1081Coating of Structural Steel

1081 COATING OF STRUCTURAL STEEL

1081.10PROTECTIVE PAINT SYSTEMS

.1 Scope. This specification covers coating new and existing bridges and structures made of structural

steel and miscellaneous metal with protective paint systems.

.2 Systems of Coatings. The required system and color or choice of systems and color will be specified

on the plans. Each coat of the specified system shall be applied to all structural steel, unless the contract specifically delineates otherwise. The system and color of coating to be shop-applied shall be shown on the shop drawings. All coatings shall comply with local VOC (Volatile Organic Compound) regulations where the paint is applied. The system and color shall not vary for any portion of the entire structure, including material for field repairs and shall be compatible products of a single manufacturer. The contractor shall coordinate the various items of work to ensure compliance with the requirements of this section. Approved material specifications and dry film thickness for the coating systems shall be as indicated in the following table: Paint Systems for Structural Steel System G (High Solids, Zinc-Epoxy-Polyurethane) Coating Section Dry Film Thickness, mils Inorganic Zinc Prime Coat or Organic Zinc Prime Coat 1045.3 or 1045.10 3.0 min. to 6.0 max. or 3.0 min. to 6.0 max. Epoxy Intermediate Coat 1045.4 3.0 min. to 5.0 max. Polyurethane Finish Coat, Gray or Brown 1045.5 2.0 min. to 4.0 max. System H (High Solids, Zinc-Waterborne Acrylic Intermediate-Waterborne Acrylic Finish) Coating Section Dry Film Thickness, mils Inorganic Zinc Prime Coat or Organic Zinc Prime Coat 1045.3 or 1045.10 3.0 min. to 6.0 max. or 3.0 min. to 6.0 max. Waterborne Acrylic, Intermediate Coat 1045.6 2.0 min. to 4.0 max. Waterborne Acrylic, Finish Coat, Gray or Brown 1045.6 2.0 min. to 4.0 max. System I (High Solids, Zinc-Polysiloxane) Coating Section Dry Film Thickness, mils Inorganic Zinc Prime Coat or Organic Zinc Prime Coat 1045.3 or 1045.10 3.0 min. to 6.0 max. or 3.0 min. to 6.0 max. Polysiloxane Finish Coat 1045.7 3.0 min. to 6.0 max. System L (High Solids, Zinc-Inorganic Ethyl Silicate) Coating Section Dry Film Thickness mils Inorganic Zinc Prime Coat 1045.3 3.0 min. to 6.0 max.. Inorganic Ethyl Silicate 1045.11 3.0 min. to 6.0 max. Aluminum & Gray Epoxy-Mastic Primer Coating Section Dry Film Thickness mils Aluminum Epoxy-Mastic Primer 1045.8 5.0 min. Gray Epoxy-Mastic Primer 1045.9 5.0 min

.3 Protective Coating of Structural Steel

.3.1 Scope. This specification covers the preparation of previously uncoated structural steel surfaces,

furnishing and applying specified coatings, protection and drying of coatings, furnishing protection from coating spatter and disfigurement, and final cleanup. 761

.3.2 Certification. Contractors performing coating operations for new structural steel shall be certified

prior to the start of coating operations under the following SSPC Certified Contractor QP program or NACE International Institute Contractor Accreditation Program (NIICAP) as follows:

Field Application or NIICAP AS-1 Field Application.

Sec 1080.3.1.6 (g).

and existing steel, no SSPC QP certification or NIICAP accreditation will be required.

.3.3 Surface Preparation

.3.3.1 Cleaning. Oil, grease and other contaminants shall be removed in accordance with procedures

from Steel Structures Painting Council specification SSPC-SP1 prior to blast cleaning. Where high strength bolts are installed prior to blast cleaning or finish coat, the lubricant on high strength bolt assemblies shall also be removed in accordance with SSPC-SP1.

.3.3.1.1 Inorganic Zinc. Surfaces to be prime coated shall be blast cleaned with abrasives in accordance

with SSPC-SP10, producing a height of profile 1.5 mils minimum and 3.0 mils maximum for all systems. The appearance of the final blast cleaned surface shall be in accordance with SSPC-Vis1, Photograph A SP-10, B SP- 10, C SP-10, or D SP-10. Conformance with the corresponding SP-5 photographs will also be acceptable. The blast profile shall be assessed with replica tape per ASTM D4417, Method C. The contractor shall make available to the engineer access to all SSPC specifications referenced for cleaning and coating operations.

