SECTION 506- SHOP APPLIED PROTECTIVE COATING - STEEL
506.01 Description This work shall consist of applying protective coating to steel
substrate in accordance with the Plans and this Specification. The protective coating system shall be as specified on the Plans. ALL REQUIREMENTS IN THIS SPECIFICATION ARE THE RESPONSIBILITY OF THE CONTRACTOR UNLESS NOTED OTHERWISE.
506.02 Materials Materials shall comply with the requirements of the respective
Subsections of this Specification.
506.03 Submittals Submit the following, as applicable:
A.The manufacturer's product data sheet for the specified protective coating system(s).
B.Material Safety Data Sheets.
C.Facility Certification, Endorsement or other Qualification(s )
D.Quality Control Plan
E.Quality Control Inspector (QCI) qualifications
506.04 General Specifications Specifications for the protective coating and/or protective
coating systems are: Zinc Rich Coating System Subsections 506.10 through 506.19 H o t - D i p G a l v a n i z i n g S u b s e c t i o n s 506.20 through 506.29 T h e r m a l S p r a y C o a t i n g S u b s e c t i o n s 506.30 through 506.39 Fusion Bonded Epoxy Coating Subsections 506.40 through 506.49
506.05 Inspection Quality Control (QC) is the responsibility of the Contractor. Inspect
all aspects of the work and supervise all sampling, measurements and testing. Record measurements and test results in a clear and legible manner in a format acceptable to the Fabrication Engineer. Reject materials and workmanship that do not meet Contract 5-89 requirements. The QCI may perform sampling, measurements and testing in addition to the minimum required. Make the results of all sampling, measurements and testing available to the Quality Assurance Inspector (QAI). Training in surface preparation, coatings application, and inspection is required for QCI’s. Acceptable training includes one or more of the following:
A.National Association of Corro sion Engineers (NACE) International: Coating Inspector Program Level 1 (minimum)
B.SSPC BCI Coatings Inspecti on Training and Certification for the Bridge Industry: (Level I without certification), or Level II
C.Other training that is acceptable to the Department. Quality Assurance (QA) is the prerogative of the Department. The QAI’s responsibility is to ensure that the QC personnel are performing acceptably, verify documentation, periodically inspect workmanship and witness sampling, measurements and testing. The QAI will schedule measurements and testing deemed necessary by the Resident in addition to the minimum requirements in a manner that minimizes interference with the production schedule. The QAI has the authority to reject material or workmanship that does not meet the Contract requirements. The acceptance of material or workmanship by the QAI will not preclude subsequent rejection, if found unacceptable by the Department.
506.06 Non-Conforming Work Submit a non-conformance report to the Fabrication
Engineer describing the deficiencies and proposed solution. Correct or replace rejected coatings as directed by the Fabrication Engineer.
506.07 Facilities for Inspection Provide a private office at the fabrication plant for the
Department’s inspection personnel, or QAI’s. The office shall be in close proximity to the work. The office shall be climate controlled to maintain the temperature between 68° F and 75° F and have the exit(s) closed by a door(s) equipped with a lock and 2 keys which shall be furnished to the Inspector(s). The QAI’s office shall meet the following minimum requirements: Description Quantity Office area (minimum ft2) 100 Drafting Table Surface (ft2) 3 5 Drafting stools-each 1 O f f i c e D e s k 1 Ergonomic Swivel Chairs 1 Folding Chairs 2 High-speed internet connection (ports) or wireless 1 Fluorescent Lighting of 100 foot-candles minimum for all work areas 2 5-90 110 Volt 60 Cycle Electric Wall Outlets 3 W a l l C l o s e t 1 Waste Basket with trash bags 1 B r o o m 1 D u s t p a n 1 Water Cooler 1 Cleaning materials-floor, surfaces, windows- for duration of the project The Contractor will be responsible for disposing of trash and supplying commercially bottled water for the water cooler. The QAI has the option to reject any furniture or supplies provided to the QAI’s office, based on general poor condition. Provide parking space for the QAI(s) in close proximity to the entrance to the QAI’s office. Maintain the pathway between the parking area and the QAI’s office so that it is free of obstacles, debris, snow and ice. The facilities and all furnishings shall remain the property of the Contractor upon completion of the Work. Payment for the facilities, heating, lighting, telephone installation, internet connection, basic monthly telephone and internet charges and all furnishings shall be incidental to the Contract. Failure to comply with the above requirements will be considered denial of access to the Work for the purpose of inspection. The Department will reject all Work done when access for inspection is denied.
