint. For contact surfaces of high strength bolted connections, the dry film thic kness shall be 1.5 to 3 mils. Both sides of steel plates that have holes for high strength fasteners are consider ed contact surfaces because they come into contact with other steel plates, nuts, washers or fastener heads. Apply 1.5 mils dry film thickness prime coat to top flanges of structural steel members that will have welded stud shear connectors applied in th e field. Do not apply the prime coat to surfaces within 6 inches of field 714 - PAINTING STRUCTURAL STEEL
700-67 welded connections. Coat unpainted su rfaces near field welded connections w ith a rust preventive coating approved
by the Engineer. The temporary coating must be easily removed with mineral spirits prior to field welding. After the non-machined surfaces of structural steel are prime coat ed, remove the masking from the machined surfaces and apply a prequalif ied coating for use on m achined surfaces approximately 3 mils thick. If the dry film thickness of the prime coat is 2 to 3 mils, and less than 24 hours old, either blast clean the deficient area to bare metal and repaint, or apply additiona l primer. If additional inorganic zinc primer is applied, thin the primer 1:1 with a solvent recommende d by the manufacturer of the paint. If the dry film thickness of the prime coat is 2 to 3 mils thick and more than 24 hours old, or if the dry film thickness is less than 2 mils, blast clean the deficient area to bare metal and repaint. Remove excessive film thickness or dry spray. Give the inorganic zinc prime coat a thorough single spray of clean water between 2 and 48 hours after application of the inorganic zinc prime coat, when recommended by the manufacturer. Before the structural steel is shipped to the project site, blast clean to bare metal and repaint defective or damaged areas. Overlap the new prime coat onto the existing prime coat a minimum of 1 inch. Shop painted structural items, except matchmarked girders and beams, that will receive a field coat of paint must have an identification mark painted on their surf ace, or they may be tagged with a weatherproof tag.
c.Field Painting New Structural Steel (Non-Weathering).
1.Prime Coat. Apply a prime coat to the field connections, field welds, nuts, bolts and washers. Re-coat all damaged or defective areas of the shop-applied prime coat . Apply the prime coat in the field complying with the general requirements painting structural steel, with these additions and exceptions: Overlap the shop coat by applying the field-applied prime coat a minimum of 1 inch beyond any surface preparation. If the surface prepared for painting or re-coating is 1 square yard or less, apply organic zinc primer. Use organic zinc primer on bolts, nuts, washers and edges of bolted splice plates. If the surface prepared for painting or re-coating is great er than 1 square yard, blast clean the entire flange or web of the area to be painted or re-coated, and apply inorganic zinc primer. Between 24 and 48 hours after the inorganic zinc primer is applied in the field, apply a co at of organic zinc primer (b y brush or spray according to subsection 714.3b. ) where the new inorganic zinc prime coat meet s or overlaps the shop applied inorganic zinc prime coat. If welded stud shear connectors are applied in the field, blast clean th e top of the top flange to SSPC-SP6, Commercial Blast Cleaning. After the welded stud shear connectors are applied, blas t clean the top flange and welded stud shear connectors to meet SSPC-SP6, Commercial Blast Cleaning. Thoroughly blast clean the welds. Apply organic zinc primer to the top flange and welded stud shear connectors. Prime the welded stud shear connectors (including the underside of the stud head). Given the complexity, areas of thin primer and some shadows are permissible on the top 1 inch.
2.Finish coat. Protect the prim ed structural steel from contamin ation during transport, storage and erection. Do not walk on the primed stru ctural steel. If the primed structural st eel is soiled, use water or light blast cleaning to remove the contamination befo re applying the finish coat of paint. The application of the finish coat in the field shall comply with the general requirements for painting structural steel, with thes e additions and exceptions: Unless otherwise noted in the Contract Documents, e ither apply an acrylic or a polyurethane finish coat after the primed structural stee l is erected. Apply 1 coat w ith a dry film thickness of 3 to 6 mils on flat areas. A thickness in excess of 6 mils is allowed in fillet areas if there is no evidence of mud crac king, and if the coating is tight. If bubbles form, allow them to collapse and apply appr oximately 1 mil of the finish coat to the area where the bubbling occurred.
