2478Organic Zinc-Rich Paint System

2478.1DESCRIPTION

This Work consists of the following for shop or field full-system applications of Organic Zinc-Rich Paint Systems for new construction and recoating of existing structures:

A Definitions For the purpose of the Work specified in section 2478, “Organic Zinc-Rich Paint System,” and 2479, “Inorganic, Zinc-Rich Paint System,” the Department defines: Coating System The surface preparation and application of specific coating classifications (i.e., Inorganic Zinc-Rich, Organic Zinc-Rich, Polyurethane, Acrylic, Polyurea, Latex, Galvanize, Powder, etc.) of coating products to provide a film forming a unified whole for the purpose of corrosion protection and/or aesthetics. Coating Thickness The Dry-Film Paint Thickness (DFT) above the peaks of the blast profile. Contact Surfaces Those surfaces in the completed Structure that touch other surfaces. Contractor Shall mean the fabricator, paint contractor, applicator, or other entity that prepares the surfaces and applies the coatings. Corner The intersection of two surfaces. Duplex Coating System A system whereas galvanizing replaces the zinc-rich primer and subsequently intermediate and top coated in accordance with this Specification. Edge An exposed, through-thickness surface of a plate or rolled shape. This may be the as-rolled side face of a beam flange, channel flange, or angle leg, or may result from thermal cutting, sawing, or shearing. Edges may be planar or rounded, and either perpendicular or skewed to adjacent faces.

Field Coating The outdoor on-site coating of new or previously coated steel Structures before or after erection. Hold Point For field application of paints only: Puts a hold on any future Activities until an inspection is passed. Do not proceed without the written approval of the Bridge Engineer. The Department and the Contractor will use the “Start-up Checklist” and the “Daily Quality Assurance Check List” located on the MnDOT Bridge Construction website so that quality is assured. Mist Coat (Fog Coat or Tack Coat) A thin mist-spray application of a coating to improve adhesion and uniformity of the subsequent full application of the same coating. A light coat of unspecified DFT used to prevent rust staining of steel substrates or temporarily inhibit corrosion. Non-contact Surfaces Surfaces that are not in direct contact with other surfaces. Paint System A set of interacting film forming paint Materials and products which combine to make up a complete Coating System. Prime Coat Application of a zinc-rich coating to a bare metal substrate. Qualified Holding appropriate documentation and officially on record as competent and experienced to perform a specified function or practice of a specific skill. Quality Assurance (QA) The process and person(s) responsible for verification of the conformance of Materials and methods of application to the governing Specification, in order to achieve a desired result. Quality Control (QC) The process and person(s) responsible for administrative and production procedures employed to attain the desired product outcome and quality. The job foreman or production painter cannot be this person. MnDOT Quality Manual (QM) The formal written document prepared by the Contractor that describes the policies and procedures that ensure and verify that the coated structural steel component will satisfy the Contract requirements. Quality Assurance Inspector (QAI) The Department’s representative responsible for duties specified in the Quality Assurance Plan, with the authority to accept Work that meets Contract requirements. Shop (in Shop coating) The indoor facility where structural metals are prepared and coated. Stripe Coat A coating, of sufficient thickness to completely hide the surface being coated, on all E dges, corners, seams, crevices, interior angles, junctions of joining members, bolt heads, nuts and threads, weld lines, and similar surface irregularities. This coating shall be followed, as soon as practicable, by the application of the full Prime Coat to its specified thickness.

2478.2MATERIALS

2478.3CONSTRUCTION REQUIREMENTS

A Contractor Qualifications and Documentation A.1 Field Applicators Submit a Quality Manual (QM), to the Engineer for acceptance, meeting the requirements of:

the QM as shown in 2478.3C.1, “MnDOT Quality Manual (QM) Requirements”