506.08 Applicator Qualification Shop-applied paint systems shall be applied by
applicators that hold a current AISC Sophisticated Paint Endorsement (SPE) or are qualified in accordance with NACE NIICAP. Thermal Spray Coating (TSC), including sealers and top coating shall be applied at facilities with a minimum of five years’ experience with additions of the certifications in the previous section or qualified in accordance with SSPC- QP6, Contractor Metallizing. Fusion bonded coatings and hot-dip galvanizing shall be applied in facilities with a minimum of five years’ experience of satisfactory performance. The Fabrication Engineer may accept other shop qualifications based on experience and/or an audit by the Department.
506.09 Inspection Measure and record the following, as applicable to the coating
application, in a Job Control Record (JCR):
A.Surface preparation - cleanliness and anchor profile.
B.Environmental conditions – ambient temperature, surface temp erature, relative humidity, dew point.
C.Coating batch and/or lot number, date of manufacture and she lf life.
D.Mixing/thinning.
E.Dry Film Thickness (DFT) for each coat. 5-91
F.Cure data-time/temperature/relative humidity.
G.Final inspection and acceptance by the QCI. Submit the format for the JCR to the Fabrication Engineer for review prior to beginning application of protective coating. Provide work area illumination as follows: Work Area Illumination Requirements in Foot Candles Description of Work Minimum Recommended General Work Area Illumination 10 20 Surface Preparation and Coating 20 50 Inspection 50 200 Provide a light meter that measures illumination in foot candles. Use SSPC-VIS 1, Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning or SSPC-VIS 3, Guide and Reference Photographs for Steel Surfaces Prepared by Hand and Power Tool Cleaning as required in order to determine acceptable surface cleanliness. Measure and record the environmental conditions during application and during the entire curing cycle. Failure to provide accurate and complete environmental data may result in rejection of the coating or an extended cure time as determined by the Fabrication Engineer. Measure and record the DFT of each coat in accordance with SSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages (PA 2). ZINC RICH COATING SYSTEM
506.10 Description This work shall consist of surface preparation and application of
coating systems in accordance with the Plans and this Specification. The color of structural steel painted in its entirety shall comply with Federal Standard 595, Color No. 14272 (Green), unless otherwise specified in the Contract. The color of partially painted weathering steel shall comply with Federal Standard 595, Color No. 30045 (Brown), unless otherwise specified in the Contract. All other coating colors shall be as specified in the Contract.
506.11 Materials Coatings systems shall be from the Northeast Protective Coating
Committee (NEPCOAT) Qualified Products List (QPL), list A or B. The list may be found through NEPCOAT’s Web page: http://www.nepcoat.org. Provide the paint batch description, lot number, date of manufacture, shelf life and the manufacturer’s storage requirements to the QAI. Provide the manufacturer's published data sheet for each coat of the coating system including equipment, surface cleanliness, anchor 5-92 profile, mixing, thinning, application, and cure time for the entire range of allowable environmental conditions and the DFT.
506.12 Limits of Work Coat all surfaces exposed in the assembled product unless
otherwise specified. Apply a mist coat, 0.5 to 1.0 mils, of primer only to surfaces to be embedded in concrete. Apply primer to faying surfaces of bolted connections that develop a class B slip coefficient in accordance with the “Specification for Structural Joints Using ASTM A325 or A490 Bolts” by the Research Council of Structural Connections (RCSC). Provide documentation to demonstrate that the primer was tested and the requirements were met. Do not exceed the DFT applied for test purposes.