d.Shop Painting New Weathering Steel. Apply the shop painting of new weathering steel complying with the general requirements for painting structural steel and the shop painting of non-weathering structural steel, with these additions and exceptions: Blast clean all surfaces of the weat hering steel, including all contact surf aces of bolted connections, to meet SSPC-SP6, Commercial Blast Cleaning. For weathering steel surfaces that require painting, blast clean to meet SSPC-SP10, Near-White Blast Cleaning. Surfaces that require paint include: 714 - PAINTING STRUCTURAL STEEL
700-68 girder ends that are embedded in the abutment - the entire embedded portion of the girder, including
diaphragms, plus an additional distance of 2 inches; the top (and sides, if in contact with concrete) of the top flanges, including shear studs and the underside of the stud head. Given the complexity, areas of thin primer and some shadows are permissible on the top 1 inch of shear studs. Note: for welded stud shear connectors applied in the field, the top of the top flange does not require a shop prime coat; all surfaces of top flange top splice plates; all surfaces of fill plates less than ¼ inch thick. Note: Fill plates need not be weathering steel. Paint fill plates of non-weathering steel, regardless of thickness; all structural steel surfaces (not in cluded above) within a distance of 2 times the depth of the girder (2D) on either side of an expansion joint. (Note: A nearby stiffener is a convenient location to stop painting.); and the exterior girders according to FIGURE 714-1 , if drainage is allowed over the side of the deck on a plate girder bridge, and the entire length of the exterior girder is to be painted. Note: If drainage is allowed over the side of the deck on a rolled beam bridge, painting of the exterior beam, except top flange, is not required.
e.Field Painting New Weathering Steel. Apply a finish coat to all primed structural steel surfaces still exposed after the placement of superstructure concrete. Th e surface preparation of the top surface of the top flange (field applied welded stud shear connectors), and the application of the prime coat (including the top of the top flange after welded shear stud connectors ha ve been applied in the field) and the finish coat in the field shall comply with the general requirements for painting structural steel and the field painting of new, non-weathering structural steel, with these add itions and exceptions: Unless noted otherwise in the Contract Documents, use a waterborne acrylic, brown finish coat color equivalent to Federal Standard No. 595a, Color No. 30045 (Carboline No. 2248). If drainage is allowed over the side of the deck on a plate girder bridge, and the entire length of the exterior girder is to be painted, apply a finish coat to the exterior girders according to FIGURE 714-1 . Unless shown otherwise in the Contract Documents, blast clean the entire exteri or facia of the unpainted exterior girders after erection to meet SSPC-SP6, Commercial Blast Cleaning. FIGURE 714-1 WEATHERING STEEL
f.Painting Galvanized Steel. Follow ASTM D 6386 to prepare galvani zed surfaces that are to be painted, then apply a primer tiecoat prior to app lication of the topcoat. Use a tiecoat th at is compatible with the topcoat and approved by the Engineer. Follow the manufacturer’s recommendations for application, including dry film thickness and cure time of the primer tiecoat. 714 - PAINTING STRUCTURAL STEEL
700-69 g. Repainting Steel Bridges - Change Paint System. Repaint the steel bridges. Comply with the general
requirements for painting structural steel, with these additions and exceptions: Remove the existing paint system and repaint the bridge with a paint system of organic zinc or inorganic zinc prime coat and acrylic or polyurethane finish coat. Clean and prepare the steel surfaces, including iron or steel casings an d metal railings previously painted that are accessible for field painting. Do not paint tops of expansion guard plat es, bars or angles across the roadway at joints between adjacent spans on which vehicular traffic comes in direct contact, and pipes or ducts owned by utility companies. If lower chords, braces of truss spans or other member s are separated by tie plates or fills, clean the spaces between backs of angles or channels (equal to the thickness of the tie plates or fills) of all rust and loose paint. Tight paint found between splice plates, beneath rivet heads and in other such narrow openings may be left intact. Take special care to remove the rust often found along the edges of the top flanges of I-beams at their line of contact with a concrete deck. Apply the type of prime coat specified in the Contract Documents with 3 to 6 mils dry film thickness of the prime coat on flat areas. More thickness will be allowed in fillet areas if there is no ev idence of mud cracking, and if the coating is tight. After the prime coat is dry, give the inorganic zinc prime coat a thorough spray of clean water a minimum of 24 hours before the finish coat is applied. Organic zinc paint does not require a water spray. Spray painting may be waived in those places where it is not possible to blast clean. Clean these areas by hand as well as possible, and apply a heavy coat of organic zinc primer with a brush or dauber. Apply 1 finish coat with 3 to 6 mills dry film thickness on flat areas. A thickness in excess of 6 mils is allowed in fillet areas if there is no evidence of mud cracking, and if the coa ting is tight. If bubbles form, allow them to collapse and apply an approximate 1 mil of th e finish coat to the area where the bubb ling occurred.