Conformance to Dry Coating Thickness Requirements

for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges

“Bridge Structural Steel Coating,” under the Guidance heading Submit a custom QM draft document E-file to be accepted by the Engineer, in writing. The Department will complete their initial review within 7 calendar days. The QM will not be accepted if the Engineer finds that is doesn’t fulfill the requirements and the Contractor will be notified to correct the QM and resubmit for review. The Department will have an additional 7 calendar days for each review until the Engineer provides written confirmation of acceptance. Collaboration is key and this process will be repeated until there are no further changes required. The accepted QM is required 10 calendar days prior to starting any work related to the painting work. Work cannot begin until the Engineer provides a final written confirmation of acceptance . Perform the preparation and application of field applied coatings with staff meeting the requirements of The Society of Protective Coatings Certified Application Specialist (SSPS CAS) Level 2. One CAS Level 2 is required on sight overseeing the Work in each Work area up to a crew of 10 workers. Multiple Work areas will require an additional CAS for each area. A.2 Shop Applicators Before the start of Work, the supplier will be Qualified on MnDOT’s Approved Suppliers for Fabricated Structural Metals Products list as maintained by the Structural Metals Engineer on the Bridge Office website, or become Qualified. To become Qualified, the supplier is to submit a MnDOT Quality Manual (QM) to the Bridge Engineer for review and acceptance, at least 60 Calendar Days before beginning Work. The QM is to meet the requirements of the MnDOT Supplier Qualification Standard which will be the basis for acceptance by the Bridge Engineer. Upon acceptance of the QM, a supplier is Qualified and will be listed on the MnDOT Approved Suppliers for Fabricated Structural Metals Products list. In addition to routine inspections, the Bridge Engineer will audit suppliers with approved QMs on a biannual or annual basis or as otherwise directed by the Bridge Engineer to ensure the implementation of the QM. The Department will invoke its Corrective Action Process if the routine inspections or audits indicate non-conformance. Any corrective actions deemed appropriate by the Bridge Engineer, are effective immediately and apply to any Work remaining on current and future

Projects. If the Bridge Engineer determines that Work does not comply with the QM or that fabrication does not follow approved fabrication procedures, the Bridge Engineer will deem the Materials as non-conforming in accordance with 1503, “Conformity with Contract Documents,” and 1512, “Unacceptable and Unauthorized Work.” If the Bridge Engineer finds non-conforming Work, direct the supplier to immediately correct the procedure and submit a written Nonconformance Report, containing data required by the Bridge Engineer to ensure compliance with the QM, Specifications, and drawings. Perform additional testing as required by the Bridge Engineer at no additional cost to the Department. For repeat offences or negligence, the Department will require corrective action of hiring a third-party Quality Control Inspector at no additional cost to the Department. The Contractor may obtain a copy of the Department’s Corrective Action Process from the Bridge Engineer. B General Provide Paint Systems listed on the APL, Bridge, “Bridge Structural Steel Coating, Three Coat Systems (organic).” Deliver the paint to the site in the original unopened containers no greater than 5 gal. Do not alter the contents unless approved by the Bridge Engineer in writing. Package multi-component coatings in separate containers or kits. Provide the Engineer or Bridge Engineer with the following:

Ensure a manufacturer’s technical representative with knowledge of the approved Paint System is available to assist during surface preparation and coating application . For new construction, preserve or transfer erection markings to ensure legibility when erecting members. Provide removable markings or place markings at locations not visible in the completed Structure. Use marking Material that will not damage the Paint System. If painting a Structure erected under a previous Contract, the Department will not require disassembly of portions of the Structure or removal of appurtenances to expose Contact Surfaces or otherwise inaccessible metal surfaces unless otherwise shown on the P lans or in the Special Provisions. For new construction projects, paint Contact Surfaces with the zinc primer at the recommended DFT, except for surfaces completely sealed by:

Coat the top surfaces of beams and girders with a Mist Coat of primer. Protect the environment and property as required by federal, State, and Department regulations. Protect non-painted surfaces (concrete Bridge deck overhangs and vertical faces of abutments) that are adjacent to the painted surfaces from overspray, unless otherwise shown on the P lans or in the Special Provisions. The Bridge Engineer will allow up to 2 inches of overspray and may require the excessive over sprayed paint be removed, covered with a special surface finish, or wire wheeled from the adjacent surface(s).