.3.3.1.2 Organic Zinc. Surfaces to be prime coated shall be blast cleaned with abrasives in accordance

with SSPC-SP6, producing a height of profile 1.0 mils minimum and 3.0 mils maximum for all systems. The appearance of the final blast cleaned surface shall be in accordance with SSPC-Vis1, Photograph A SP-6, B SP- 6, C SP-6, or D SP-6. Conformance with the corresponding SP-5 and SP-10 photographs will also be acceptable. The blast profile shall be assessed with replica tape per ASTM D4417, Method C. The contractor shall make available to the engineer access to all SSPC specifications referenced for cleaning and coating operations.

.3.3.2 Preparation for Coating. After blast cleaning, all surfaces shall be cleaned to remove any trace

of blast products, dust or dirt from the surface and from all pockets and corners. Sharp fins resulting from the blast cleaning operation shall be removed with an approved method that will maintain the minimum anchor profile for the prime coat. The blast-cleaned surfaces shall be given the specified prime coat as soon as practical, but within 24 hours after blast cleaning. If blast cleaned surfaces rust before coating is accomplished, the surface shall be reblasted by the contractor at the contractor's expense. All rusted, damaged or uncoated areas, including ungalvanized nuts, bolts and washers to be prime coated in the field, shall be blast cleaned to the same degree as specified above for the applicable coating system. Care shall be exercised to ensure the blasted steel remains free of grease and oil during handling.

.3.3.3 Recleaning. When there is contamination of any blast-cleaned surface to be coated, the material

shall be recleaned to the requirements of SSPC-SP10 for inorganic zinc and SSPC-SP6 for organic zinc.

.3.4 Limits of Coating Application. Unless otherwise indicated on the plans, the application of the

intermediate and finish coats for Systems G and H, and the application of the finish coat for System I and L, hereinafter referred to as field coats, shall be applied to the structure within the following limits.

.3.4.1 Bridges over Roadways. This section will not apply to bridges over railroads

.3.4.1.1 The intermediate field coat for beam and girder spans shall be applied to the surfaces of all

structural steel, except that areas of steel to be in contact with concrete shall not receive the intermediate coat. The intermediate coat shall also be applied to the bearings, except where bearings will be encased in concrete. The finish coating for beam and girder spans shall include the facia girder or beams. The limits of the facia girders or beams shall include the bottom of the top exterior flanges, top of the bottom exterior flanges, the exterior web area, the exterior face of the top and bottom flange and the bottom of the bottom flange. Areas of 762 steel to be in contact with concrete shall not receive the finish coat. The finish coat shall also be applied to the exterior bearings, except where bearings will be encased in concrete.

.3.4.1.2 The surfaces of all structural steel located under expansion joints of beam and girder spans shall

be field coated for a distance of 1 1/2 times the girder depth, but no less than 10 feet from the centerline of the joint. Within this limit, the items to be field coated shall include all surfaces of beams, girders, bearings, diaphragms, stiffeners and miscellaneous structural steel items. Areas of steel to be in contact with concrete shall not receive the field coats. The limits of the field coatings shall be masked to provide crisp, straight lines and to prevent overspray on adjacent areas.

.3.4.1.3 For all truss or steel box girder spans, the above limits will not apply and all structural steel for

these span types shall be field coated, except the areas of steel to be in contact with concrete.

.3.4.1.4 Straps for steel stay-in-place forms shall be removed in areas where field coating shall be

required in accordance with this Specification. Flame cutting will not be permitted. The contractor shall take care not to damage the structure or the shop coating during strap removal. Any damage to the shop coating as a result of the contractor's operations shall be repaired by the contractor in accordance with this Specification. Any damage to the rest of the structure shall be repaired as approved by the Engineer.

.3.4.1.5 When System I is specified on the plans for beam and girder spans, a System G intermediate

coat shall be applied similarly in accordance with Sec 1081.10.3.4.1.1 intermediate field coating requirements except that an intermediate coat will not be required to be applied to the beams and girders where the System I finish coat is to be applied. The contractor shall have the option to substitute the System I finish coat in place of a System G intermediate coat.