h.Repainting Steel Bridges - Painting In Kind (Bri dges with either organic zinc or inorganic zinc prime coat and acrylic or polyurethane finish coat paint systems). Repaint the steel bridges. Comply with the general requirements for painting structural steel, with these additions and exceptions: Prepare the metal surfaces and repaint the bri dge with the same paint system as existing. Clean and prepare the steel surfaces, including iron or steel casings an d metal railings previously painted that are accessible for field painting. Do not paint tops of expansion guard plat es, bars or angles across the roadway at joints between adjacent spans on which vehicular traffic comes in direct contact, and pipes or ducts owned by utility companies. If lower chords, braces of truss spans or other member s are separated by tie plates or fills, clean the spaces between backs of angles or channels (equal to the thickness of the tie plates or fills) of all rust and loose paint. Tight paint found between splice plates, beneath rivet heads and in other such narrow openings may be left intact. Take special care to remove the rust often found along the edges of the top flanges of I-beams at their line of contact with a concrete deck. Blast clean the steel surfaces to remove any defectiv e coating. Hand clean widely spaced damaged spots (3/16 inch or less in diameter) on an otherwise tight exis ting coating. Remove oil a nd grease using a non-flammable solvent approved by the Engineer. Clean areas according to SSPC-SP6, Commercial Blast Cleaning to produce a height of profile of 1 to 3 mils. Apply 1 coat of organic zinc (minimum dry film thickness of 3 mils) to bare metal. Cover the bare metal and overlap the existing finish coat by 1 inch. Spray painting may be waived in those places where it is not possible to blast clean. Clean these areas by hand as well as possible, and apply a heavy coat of organic zinc primer with a brush or dauber. Use the type of finish coat specified in the Contract Documents. Apply 1 finish coat with 3 to 6 mils dry film thickness on flat areas. A thickness in excess of 6 mils is allowed in fillet areas if there is no evidence of mud cracking, and if the coating is tight. If bubbles form, allow them to collapse and apply an approximate 1 mil of the finish coat to the area wh ere the bubbling occurred. 714.4 ENVIRONMENTAL PROTECTION (Existing Lead-based Paint Systems) Provide environmental protection on a structure whether partially or completely removing an existing paint system that is defined as hazardous per federal Re source Conservation and Recovery Act (RCRA) Disposal 714 - PAINTING STRUCTURAL STEEL
700-70 Regulations (40 CFR 261). The removal of existing lead-bas ed paint may result in creation of waste subject to the
above hazardous waste regulations.
a.Structure Classification. The bridge classification will be included in the Contract Documents, prior to letting. For the purpose of this specifica tion, bridges are classified as:
1.Class A: A bridge in which any part is within 300 feet of: a residence, a school, a public use area, a commercial/industrial property, agricultural buildings; or a protected natural area property.
2.Class B: Any bridge that is not Class A.
b.Health and Environmental Sampling.