Provide a system for inspection that will allow the Inspector to safely access the steel components. For safety systems that require temporary fastening to the steel to support the system, use fastening hardware that will not damage the paint. Repair damages as approved by the Bridge Engineer at no additional cost to the Department. C Inspection Perform QC inspections of the Shop and field painting in accordance with an approved QM. The Department will appoint a Quality Assurance Inspector (QAI) as a Department representative to accept Work meeting the Contract requirements. C.1 MnDOT Quality Manual (QM) Requirements Provide the minimum requirements and frequencies in the QM as shown in Table 2478.3-1: Table 2478.3-1 Coating Inspection Requirements Requirement Frequency/Extent General Ambient temperature Every 4 (field) hours; Every 8 (Shop) hours or at the start of each shift Dew point and relative humidity Every 4 (field) hours; Every 8 (Shop) hours or at the start of each shift Surface temperature Every 4 (field) hours;; Every 8 (Shop) hours or at the start of each shift Date and time Every 4 (field) hours; Every 8 (Shop) hors or at the start of each shift Piece mark or bundle Every 4 (field) hours; Every 8 (Shop) hours or at the start of each shift Compressed Air Test ASTM D4285* Daily – when abrasive blasting or blow down operations are occurring DFT (each coat of paint) SSPC PA 2ǁ Visual inspection (each coat of paint) 100 percent Surface Preparation Pre-clean per SSPC-SP 1, Solvent Cleaning Each component to be Prime coated. Visually inspect 100 percent Abrasive blast clean per SSPC-SP 10† Each component to be Prime coated Visually inspect per SSPC VIS-1ǂ 100 percent Soluble Salt Test See Special Provisions Blast profile inspection per ASTM D4417#

Steel Girders – minimum of 3 locations per each blasted. Diaphragms – 3 locations minimum per each blasted. § Sole Plates – 3 locations minimum per each blasted. § Pedestrian Bridges** Railingǁǁ Bridge Truss – 3 location minimum for each 1000 square feet or the amount of truss blasted by each blasting nozzle in an 8 hour shift (whichever is less). Items not covered by this list shall have 3 documented profile locations for every 1000 square feet blasted. P r

Batch number Every paint kit

Requirement Frequency/Extent Verification of surface cleanliness Examine visually within 1 hour before prime painting. For field applications include a white cloth wipe test (nothing is transferred on to the cloth surface) – 5 locations, designated by the Engineer, minimum or more as requested by the Engineer Temperature of mixed product When mixing components Proper mixing and straining Every pot mix Induction time and reaction time Every pot mix Pot life Every pot mix Cure time Each lot of work Cure Verification Prior to the next coat application Proper use of Stripe Coats (Prime Coat only) Visual, 100 percent of applicable areas, as specified in 2478.3F, “Paint Coats” Coating evaluation and repair Visual, 100 percent of each element Recoat time Each lot of Work and as recommended by the manufacturer Adhesion (Final Coating System) As required by the Bridge Engineer Coating System final evaluation and repair Visual, 100 percent of each element * ASTM D4285, Standard Test Method for Indicating Oil or Water Compressed Air ǁ SSPC PA 2, Procedure for Determining Conformance to Dry Coating Thickness Requirements † SSPC-SP 10, Near-White Metal Blast Cleaning ǂ SSPC VIS-1 Guide and Reference Photographs for Steel Surfaces Prepared By Dry Abrasive Blast Cleaning # ASTM D4417, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel § For Inorganic Zinc-Rich Paint Systems: The amount of diaphragms or sole plates going through an automated blast machine at one time or the amount being blasted in an 8 hour shift. ** For organic Zinc-Rich Paint Systems: Minimum of 3 locations on each truss and a minimum of 3 locations on the floor beam. For Inorganic Zinc-Rich Paint Systems: Minimum of 3 readings on each truss and a minimum of 3 readings on the floor beam. ǁǁ For organic Zinc-Rich Paint Systems: Ten locations minimum for each 100 lineal feet of rail. For Inorganic Zinc- Rich Paint Systems: 3 readings minimum for each 100 lineal feet of rail.

In addition to the above requirements, include the following information in the field painting QM:

Industrial/Marine Painting Contractors certification for field painting and that it is maintained throughout all aspects of the cleaning and painting portion of the Contract per AASHTO/NSBA Steel Bridge Collaboration S8.1 SSPC-PA Guide 13, Guide Specification for Application of Coating Systems with Zinc -Rich Primers to Steel Bridges

application of the paint were trained on mixing and application of the Coatings System