506.13 Surface Preparation Surface cleanliness shall be SSPC-SP 10, Near-White Blast
Cleaning (SP 10) unless a higher standard of surface cleanliness is required by the manufacturer's published data sheet. Round all corners exposed in the assembled product to approximately a 3/32 inch radius, prior to abrasive blast cleaning. A series of tangents that approximate a radius may be considered as a rounded edge if there are no sharp breaks. Provide radius gauges to inspect corner preparation. The radius shall be the minimum specified above, but not greater than 3/16 inch. The abrasive blast media shall meet the requirements of SSPC-AB 1, Mineral and Slag Abrasives, AB 2, Cleanliness of Recycled Ferrous Metallic Abrasives and/or AB 3, Ferrous Metallic Abrasive. The anchor profile shall be angular and meet the requirements of the coating manufacturer's published data sheet. If compressed air is used for abrasive blast cleaning, perform a blotter test ASTM D4285 at the beginning of each shift and at any time requested by the QAI. Notify the QAI prior to performing the test. Measure and record the anchor profile in accordance with ASTM D4417 Method C (replica tape). If the anchor profile fails to meet the minimum requirements, re-blast the substrate until the required anchor profile is achieved. If the anchor profile exceeds the maximum allowed, generate a Non-Conformance Report (NCR) describing the condition of the substrate and a proposed solution and submit it to the Fabrication Engineer for review. Measure the anchor profile of the substrate on every plane of each beam or girder. If it has been established to the satisfaction of the QAI that the abrasive blast equipment is capable of providing uniform, acceptable anchor profile, a diminished degree of testing may be allowed at the discretion of the Fabrication Engineer. The allowable time between abrasive blast cleaning and primer application shall not exceed the manufacturer’s published recommendations or one work shift, whichever is less. Any evidence of rust bloom, flash rust or other surface conditions that cause the substrate cleanliness to fall outside the specified cleanliness standard will be rejected. Inspect all 5-93 substrate immediately prior to coating application. Re-blast steel substrate that does not meet the surface cleanliness requirements.
506.14 Mixing and Application Record the batch and lot numbers of the coating, the
type and amount of thinner used, the time and pot life of the coating. Add thinner in accordance with the manufacturer's published data sheet. Measure thinner with a graduated cup, or other container, that clearly indicates the amount of thinner being added. Record the amount of thinner added. Mix the paint using the method, equipment and time recommended by the coating manufacturer. Mix each component separately and mix all components together for at least the minimum time recommended on the Manufacturer's Product Data Sheet but not less than two minutes. Measure the environmental conditions in the immediate vicinity of the piece(s) being coated during the coating operation and during the entire cure period. Provide two data loggers capable of measuring ambient humidity and temperature. The data loggers shall come with software that can download the data onto a computer. Print out the data and provide a copy to the QAI for review prior to applying the subsequent coat of paint. Place the data loggers in the immediate vicinity of the coating operation during the entire application and curing cycle. The data will be used to determine that the cure/recoat time requirements for each coat have been met. Failure to comply will result in the coating being cured for the maximum time necessary to assure adequate cure, as determined by the Fabrication Engineer. Stripe all corners, fasteners, welds and locations with poor access, in accordance with SSPC-PA 1, Shop, Field and Maintenance Painting of Steel (PA 1). Do not stripe using inorganic zinc primer (IOZ). Stripe the IOZ primer between the primer and intermediate coats using the intermediate coating. Apply the coating using equipment recommended in the Manufacturer's Product Data Sheet, or equal. Apply the coating in a uniform manner without sags, runs or drips.