.3.4.1.6 When System L is specified on the plans for beam and girder spans, an intermediate coat shall

not be applied to the beams and girders. The System L finish coat shall be applied to the surfaces of all structural steel, except that areas of steel to be in contact with concrete shall not receive the finish coat. The finish coat shall also be applied to the bearings, except where bearings will be encased in concrete.

.3.4.2 Bridges Over Streams or Railroads

.3.4.2.1 The field coating for beam and girder spans shall include the facia girders or beams. The limits

of the facia girders or beams shall include the bottom of the top exterior flanges, top of bottom exterior flanges, the exterior web area, the exterior face of the top and bottom flange and the bottom of the bottom flange. Areas of steel to be in contact with concrete shall not receive the field coats. The field coatings shall also be applied to the exterior bearings, except where bearings will be encased in concrete. The interior beams or girders shall only have the prime coat applied with no other field coating required.

.3.4.2.2 The surfaces of all structural steel located under expansion joints of beam and girder spans shall

be field coated for a distance of 1 1/2 times the girder depth, but no less than 10 feet from the centerline of the joint. Within this limit, the items to be field coated shall include all surfaces of beams, girders, bearings, diaphragms, stiffeners and miscellaneous structural steel items. Areas of steel to be in contact with concrete shall not receive the field coats. The limits of the field coatings shall be masked to provide crisp, straight lines and to prevent overspray on adjacent areas.

.3.4.2.3 For all truss or steel box girder spans, the above limits will not apply and all structural steel for

these span types shall be field coated, except the areas of steel to be in contact with concrete.

.3.4.2.4 Straps for steel stay-in-place forms shall be removed in areas where field coating shall be

required in accordance with this Specification. Flame cutting will not be permitted. The contractor shall take care not to damage the structure or the shop coating during strap removal. Any damage to the shop coating as a result of the contractor's operations shall be repaired by the contractor in accordance with this Specification. Any damage to the rest of the structure shall be repaired as approved by the Engineer.

.3.4.2.5 When System L is specified on the plans for beam and girder spans, an intermediate coat shall

not be applied to the beams and girders. The System L finish coat shall be applied to the surfaces of all structural steel, except that areas of steel to be in contact with concrete shall not receive the finish coat. The finish coat shall also be applied to the bearings, except where bearings will be encased in concrete. 763

.3.4.3 Weathering Steel Bridges

.3.4.3.1 The surfaces of all structural steel located under expansion joints, but not in contact with

concrete, shall be coated with complete specified paint system within a distance of 1 1/2 times the girder depth, but no less than 10 feet, from the centerline of all deck joints. Within this limit, items to be coated shall include all surfaces of beams, girders, diaphragms, stiffeners, bearings and miscellaneous structural steel items. The prime coat for the specified paint system shall be applied to the structural steel within the above limits in the fabrication shop. The intermediate and finish coats shall be applied in the field in accordance with Sec

.3.3. The color of the finish coat shall be brown

.3.4.3.2 Portions of the structural steel embedded in or in contact with concrete, including but not

limited to the top flanges of girders, shall be coated with no less than 2.0 mils of the prime coat for the specified paint system and this coating shall extend a minimum of 12 inches beyond any vertical concrete face. Shear connectors need not be coated or protected from overspray.

.3.4.3.3 Required work shall include blast cleaning for all areas to receive the specified prime coat to

SSPC-SP-10 (Near White Blast Cleaning) in accordance with Sec 1081.10.3.3, except that areas to be primed that will be embedded in concrete may be prepared to no less than SSPC-SP-6. The limits of the areas to be shop and field coated shall be masked to provide crisp, straight lines to prevent overspray on adjacent areas.

.3.4.3.4 The galvanized surfaces of drain support brackets shall be prepared according to the coating

manufacturer's recommendation and field coated with a gray epoxy mastic primer (nonaluminum) within a distance of 6 inches from the point of connection to the weathering steel structure.

.3.5 Coating Thickness Measurement. The dry film thickness of the coatings will be measured by

magnetic-type gauges in accordance with Steel Structures Painting Council, specification SSPC-PA2. At the option of the engineer, the adhesion of the prime coat will be measured in accordance with ASTM D3359, Test Method A. When the adhesion is tested, each test result shall equal or exceed scale 3A. Locations for adhesion tests shall be randomly selected. Test locations shall be in areas of least visibility in the completed structure and shall be touched up in an approved manner after completion of the test. When satisfactory test results are not obtained, additional adhesion tests shall be taken to determine the area of insufficient adhesion. For these areas, the surface shall be prepared in accordance with Sec 1081.10.3.3.1 and the area recoated in accordance with these specifications. If additional prime coat is required to provide the specified minimum thickness, the prime coat shall be applied as soon as possible, but within 24 hours of the initial application.