Coats”

abrasive blast profile and cleanliness, Stripe Coat, Prime Coat, intermediate coat, and finish coat Provide written records meeting all Coating Inspection requirements to the Bridge Engineer upon request on an ongoing basis as the Work is being performed. For field applications, also provide complete written records within 5 Working Days from when the shift was completed to receive partial payment. Provide written records meeting all Coating Inspection requirements, in its entirety, at the completion of the job, prior to receiving final payment. The QAI or the Bridge Engineer will reject the Coating System or apply a monetary deduction per 1512, “Unacceptable and Unauthorized Work,” if the Contractor did not adhere to the approved QM or provided inadequate documentation of adherence to the QM. Conduct subsequent testing with the QAI for the Bridge Engineer's approval, at no additional cost to the Department, to determine compliance. D Surface Preparation The QAI or Bridge Engineer will inspect the surface preparation as it is done, after its completion, or review the QM documentation, or any combination of the three. Notify the QAI or the Bridge Engineer at least 5 Working Days before beginning surface preparation. D.1 Cleaning D.1.a Solvent Cleaning Clean areas containing organic, synthetic, and other visible contaminants with solvent meeting the requirements of SSPC-SP 1, Solvent Cleaning. Protect the adjacent environment and property while solvent cleaning. D.1.b Abrasive Blasting Abrasive blast clean surfaces to achieve a SSPC-SP 10/NACE No. 2, Near-White Metal Blast Cleaning before applying Prime Coat. Use job site visual standards and SSPC- VIS 1, Guide and Reference Photographs for Steel Surfaces Prepared by Abrasive Blast Cleaning. In the event of conflict, the hierarchy is the written word, the jobsite standard, then VIS 1. Use job site visual standards for profiles, as well. Perform blast cleaning operations meeting the requirements of MPCA Rules 7025.0200 through 7025.0380. For Organic Zinc-Rich Epoxy System Paint Systems: Abrasive blast clean to achieve a profile range from 2.0 mils to 4.0 mils. Reblast clean surfaces when the surface profile is less than 2.0 mils. Provide a Nonconformance Report (NCR) as stated in the QM, to the QAI or Bridge Engineer if the profile exceeds 4.0 mils. Provide written documentation proving that the specified profile has been achieved. For Inorganic Zinc-Rich Paint Systems: Abrasive blast clean to achieve a profile range from 2.0 mils to 3.5 mils. Reblast clean surfaces when the surface profile is less than 2.0 mils. Provide a Nonconformance Report (NCR), as specified in the QM, to the Bridge Engineer if the profile exceeds 3.5 mils. Provide written documentation proving that the specified profile has been achieved. When recyclable blast media is used, assess the blast cleaning abrasives, prior to using, for the presence of conductive potential, ionic contaminants by determining the total concentration of water soluble conductive species using a conductivity test ASTM D4940, Standard Test Method for Conductimetric Analysis of Water Soluble Ionic Contamination of Blast Cleaning Abrasives.

Monitor Exhaust Dust During Blasting Operations. Do not allow fugitive dust emissions to leave the property line or contaminate the air in the P roject. Ensure that control equipment (Baghouse) is being operated and maintained according to the manufacturer’s specifications. Monitor and report to the Engineer the emissions coming from all machines used on the Project on an immediate schedule. D.1.b(1) Duplex System (shop) Perform preparation of galvanized surfaces prior to application of paint in accordance with SSPC SP16 Brush-off Blast Cleaning of Non-Ferrous Metals, and ASTM D6386, Standard Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product and Hardware Surfaces for Painting. Inspect brush-off blasted surfaces for fins, tears, reduced DFTs that fall below the required minimum, or any other damage . Submit to the Bridge Engineer an NCR documenting all damage prior to repairing the surface. D.1.c Post Blasting After blast cleaning, remove blasting debris from steel surfaces using procedures that leave the surfaces free of moisture and contaminants . Remove the blasting residue from the containment area, specifically the floor area, to prevent dust from being airborne once painting process starts. Provide structural steel members free of surface defects, such as small seams, blisters, weld spatter, fins, laps, and tears . Perform grinding up to 1/32 inch or 5 percent of the Material thickness, whichever is less. Perform grinding parallel to the direction of the stresses. Remove surface defects and repair gouges before applying Prime Coat. E Application of Paint E.1 General For Shop application of paint, submit documentation to the Quality Assurance Inspector