506.15 Dry Film Thickness Measure and record the DFT of each coat in accordance
with PA 2. Record the following:
A.Gauge type/manufacturer/model
B.Serial number
C.Coat/shim used for calibration (e.g., Primer Coat or 5 mil s him)
D.Measurements/spot average/location
E.Cure time
F.Non-conforming areas and determination for correction Each piece or area presented for acceptance, regardless of size, shall be considered a separate structure for purposes of determining the number of spot measurements to be taken, except that large quantities of small parts and/or secondary framing members coated at the same time may be measured at a lesser frequency, as directed by the Fabrication Engineer. 5-94 When random DFT testing of a large quantity of small parts and/or secondary framing members results in unacceptable DFT’s, the Contractor shall have the option of measuring and documenting the DFT of each piece or removing the coating and/or recoating all pieces represented in the production lot.
506.16 Touch-up and Repairs Touch-up is the repair of minor blemishes, including but
not limited to, scratches and abrasions that to do not penetrate underlying layers of coating. Perform touch-up using the same coating and methods specified in the Manufacturer's Product Data Sheet. Cure the touch-up coating in the same manner as the original coating. Repair coating damage that penetrates underlying layers in accordance with the Manufacturer's Product Data Sheet and this Specification. Prepare areas to be repaired in a manner that assures the proper adhesion of each coat. Feather back each damaged layer so that each repair coat is continuous with each corresponding existing coat. The topcoat shall be smooth and uniform in appearance. Repair damaged or unacceptable shop coating before the piece is removed from the paint area.
506.17 Handling and Storage Handle coated members in a manner that avoids damage
to the coating. Lift and move members using non-metallic slings, padded chains and beam clamps, softeners or by other non-injurious methods. Store painted material in a manner that prevents damage to the coating. Document damage to the coating that is discovered after the product is loaded for shipment to the job site. Minor damage as a result of handling shall be considered field repair unless, in the opinion of the Fabrication Engineer, the damage is the result of negligence or poor handling methods. Damage that is deemed to be the result of negligence or poor handling methods shall be repaired as directed by the Fabrication Engineer.
506.18 through 506.19- Reserved
HOT-DIP GALVANIZING
506.20 Description This work shall consist of surface preparation and application of
hot-dip galvanizing in accordance with the Plans and this Specification. Hot-dip galvanizing shall meet the requirements of AASHTO M111/ASTM A123, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel (A123), including any applicable requirements listed in Section 2-Referenced Documents. The minimum average coating thickness grade shall conform to Table 1. The frequency of testing shall be in accordance with Section 6. The choice of the test method is the prerogative of the Contractor. Record the test results and provide them to the Department. Provide certification of compliance and written test results to The Department in accordance with A123 -Section 10. 5-95
506.21 Surface Preparation Abrasive blast-clean the steel to a minimum of SSPC-SP 6,
Commercial Blast Cleaning (SP6) prior to galvanizing. Grind all corners exposed in the assembled product to a 1/16 inch radius prior to galvanizing.
506.22 Repairs Repairs to galvanizing shall be in accordance with ASTM A780,
Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings (A 780), Annex A1 or A3. Zinc-rich paints for repairs may only be used with approval of the Fabrication Engineer.
506.23 Top-coating Galvanized Surfaces Areas of galvanized surfaces to be top-coated
will be described on the Plans or in the Special Provisions. Do not use chromate quenching or other types of quenching after galvanizing. Remove runs, sags, dross and other deleterious material from surfaces to be painted. Provide a smooth uniform surface, free of heavy build areas or other discontinuities that will project through the finish coat. Perform repairs to galvanizing in accordance with A 780. Remove visible surface contaminants in accordance with SSPC-SP 1, Solvent Cleaning (SP 1) prior to blast cleaning. Blast-clean surfaces to be coated in accordance with SSPC-SP 7/NACE No.4-Brush-Off Blast-Cleaning (SP 7). Measure the anchor profile in accordance with ASTM D4417 Method C (replica tape). Record the results in a manner acceptable to the Fabrication Engineer. Assure that the anchor profile corresponds with the anchor profile requirements on the Manufacturer's Product Data Sheet.