.3.6 Coating Material Storage. All coating material shall be stored in accordance with the coating

manufacturer’s recommendations. Exposure to storage temperatures outside the range recommended in the manufacturer's specifications will be considered cause for rejection of the coating material.

.3.7 Weather Conditions

.3.7.1 Temperature Limitations. The prime coat shall be applied in accordance with the manufacturer’s

recommendations, except that the minimum air and steel temperature shall be no less than 34 F. Finish and intermediate coats applied over the prime coat shall be applied in accordance with the manufacturer's recommendations, which shall be furnished to the engineer. The minimums and maximums or additional requirements established by the coating manufacturer’s written specifications for recommended air or metal temperature, or relative humidity will apply if those requirements are more restrictive than those specified in the contract documents.

.3.7.2 Moisture Limitations. Coatings shall not be applied in rain, snow, fog or mist, or when the steel

surface temperature is less than 5 F above the dew point. The dew point shall be determined in accordance with MoDOT Test Method TM 38. Coatings shall not be applied to wet, damp, frosted or ice-coated surfaces.

.3.7.3 Application in Protected Areas. When coatings are applied in a protected area to eliminate the

weather conditions, the coated steel shall remain in the protected area until the coatings are cured.

.3.7.4 Damaged Coatings. Any uncured coatings exposed to freezing, excess humidity, rain, snow,

condensation or curing temperatures outside the range recommended by the manufacturer will be considered 764 damaged. Damaged coatings shall be permitted to dry, then shall be removed and the surface blast cleaned and recoated at the contractor’s expense.

.3.8 Thinning. Thinners will be permitted as recommended by the manufacturer's recommendations,

provided VOC limits are not exceeded.

.3.9 Application. Coatings shall be applied in accordance with the Steel Structures Painting Council

specification SSPC-PA1, unless otherwise specified by the product manufacturer. Stripe coating, as defined by SSPC-PA1 shall be required for all applied coating layers. The manufacturer's written specifications for application, upon request, shall be submitted to the engineer for review prior to application.

.3.9.1 Application Repairs. If deficiencies in the quality of work or material result in rejection, the

contractor shall submit a repair proposal for approval by the engineer.

.3.9.2 Curing of Coatings. Curing time for recoating shall be within the limits of the manufacturer's

recommendations. Application of the finish coat over the intermediate coat shall be accomplished within the recoat time for proper adhesion established by the manufacturer's recommendations.

.3.10 Shop Coating. All surfaces of fabricated structural steel, including areas that will be inaccessible

after assembly, contact surfaces of high strength bolted connections and all surfaces to be in contact with concrete in the completed structure shall be coated in the shop with the prime coat. The primer shall be of the type and thickness specified, except as modified by Secs 1081.10.3.10.1 and 1081.10.3.10.2. Structural steel sway bracing for the substructure may be prepared and coated in the field.

.3.10.1 Contact Surfaces. Contact surfaces of high strength bolted field splice and diaphragm

connections shall be prime coated to produce a dry film thickness no less than 1.5 mils or more than 2.5 mils. The limits of the coating thickness for these surfaces shall be shown on the shop drawings. The maximum limit of 2.5 mils may be increased provided acceptable test results in accordance with the Testing Method to Determine the Slip Coefficient for Coatings Used in Bolted Joints (RSCS Specification for Structural Joints Using High Strength Bolts, Appendix A) are submitted and approved by the engineer. Revised shop drawings will not be required upon acceptance of the test results. The tests shall meet the requirements for the slip coefficient and creep resistance for Class B coatings and shall be performed by a nationally recognized independent testing laboratory. Any change in the formulation of the coating will require retesting, except when thinned within the limits of manufacturer's recommendations. At the contractor's option, the contact surfaces of connections for all non-slab bearing diaphragms on non-curved girders may be prime coated with a dry film thickness of no less than 3.0 mils or more than 6.0 mils, unless noted otherwise on the plans.