Shop personnel (including QC) on the proper mixing and application of the Coatings System for the Project. Make training curriculum available to the Bridge Engineer upon request. Provide Prime, intermediate, and finish coats of paint in accordance with 2478.2A, “Zinc-Rich Paint Systems.” For Shop applied Duplex Coating System, the hot-dip galvanize coating replaces the liquid zinc-rich Prime Coat. Do not start painting until the QAI or the Bridge Engineer approves the surface preparation and paint. Before applying paint, clean the surface of rust back, dust, dirt, grease, oil, moisture, overspray, and other deleterious contaminants that will prevent the paint from adhering (Hold Point). For field painting applications, provide a white cloth Material to the QAI for cleanliness testing. Apply paint to produce a smooth and uniform film free of runs, drips, sags, pinholes, blisters, mudcracking, and other deleterious conditions. Apply paint in accordance with manufacturer's printed instructions except as stated in this document. For field applications:

allowed in the Contract

approved by the Engineer in writing

Do not apply paint to metal surfaces when weather conditions that the manufacturer’s literature defines as unsatisfactory are present, and when:

Do not apply paint if other Work operations, wind, or traffic causes the air to carry dust, dirt, or sand onto the prepared or newly painted metal surfaces. Do not apply spray applied paint without protective shields that prevent scattering wet paint particles in areas where rebounding or blowing paint particles cause harm to persons, adjacent environment, or property. The QAI or Bridge Engineer will suspend spray painting operations if the Contractor does not properly control paint application. Do not thin paint more than what is stated in the manufacturer’s written instructions. After mixing, strain the primer through a 30 – 60 mesh screen or a double layer of cheesecloth. Do not allow un-dispersed clumps of zinc to remain in the paint after mixing. Before applying a subsequent coat of paint, perform the following:

Product Data Sheet

abraded areas Remove dust or chalk-like deposits. Repair or replace defective previously applied paint coats as required by the Bridge Engineer and at no additional cost to the Department. Apply the subsequent paint coat within the maximum time interval recommended by the manufacturer . If the maximum time interval is exceeded, blast the areas to SSPC-SP 10/NACE NO. 2, “Near-White Metal Blast Cleaning,” and recoat at no additional cost to the Department. Do not paint within 2 inches of the zones requiring field welding as shown on the Plans. Prepare and paint the heat affected areas after field welding, in accordance with this section. When the Contract specifies Shop painting and the Contractor does not provide the specified coating(s) in the Shop, apply the paint coat(s) for the unpainted portion at the P roject Site. Submit paint repair procedures to the QAI or the Bridge Engineer for approval. E.2 Spraying Perform power spraying using a fine, even spray. The Contractor may brush out paint applied with spray Equipment to obtain uniform coverage and to eliminate wrinkling, blistering, sags, runs, and air holes if the brushing is done immediately. When spraying, maintain a “spray tip-to-surface” distance to achieve an even, wet coat, free of runs, drips, sags, overspray , and dry spray. For Organic Zinc-Rich Paint Systems: When using conventional air spray, equip the air lines with approved water and oil traps. Use ASTM D4285, Standard Test Method for Indicating Oil or Water in Compressed Air to ensure the compressed air is oil and water free. E.3 Rollers, Brushes, and Daubers For field application, this entire section may only be used with written permission from the Bridge Engineer.

The Contractor may apply paint by rolling, brushing, or daubers in areas unsuitable for spray painting, such as small surface areas where over-spray would be excessive, and small areas requiring paint repair. If using brushes, manipulate the paint under the brush to provide a smooth, uniform coating over the entire surface, including Corners and crevices. Perform final brush strokes horizontal and parallel to each other. Remove brush hairs on the paint surface. The Contractor may use sheepskin or other approved daubers to paint surfaces inaccessible by spray or brush. F Paint Coats F.1 Measurement of Paint Thickness The Department refers to “Dry Film Thickness” (DFT) when using the term “thickness” in this section. Use a properly calibrated thickness gage to measure the paint thickness and average thickness meeting, the requirements of SSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages. Measure paint thickness from the top of the peaks of the blast profile. Perform painting operations as recommended by the manufacturer’s literature, unless otherwise specified in this section. If the manufacturer’s recommended DFT differs from the DFT in accordance with this section, submit a request in writing to the Engineer or Bridge Engineer before painting to approve the DFT deviation from the manufacturer’s written recommendations. Refer to 2478.3J, “Paint Repair,” for deficient paint thickness. F.2 Stripe Coats Before applying Prime Coat, apply a Stripe Coat on the Edges, Corners, seams, crevices, interior angles, junctions of joining members, rivets or bolt heads, nuts and threads, weld lines, and similar irregularities. Ensure the Stripe Coat completely hides the surface to be covered. Apply the Prime Coat on top of the Stripe Coat before it is fully cured, to its specified thickness as defined in this section, and after the QAI or the Bridge Engineer accepts the stripe coat (Hold Point). Apply the Stripe Coat per 2478.3E, “Application of Paint.” F.3 Prime Coat Apply the Stripe Coat and primer coat after preparing the surface in accordance with this section and as approved by the QAI or the Bridge Engineer and before the surface experiences rust back or within 12 hours of blasting. Equip the paint pot with an agitator during spray painting Work. Provide an agitator or stirring rod capable of reaching within 2 inches of the bottom of the pot to keep the paint mixed during application. For Organic Zinc-Rich Paint Systems: Apply Prime Coat to a DFT as stated in Table 2478.3-2, with no spot reading measuring less than the minimum primer DFT listed, unless the manufacturer requires otherwise. Remain within the maximum DFT limits as defined by the manufacturer.