506.24 Materials Provide materials in accordance with 506.11.
506.25 Mixing and Application Mix and apply in accordance with 506.14.
506.26 Dry Film Thickness Measure and record the DFT in accordance with 506.15.
506.27 Touch-up and Repairs Perform touch-up and repairs in accordance with 506.16.
506.28 Handling and Storage Handle and store material in accordance with 506.17.
506.29 Reserved
THERMAL SPRAY COATING
506.30 Description This work shall consist of surface preparation and application of
Thermal Spray Coatings (TSC) in accordance with the Plans and this Specification. Application of TSC to steel substrate shall be done in accordance with requirements, recommendations and appendices of the current Joint Standard AASHTO S8.2:Specification for the Application of Thermal Spray Coating Systems to Steel Bridges (The Standard) and this Specification. The applicator shall provide copies of application procedures, operator qualifications, QC Manuals and repair procedures. 5-96
506.31 Submittals Submit an application procedure and QC Plan for review by the
Department prior to beginning work. Submit a certified analysis of the feedstock to the Department. Submit sample copies of QC records for review. Submit copies of applicator qualifications, job history, etc. Provide the name and qualifications of the QCI.
506.32 Surface Preparation Prior to abrasive blast cleaning, round all corners exposed
in the assembled product to approximately a 3/32 inch radius. A series of tangents to the approximate radius will be considered acceptable. Remove h ardened condition on thermal cut surfaces. Abrasive blast clean all surfaces to be coated in accordance with The Standard and SSPC-SP 5, White Metal Blast Cleaning (SP 5). Use SSPC -VIS. 1 as a visual standard to determine acceptable cleanliness. Inspect t he substrate immediately before spray application. The anchor profile shall be per The Standard (minimum 2.5 mils). Measure and record the anchor profile in accordance with ASTM D4417 Method B or C (Replica Tape) or both on each plane to be sprayed or at 120 ° intervals on pipe or tu be. Measure at the frequency in The Standard. Angular blast media shall conform with The Standard. If the anchor profile fails to meet the minimum required profile, re-blast th e substrate until the required anchor profile is achieved. If compressed air is used for abrasive blast cleaning, perform a blotter test in accordance with ASTM D4285 at the beginning of each shift. Empty moisture traps at the beginning of each shift and at any time thereafter when moisture appears to be present on the substrate. Notify the QAI prior to performing the test in order that the QAI can witness the blotter test.
506.33 TSC Requirements The coating thickness shall be a minim um of 14 mils. The
DFT on faying surfaces shall not exceed the thickness tested fo r Class B slip coefficient rating. The TSC shall have a minimum tensile bond per The Standard. Test the tensile bond in accordance with ASTM D4541. The frequency of testing shall b e per The Standard. The test location will be as directed by the QAI. The specified ten sile force shall be applied to the TSC and removed. If the test does not reveal a failure of the TSC, the tensile bond shall be considered acceptable. Repair or recoat unacceptable work. Tensile testing may be performed on witness panels coated by each technician on each shift TSC is applied; notify the QAI so witness panel coating may be observed. Perform a bend test as described The Standard, at the beginning of each shift. If the bend test fails, take corrective action and perform another test. After performing the bend test successfully a number of times, the Fabrication Engineer m ay reduce the frequency of testing. Document the results of the tensile bond test and bend test and provide the results to the Department. Satisfactory bend test results with 7-12 mils thickness will be acceptable. The TSC shall have a uniform appearance, free from blistering, cracks, loose particles, or exposed steel substrate when examined with 10-X magnification. 5-97
506.34 TSC Application Record the batch and lot numbers of the consumables.
Measure the environmental conditions in the immediate vicinity of the piece(s) being coated during the coating operation and during the entire cure period for intermediate and top coat. Provide two data loggers capable of measuring ambient hu midity and temperature. The data loggers shall come with software that can download the data onto a computer. Print out the data and provide a copy to the QAI for review pri or to applying the subsequent coat of paint. Place the data loggers in the immedi ate vicinity of the coating operation during the entire application and curing cycl e. The data will be used to determine that the cure/recoat time requirements for each coat have been met. Failure to comply will result in the coating being cured for the maximum t ime necessary to assure adequate cure as determined by the Fabrication Engineer.