.3.10.2 Inaccessible Surfaces. Surfaces that will not be in contact, but that will be inaccessible after

assembly, shall be prime coated to produce a dry film thickness of no less than 3.0 mils and no more than 6.0 mils. Dry film thickness on surfaces that will be in contact with concrete may be reduced to 2.0 mils provided thorough and complete coverage is obtained. Although shear connectors need not be coated, protection of the connectors from overspray when coating other parts of the beam or girder will not be necessary. Coating thickness measurements will not be made on shear connections.

.3.10.3 Touch-up of Galvanized Bolts. The galvanized coating of nuts, bolts and washers damaged

during shop installation shall be shop repaired in accordance with Secs 1081.10.3.11.1 and 1081.10.3.11.1.1.

.3.10.4 Inspection Prior to Coating. No coatings shall be applied before shop inspection of fabrication

has been completed. Surfaces of steel within 2 inches of edges to be field welded shall not be coated in the shop.

.3.10.5 Erection Match Marks. Erection match marks shall not be visible in the completed structure

.3.11 Field Coating. Intermediate and finish coats for the specified coating system shall be applied in

the field. The contractor shall be responsible for final cleanup and field touch-up of any shop applied coating, including surface preparation and coating of field connections, welds or bolts, areas masked in the shop and all damaged or defective coating and rusted areas. Surface preparation for field touch-ups shall be performed in accordance with Sec 1081.10.3.3, unless otherwise approved by the engineer. The touch-up field coat shall consist of the same coating used for the shop-applied coat. Contact surfaces of high strength bolted connections shall be protected from the intermediate and finish coats. Damage to the coating of galvanized bolts, nuts and 765 washers where bare steel is exposed shall be repaired in accordance with these specifications or, the connection may be prepared as specified in Sec 1081.10.3.3, followed by a touch-up field coat application of the required coating system.

.3.11.1 Field Touch-up of Galvanized Bolts. The galvanized coating of nuts, bolts and washers

damaged during installation shall be repaired. Lubricants shall be removed in accordance with SSPC-SP1. Rust shall be removed in accordance with SSPC-SP-2 or SSPC-SP-3. Touch-ups shall consist of the application of an approved gray epoxy mastic. The touch-up material shall be compatible with and from the same manufacturer as the coating system to be used for the structure. Prior to field coating operations, the contractor shall submit information on the specific products to be used, including compatibility data and applicable recoating times, to the engineer for review. Subsequent coatings shall be applied within the recoat time recommended by the manufacturer.

.3.11.1.1 Touch-up Color. For areas of the structure that will not receive a field coat, the color of the

touch-up material for bolts specified in Sec 1081.10.3.11.1 shall be similar to galvanized metal.

.3.11.1.2 Previously Repaired Material. If repairs to the galvanized coating of shop-installed nuts,

bolts and washers have previously been performed in accordance with Sec 1081.10.3.10.3 or if epoxy mastics are otherwise shop-applied to structural steel, the contractor shall be responsible for any special field preparation required for proper adhesion of subsequent field coats to the epoxy coating. Prior to field coating operations, the contractor shall submit the manufacturer's recommendations to the engineer.

.3.11.1.3 Masking. Previously coated or adjacent areas shall be masked or otherwise protected from

material used to touch-up the galvanized coating of fasteners.

.3.11.2 Sequence of Work. Field coatings, except for touch-up and coating of inaccessible surfaces,

shall not be applied until the concrete deck has been placed, the forms removed and all concrete spatter, foreign material and contaminants are removed from existing coatings, unless otherwise approved by the engineer. Prior to submittal of alternative application methods, the contractor shall present methods to be used to prevent damage to the intermediate and final field coatings. The sequence of work shall be arranged to provide ample time for each coat to cure before the next coat is applied. The intermediate field coats shall be free of all oil, grease, dust or dirt prior to application of the next coat. Intermediate or prime coats that have been exposed to chlorides used in snow removal operations shall be cleaned by power washing as defined in Sec 1081.10.5.4.2.2 prior to application of the subsequent intermediate or final coats. In no case shall a coat be applied until the previous coat has been approved by the engineer. Excessive rust streaks or coatings on concrete masonry shall be removed by sandblasting or by other approved methods without damage to the masonry.