1.The Environmental Services Secti on (ESS) of the Bureau of Design w ill conduct a bridge Site Review and Field Survey (SRFS) to document the details of the project and the environmental concerns in the vicinity. (2) Soil samples will be collected by the ESS prior to and at the conclusion of paint removal operations. While conducting the SRFS, soil samples will be collected within KDOT right-of-way from a minimum of 1 test site 10 to 100 feet away from the structure in each of 4 directions. The specific location of each site will be documented. Each test site shall consist of a 1 square foot area. A co mposite sample will be obtained by collecting soil ¾ inch in diameter and ½ inch in depth at the center of the square and at each of the 4 corners. At the conclusion of the project, soil samples will be collected by the ESS in the same manner at a 1 square foot area within a radius of 5 feet of the original sample location. The pre-job and post-job samples will be analyzed for total lead at a Kansas Department of Hea lth and Environment (KDHE ) certified laboratory.
3.The air sampling equipment shall be provided by the Contractor and will remain the property of the Contractor. Collect air samples, unless stated otherwise in the Contract Documents, on all Class A bridges. Collect the samples following the procedures specified in the Code of Federal Regulations (CFR), 40 CFR 58, Appendix G and the quality assurance procedures as specified in 40 CFR 58, Appendix B and 40 CFR 58.20. Employ high volume air samplers to assess the effects of blasting operations on ambien t air quality outside the containment structure. Collect air samples each day paint is blasted from the structure. Place the air samplers on KDOT right-of-way in the upwind and downwind position to the prevailing wind at locations expected to experience maximum impact. Locations for air sampling will be approved by th e Engineer. Remove and replace the sample fi lters each day. Store the used filters in air-tight bags, properly identified with date, sample location and KDOT project number. Submit the air sample filters to a KDHE certified laboratory a minimum of once every 5 working days, where they will be analyzed fo r total lead. Lead concentrati ons in ambient air must be in compliance with 40 CFR 50, which allows a maximum of 0.05 mil/cubic yard (See Guide 6, Section 5.5.4). The labor atory analyses must be accelerated in order to have analytical results to the Engineer within 5 working days of the original transmittal to the laboratory. Identify the analytical results by the date of collection, type and locati on of sample, and KDOT project number. If ambient air concentrations exceed regulatory limits, halt blasting operations until containment design controls have been implemented to redu ce emissions to a satisfactory level.
4.Collect surface water samples on a ll bridges located over any perennial st ream, river or body of water. Sediment samples may also be required, at the discretion of the Engineer, where stream flow is extremely low, where containment has obviously failed or when paint removal operations exceed 30 calendar days . At the direction of the Engineer, a minimum of 1 sample shall be collected upgradient of the structure and 1 in the down gradient position of the structure during blasting operations. The samples will be representative of the project’s potential impact to the water body and will be collected in the presence of the Engi neer. If visible waste or paint chips are observed on the surface of the waterway, halt blasting ope rations until the containment has been modified to eliminate debris contact with the water surface. This determination will be made by the Engineer. Identify water samples by date, type and location of sample, and KDOT project number. Submit th e water samples to a KDHE certified Laboratory for the analysis of total lead within 1 week from the time of collection. Submit the analytical results to the Engineer upon receipt from the laboratory. Identify the analytical results by date of collecti on, type of sample, Chain of Custody forms, and KDOT project number.
5.Failure to submit analytical data for air and wate r samples on a timely basis as described above may result in work on the project being suspended by the Engineer until submittals are in compliance. Temporary suspension of work on the project due to non-compliance by the Contractor will not alter or waive the charging of working days for the project. 714 - PAINTING STRUCTURAL STEEL
700-71 (6) Submit all documentation relative to air and water sample collection and analyses to the ESS within 30
days of completion of the paint removal process. If documentation is not submitted, the Engineer may stop work on the project until such documentation has be en received by the Engineer and ESS.