506.35 Seal Coat and Top Coat Application (Paint) Apply a wash primer and/or seal
coat of 2 to 3 mils thickness . The seal coat shall be compatible with an epoxy intermediate coat and a polyurethane top coat from the NEPCOAT QPL. Provide certification of compatibility between the seal coat and intermediate coat from the intermediate coat/top coat manufacturer. Top flanges of beams r equiring shear connectors shall receive a seal coat only.
506.36 Materials Provide materials in accordance with 506.11.
506.37 Mixing and Application Mix and apply in accordance with 506.14.
506.38 Dry Film Thickness Measure and record the DFT in accordance with 506.15.
506.39 Touch-up and Repairs Repai r damage to TSC by re-blastin g the damaged area
and re-applying TSC in accordance with this Specification. Perform touch-up and repairs to paint in accordance with 506.16. FUSION BONDED EPOXY COATING
506.40 Description This work shall consist of surface preparation and application of
Fusion-Bonded Epoxy (FBE) coating, in accordance with the Plans and this Specification, including measuring and documenting DFT and testing for holidays and other discontinuities in the epoxy coating. The FBE shall be applied to all surface areas indicated on the Plans. Perform surface preparation and application of FBE in accordance with the following Specifications:
A.Steel pipe pile- ASTM A972, Fusion Bonded Epoxy-Coated Pipe Pile 5-98
B.H-pile and sheet pile- ASTM A950, Fusion Bonded Epoxy-Coated Structural Steel H-Piles and Sheet Piling
C.Reinforcing steel- ASTM A775, Epoxy-Coated Steel Reinforcing Bars
506.41 Materials The FBE coating shall meet all of the physical and testing
requirements of the applicable Specifications above (including Annexes). Provide a certification that identifies the coating, batch or lot number, date of manufacture and test results. Supply patching material from the same manufacturer.
506.42 Surface Preparation Prepare the surface(s) in accordance with applicable
Specifications listed above. Grind all welds flush on spiral welded pipe pile prior to abrasive blast cleaning.
506.43 Inspection The DFT shall be between 12 mils and 20 mils, unless otherwise
specified. Measure the DFT using a fixed-probe gauge in accordance with SSPC-PA 2. The testing procedure and reporting shall be in accordance with ASTM G12. The frequency of testing shall be each piece coated, unless a lesser frequency of testing is directed by the Fabrication Engineer. After curing, the coating shall be checked for holidays (pinholes not visible to the unaided eye) using a 67½ Volt d-c, wet sponge, holiday, detector, in accordance with the requirements of ASTM G62, Test Methods for Holiday Detection in Pipeline Coatings. An average of more than five holidays per foot, in the coated length of a pile, will be cause for rejection of that pile.
506.44 through 506.59- RESERVED
506.60 Method of Measurement Protective coating shall be measured by the lump sum,
complete and accepted. The coating limits shall be as shown or described in the Contract Documents.
506.61 Basis of Payment All work for Protective Coating will be paid for at the lump
sum price for the respective item. Payment will be full compensation for all labor, materials and equipment required to complete the surface preparation and coating work, including, but not limited to, coating and cleaning materials, staging or accessing, testing, surface preparation, cleaning, application, curing and repairs. Payment will be made under: P a y I t e m s P a y U n i t 506.9102 Zinc Rich Coating System (Shop Applied) Lump Sum 506.9103 Galvanizing L u m p S u m 506.9104 Thermal Spray Coating (Shop Applied) Lump Sum 506.9106 Fusion Bonded Epoxy Coating L u m p S u m 5-99
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Source: Standard Specifications — Highways and Bridges, 2020 Edition. Pages 380–391 of 817. View official source ↗