.3.11.3 Work Under Stage Construction Contracts. If complete field coating is not included in the

contract for erection of structural steel, the touch-up coating of newly erected work and the coating of surfaces that will be inaccessible after erection shall be included as part of the work to be performed under the contract for erection. Field coating under any contract that does not include the erection shall include cleaning, preparation of any previously applied coatings, repairs and spot application of coatings required at the time the work is performed. Prior to field coating structural steel that was erected under a previous contract, the contractor shall submit the manufacturer's recommendations to the engineer, outlining requirements for cleaning and preparation of all existing coatings. The manufacturer’s recommendations shall include requirements for preparation of epoxy mastics previously applied for touch-up or other purposes.

.3.11.4 Partial Applications. If partial applications of the field finish coats to a structure as provided in

Sec 1081.10.3.4 is required or permitted, the contractor shall perform field touch-up coating to areas of the structural steel outside the limits to receive the intermediate and finish coats. Touch-up shall be in accordance with Sec 1081.10.3.11 and at the contractor’s expense.

.3.12 Identification. The contractor shall, at the completion of the coating application, stencil in black

paint on the structure the number of the bridge, the word "COATED", the system used and the month and year the coating was completed. The letters shall be capitals approximately 3 inches high. The legend shall be stenciled on the outside face of an outside stringer or girder near each end of the bridge as directed by the engineer. 766

.3.13 Property and Traffic Protection. The contractor shall protect pedestrian, vehicular, railroad and

other traffic, persons and property, upon, beneath and in the vicinity of the structure and all portions of the bridge against damage or disfigurement by blast media, blast residue, coatings, coating material, equipment or by any other operations.

.4 Recoating of Structural Steel (System G, H, I or L)

.4.1 Scope. This specification covers the field preparation of structural steel surfaces to be recoated,

furnishing and applying specified coatings, protection and drying of coatings, furnishing protection from coating spatter and disfigurement, and final cleanup.

.4.2 Certification. Contractors performing coating operations for field applied recoating shall be

certified prior to the start of the coating operations under the appropriate category of the AMPP QP program as follows:

materials, the contractor shall be certified to the AMPP QP1 – Field Application.

contractor shall be certified to the AMPP QP2 – Field Removal of Hazardous Coatings.

.4.3 Systems of Protective Coatings. All structural steel shall be recoated by the contractor in the field

using one of the complete systems, including prime coats, in accordance with Sec 1081.10.2, unless noted otherwise. Recoating of structural steel, including surface preparation, weather conditions, application, touch-up and protection, shall be in accordance with all requirements of Sec 1081.10.3 unless in conflict with Sec 216, which shall control.

.4.4 Surface Preparation. Cleaning and coating of structural steel shall proceed in areas or sections as

approved by the engineer, usually consisting of one or more complete spans. The cleaning and application of the coatings for each specified section shall be entirely completed and accepted by the engineer prior to proceeding with additional cleaning or coating. Surface preparation shall be in accordance with Sec 1081.10.3.3. All existing coatings and paint shall be removed by blast cleaning unless specifically indicated otherwise in the contract.

.4.4.1 Chloride Remediation. Before any blast cleaning, surface preparation procedures and processes

shall be used to remove chlorides from the surfaces. When a chemical soluble chloride remover is used, a letter from the coating manufacturer shall be provided to the engineer indicating the chemical soluble chloride remover shall not adversely affect the performance of the coating system. Methods of chloride removal may include, but are not limited to, steam cleaning or pressure washing with or without a chemical soluble chloride remover as approved by the coating manufacturer and scrubbing before blast cleaning. The contractor shall provide the proposed procedures for chloride remediation to the engineer for review.

.4.4.1.1 Chloride Testing. Upon completion of the chloride remediation process and prior to any

required blast cleaning, the contractor shall use cell methods of field chloride extraction and test procedures accepted by the engineer, (e.g., silver dichromate), to test representative surfaces that were previously rusted, (e.g., pitted steel), for the presence of remaining chlorides. Remaining chloride levels shall be no greater than 30 µg/cm2 as read directly from the surface without any multiplier applied to the results. The testing shall be performed and the results acceptable to the engineer prior to coating each day. A minimum of 5 tests per 1000 ft2 shall be completed. If chloride levels detected are greater than 30 µg/cm2, the surfaces shall be recleaned and retested at the same frequency. If acceptable chloride levels are detected on 3 consecutive days, the test frequency may be reduced to one test per 1000 ft2 provided the chloride remediation process remains unchanged. If unacceptable results are encountered or the methods of chloride remediation are changed, the contractor shall resume testing at a frequency of 5 tests per 1000 ft2.