Table 2478.3-2 Blast Profile / Paint Thickness Requirements for Primer Blast Profile Minimum Primer DFT Average Primer DFT 2.0 – 3.0 mils 3.0 mils minimum 4.0 mils average 3.0 – 4.0 mils 4.0 mils minimum 5.0 mils average >4.0 mils Write a Nonconformance Report

for Deviation” as stated in your QM Write a Nonconformance Report

for Deviation” as stated in your QM

For Inorganic Zinc-Rich Paint Systems: Apply Prime Coat to a DFT average of at least 4.0 mils with no spot reading measuring less than 3 mils, unless otherwise required by the C ontract. For Contact Surfaces of bolt splices, do not apply Prime Coat to a thickness greater than the manufacturer’s certified thickness for Class B slip co -efficient. Apply the prime paint coat per 2478.3E, “Application of Paint,” (Hold Point). F.4 Intermediate Coat Apply the intermediate coat to a DFT of at least 3.0 mils after the Prime Coat cures to the “dry-to-topcoat,” as defined in the manufacturer’s Product Data Sheet. Remain within the maximum DFT limits as defined by the manufacturer. Provide epoxy intermediate coat in a color that will contrast between the organic zinc-rich primer and the polyurethane topcoat. Apply the intermediate paint coat to Prime Coated surfaces exposed in the completed Structure. Apply the intermediate paint coat per 2478.3E, “Application of Paint,” (Hold Point). F.5 Finish Coats Apply the finish coat to a DFT of at least 2.0 mils (remain within the maximum DFT limits as defined by the manufacturer) after the intermediate cures to the “ dry-to-topcoat,” as defined in the manufacturer’s Product Data Sheet. Ensure the finish coat color matches the color standard required by the Contract. Assure the supplied product meets the requirements of 3501, “Basic Requirements for Paints.” Per 3501, “Basic Requirements for Paints,” provide a color draw down sample on a Leneta chart per ASTM D2805, Standard Test Method for Hiding Power of Paints by Reflectometry to the Bridge Engineer. The Department requires an acceptable initial draw down sample prior to beginning any Work because color testing is the initial control for the quality of the product. Apply the finish paint coat to intermediate coated surfaces exposed in the completed Structure. Ensure the finished surface is uniform in color and free of visible lap marks and other blemishes. Apply the finish paint coat per 2478.3E, “Application of Paint,” (Hold Point). Fillet seal crevices and cavities along the Edge of faying surfaces that are separated by 1/16 inch or more with an approved paint supplier's recommended caulk that is listed on the APL, Bridge, “Structural Steel Coating” and apply per the coating manufacturer installation instructions. Do not seal the bottom Edge of vertical faying surfaces allowing the juncture to release trapped moisture. Ensure the sealant color is a match to the finish paint color by submitting a sample to the Department laboratory for color approval or utilize an approved clear caulk. Apply the caulk in a smooth manner (Hold Point).