c.Notifications and Record Keeping. The ESS will submit a SRFS report to the Bureau of Waste Management (BWM), KDHE, Forbes Field, Topeka, Kansas 66620-0001 a maximum of 60 days before beginning work on the bridges. At the same time, a copy will also be provided to the Bridge Management Section and the appropriate KDOT Distri ct Office. The District Office will provide a copy of the Site Review and Field Survey report to the Contractor. At the conclusion of the blasting operations, the ESS will submit a report to the BWM, which includes the results of all air, soil, and surface water samples obtained duri ng the project. A copy of this report will also be provided to the appropriate District Office. The Contractor may receive a copy of this report upon request to the Engineer or ESS.
d.Lead Base Paint Removal. The Contractor engaged in lead base paint removal operations must carry a pollution liability (access liabilit y) policy with a minimum coverage of $1,0 00,000. Maintain this policy in force until the Secretary releases the Contractor from all obliga tions under the contract. The insurance contract must cover claims for such length of time as said claims are permitted by law. Provide a copy of this insurance certificate to the Engineer prior to beginning lead base paint removal operations. Use best industry practices to prot ect the environment, persons and ad jacent property from contamination due to blasting of the existing structure. When "Power Wash" is shown as a bid item, clean the existing steel before initiating the blasting operations. Use a power washer with pr essure in the range of 700 to 1000 pounds per square inch to clean the structure, at a maximum rate of 4 gallons per minute, using potable water. Comply with all applicable regulations contained in K.A.R. 28-16-28 (b) through (f) for protection of water quality, K.A.R. 28-29-1 through
28-29 27 for disposal of solid waste and K.A.R. 28-31-1 through 28-31-14 for disposal of hazardous waste. In
addition, comply with all applicable Occupational Safety and Health Administration standards including those found in 29 CFR 1910.1025 covering the occupationa l exposure to lead and 29 CFR 1926.62 outlining the requirements for the removal of lead-based paint from bridge repair and rehabilitation activities. Contain paint chips, corrosion residues and spent abra sives, referred to as waste materials, resulting from blasting and other cleaning operations. The containment requirements are covered in subsection 714.4e . Use special containment methods or removal procedures over power lines, communication lines, railways or roadways not closed to traffic. Obtain the permits and permission from the line owner on the containment methods and removal procedures. The proposed containment method or removal procedures must be sealed by a licensed Professional Engineer, and submitted to the Engineer before commencing paint removal operations. Clearing of the work area for containment purposes is the responsibility of the Contractor. Clearing may not extend beyond right-of-way. Burning on the right-of-way is prohibited. The area to be cleared and the clearing method must be approved by the Engineer before starting the clear ing operation. Provide locations, approved by the Engineer, and dispose of all the debris at said locations.
e.Removal and Containment Requirements.
1.Class A Bridges. On all Class A bridges, provide a KDHE certified Lead Abatement Supervisor for oversight of all paint removal, storage and disposal operation. These operations shall adhere to work practices established in K.A.R. 28-72-18(g) and K.A.R. 28-72-18d(a). The Lead Abatement Supervisor must have available at the job-site a telephone number for the nearest Local Emergency Planning Commission (LEPC), or if none can be found within a 50 mile radius, the nearest Haz-Mat Response Contractor. Dry abrasive blasting or any other approved method which meets the paint specification may be used to remove the lead paint from the bridge. Use the containment methods shown below to maximize pollution control.
a.Power Tools: Use containment unless the power tools are vacuum equipped and all parts of the vacuum equipment are in a condition that prevents emissions of wast e material. This determination will be made by the Engineer. (b) Dry Abrasive Blasting: Use 100% air impenetrable walls with rigid or flexible framing, fully sealed joints, airlock or resealable entryways, and negative air achieved by forced or natural air flow (verified by instrument or visual monitoring) and exhaust air filtration (See SSPC – Guide 6, Paragraph 4.2.2.1). Design the containment to withst and the effects of negative air pressure equal to the combined volume of all blast nozzles inside the enclosure plus 4 air changes of the enclosure per hour. The
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 397–402 of 978.