.4.4.1.2 QA Testing by the Engineer. The engineer reserves the option to test blasted surfaces for

chlorides. Chlorides after blasting and blow down shall be less than 7 µg/cm2. Areas that are not equal to, or below, these criteria will need to be re-washed, brush blasted, and retested. The engineer will measure chloride 767 contamination by using a Surface Contamination Analysis Kit, marketed by KTA-Tator Inc. or an equivalent analytical process.

.4.4.2 Approved Blast Media. Only silica sand and steel abrasive shall be allowed for use as approved

blast media for paint removal. A safety data sheet (SDS) for the blast media selected for use shall be submitted for approval at the pre-construction conference held with the contractor. The SDS shall be maintained on site by the contractor and shall be available for review upon request. All paint removed with approved blast media shall be sent to the Doe Run lead smelter for recycling and is not considered a solid or hazardous waste in accordance with 40 CFR 261.2(e)(1)(ii). Surface preparation areas cleaned with unapproved blast media shall be at the contractor’s expense. The collected residue shall consist of media no larger than one inch and removed paint chips.

.4.4.3 Environmental Regulations. The paint removal operation shall comply with all local, state and

federal regulations, including but not limited to, the EPA, OSHA Standards 29 CFR 1910 and 1926.62, and the Missouri Code of State Regulations, including 10 CSR 10 Air Conservation Commission, 10 CSR 20 Clean Water Commission, 10 CSR 25 Hazardous Waste Commission, and 10 CSR 80 Solid Waste Management. The contractor shall have all necessary licenses and certifications as required by the Missouri Department of Health including necessary licenses and certification for lead abatement/removal workers prior to commencement of the cleaning operation. If hazardous waste will be generated at the site, the contractor shall notify the engineer and Environmental Section in Design Division and comply with all applicable hazardous waste generator requirements.

.4.4.4 Containment and Collection of Blast Residue. A containment system, or enclosure, is required

to prevent the release of blast media residue and other debris generated during surface preparation activities from entering the environment. Enclosures are typically made up of combinations of cover panels, scaffolds, supports, screens, and tarps. The complexity of any given enclosure will vary depending on the method of paint removal being employed and the degree of surface preparation that is specified. For a simple scraping operation ground-covering tarps may be sufficient while for a blasting operation, the enclosure could be a designed structure with a negative pressure ventilation system. The contractor shall collect all blast residue (paint residue/blast media) from the cleaning operations for recycling. All blast media and residue shall be contained or collected; should an accidental release occur, the contractor shall complete all necessary cleanup efforts as directed by the Engineer. Blast residue shall be managed as a recyclable material. Container management shall be in accordance with Sec 1081.10.4.4.4.3. Analytical testing required for the disposal of blast residues shall be the responsibility of the contractor.

.4.4.4.1 Waste Solvent Management. All waste solvent generated from painting operations shall be

containerized, sampled, and submitted for analytical testing to enable a hazardous waste determination.

.4.4.4.2 Hazardous Waste Notification. The contractor shall submit a “Notification of Regulated Waste

Activity” form to MDNR Hazardous Waste Program to obtain the EPA identification number. Requests shall be submitted as soon as hazardous waste is determined or at least 30 days prior to shipping hazardous waste. The cost of obtaining the EPA identification number will be considered as part of the surface preparation cost and the engineer will subtract the cost from the contract. Hazardous waste shall not be shipped offsite until the EPA identification number has been received. The contractor will file the quarterly and annual hazardous waste reports in accordance with 10 CSR 25-5.262(2)(D)1 and will deactivate the EPA identification number upon contract completion. The contractor shall submit copies of all hazardous waste manifests and quarterly/annual reports to MoDOT’s Environmental Section.