F.6 Total Paint Thickness Ensure the total paint thickness of the entire Paint System averages at least 10 mils for Organic Zinc-Rich Paint Systems and 9 mils for Inorganic Zinc-rich Paint Systems but remains in the maximum thickness limits defined by the manufacturer of the P aint System. If the Bridge Engineer finds total paint thickness deficient or excessive over any part of a S tructure and if the Bridge Engineer does not require additional paint applications or removal of paint, the Department may apply a monetary deduction for the appropriate item of Work. G Markings for Identification Stencil the year of painting and the Specification numbers of the Prime, intermediate, and top coats in numerals 3 inches high on the interior surface of fascia beams, at the same Corner displaying the Bridge name plate and at the Corner diagonally opposite that Corner (example: 2020 2478). G.1 Stenciling after Primer When the primer is applied in the Shop, ensure the fabricator/painter stencils the name of the paint manufacturer and the primer product name applied in the S hop on the inside web of both fascia girders in characters 3 inches high and in a contrasting color compatible with the specified Paint System. H Fasteners All hardware, fasteners, anchorage nut, washer, and threaded rod stick out used to install metal railings in the field are not field painted. I Handling, Storage, and Shipping of Painted Steel Do not apply paint to members loaded for shipment except to apply touch- up paint as approved by the QAI or the Bridge Engineer. Do not damage the painted steel in the Shop and field during shipping, erection, and construction of the Bridge and components. Do not move or handle the painted steel items until the coating dries in accordance with the manufacturer's data sheet. Use nylon straps, padded hooks, slings, or other nonmetallic lifting devices to protect coated components or products during handling and loading. Use softeners and Edge protection devices to protect the steel from binding chains. Provide padded hooks and slings to hoist the painted components. Store completed items in accordance with 1606, “Storage of Materials,” and the following:

Bridge number, Project number, manufacturer number, and the applicator job number in the identification markings

the full weight of the members or items and stable enough to maintain bundles, members, or items within the supporting substrate. Inspect and store bundles, members, or items in one general location before final acceptance unless otherwise approved by the QAI or the Bridge Engineer Support individual items or bundles of coated products in transit in a manner that will prevent damage to the coating. Do not drop or drag individual items or bundles of coated products . Pad when shipping, bundling, or banding Materials to protect the components from direct contact with packaging Materials that may damage the coated products finish. Use softeners and Edge protection devices in conjunction with high-density foam or other acceptable packaging Materials at points of contact.

J Paint Repair The Contractor may use a “Tooke Gauge” to perform a destructive test to measure the DFT, at no additional cost to the Department, if it is not possible to satisfactorily determine the coating thickness of any paint coat after application. Repair the destructively tested area as approved by the Bridge Engineer and at no additional cost to the Department. Do not perform mechanical grinding to reduce paint thickness. Completely remove and recoat the Paint System with deficient or excessive paint thickness, as defined in this section, for Prime, intermediate, or topcoat if directed by the Bridge Engineer. Submit paint repair procedures to the Bridge Engineer in writing for acceptance.

2478.4METHOD OF MEASUREMENT

The Engineer will make area calculations. The Engineer will not make allowance in area calculations for actual areas of rivets and bolt heads, curved surfaces of welds, radii, or C orners. A Shop Painting The Engineer will measure Shop painting required by the Contract based on the area of acceptable paint coverage on non-contact areas, as computed from the dimensions shown on the P lans. The Engineer will not include contact areas in the measurement for payment. B Field Painting for New Construction The Engineer will measure field painting in the bolted field splice areas of newly constructed Shop painted steel based on the field splice area of acceptable paint coverage as shown on the P lans. The Department will consider the cost of paint repairs to correct damage from field storage or erection with the relevant Contract Unit Prices for structural steel. C Field Painting of an Existing Bridge The Engineer will measure field painting of structural steel on the basis of the area of acceptable paint coverage, as computed from the dimensions as shown on the P lans for the Structure.

2478.5BASIS OF PAYMENT

A Shop Painting The Contract square foot for Organic Zinc-Rich Paint (Shop) includes the costs providing and applying an acceptable Shop applied Paint System, including necessary repairs to the paint coating that occur before unloading at the Project storage site. B Field Painting of Shop Painted Components The Contract square foot price for Organic Zinc-Rich Paint System (Field) includes the costs of preparing and applying field applied Paint Systems to Shop primed bolted splice areas. C Painting of Existing (Old) Components or Structures The Contract square foot price for Organic Zinc-Rich Paint System (Old) includes the costs of surface preparation, providing, and applying Coating System to existing structural steel. D Schedule The Department will pay for Organic Zinc-Rich Paint System on the basis of the following schedule: Item No. Item Unit

2478.518 Organic Zinc-Rich Paint System (Shop) square foot

8 Organic Zinc-Rich Paint System (Field) square foot

8 Organic Zinc-Rich Paint System (Old) square foot