.4.4.4.3 Container Management

.4.4.4.3.1 The blast residue from cleaning operations shall be stored in contractor furnished, watertight

55-gallon steel drum containers stacked on wooden pallets with labels facing outward. The containers shall be free of structural defects and all other materials including but not limited to construction debris, solvents, flammables, aluminum, magnesium, aerosol cans, rags and any ferrous or non-ferrous metals larger than one cubic inch. The containers shall have removable lids complete with a bolt ring, bolt and nut. Containers shall remain closed at all times, except when necessary to add blast residue. Material other than the blast residue from the cleaning operations shall not be placed in the containers. At the end of each day’s work, the containers shall be stored outside the 100-year floodplain in a secure area as approved by the engineer. Containers of approved 768 blast residue destined for recycling, shall be marked with a “Blast Residue” label provided by the Engineer or Environmental Section in the Design Division and marked with the following information:

.4.4.4.3.2 Containers of hazardous waste shall be packaged, marked and labeled according to hazardous

waste regulations 10 CSR 25-5.262(2)(C)1. Containers of hazardous waste shall be stored separate from containers of non-hazardous waste and approved blast media destined for recycling. The contractor shall maintain an inventory of the quantity of the containers stored at the site and the quantity delivered to an approved facility. All containers shall be delivered to the approved facility within 30 days upon completion of the surface preparation. Copies of container inventories, all test results, shipping papers, hazardous waste manifest signed by the receiving facility, solid waste disposal request, recycling certificates and any other disposal documentation shall be submitted to the engineer with a copy to the Environmental Section in the Design Division within 30 days upon delivery to the approved facility.

.4.4.4.4 Shipment of Residue. Approved blast media containing paint residue shall be shipped with a

bill of lading to the Doe Run smelter for recycling. The contractor shall obtain appropriate shipping papers (bill of lading), if required, from the Engineer or Environmental Section in the Design Division. These shipping forms shall be completed prior to shipment. The Doe Run smelter will reject any shipment received without the proper shipping papers. The contractor shall notify the Doe Run smelter at least 2 days prior to shipment to ensure the receiving facility will be able to accept the material.

.4.4.4.5 Personal Protective Equipment. Clothing, tarps, hoses and other cleaning material containing

blast residue shall be managed as a hazardous waste unless determined non-hazardous. Personal protective equipment being disposed, such as Tyvek suits, respirator cartridges, boots, etc. but not tarps, shall be placed into 55-gallon steel drums. Spent tarps shall be placed into DOT approved cardboard boxes and stacked on wooden pallets. Container management shall be in accordance with Sec 1081.10.4.4.3.3.

.4.4.4.6 Invoices and Payment. The contractor shall dispose of all paint residue/blast media and

personal protective equipment in accordance with all Federal and State regulations at the Doe Run smelter. Spent solvents shall be disposed of at an EPA approved hazardous waste treatment, storage and disposal facility. Transporting and disposal cost shall be the contractor’s responsibility. A copy of the disposal manifest and paid receipt shall be given to the engineer. Failure to provide proper documentation will result in withholding payment. For more information concerning management of blast residue or approved hazardous waste treatment, storage and disposal facilities, contact the Environmental Section in the Design Division.

.4.5 Joints. All seams and joints that cannot be satisfactorily sealed or coated shall be adequately

caulked with compounds compatible with the coating system being applied. Caulking material shall be in accordance with the coating manufacturer's recommendations and shall meet the approval of the engineer. Caulking shall be satisfactorily completed for an entire joint or seam after application of the prime coat and before application of any specified finish or intermediate coats.

.4.6 Identification. At the completion of recoating, the contractor shall stencil in black paint on the

structure the number of the bridge, the word "RECOATED", the system used and the month and year the coating was completed. The letters shall be capitals approximately 3 inches high. The legend shall be stenciled on the outside face of an outside stringer or girder near each end of the bridge as directed by the engineer. 769

.4.7 Property and Traffic Protection. The contractor shall provide protection in accordance with Sec

.5 Overcoating of Structural Steel

.5.1 Scope. This specification covers the field preparation of structural steel surfaces to be overcoated,

disposal of paint residues and power washing water, furnishing and applying the specified coatings, protection and drying of the coatings, furnishing protection from coating spatter or disfigurement and final cleanup.

.5.2 Certification. Contractors performing coating operations for field applied overcoating shall be

certified prior to the start of the coating operations under the appropriate category of the AMPP QP program as follows:

materials, the contractor shall be certified to the AMPP QP1 – Field Application.

contractor shall be certified to the AMPP QP2 – Field Removal of Hazardous Coatings.

.5.3 System of Protective Coatings. All exposed and accessible surfaces of structural steel and steel

bearings shall be coated with the specified paint system in accordance with Sec. 1081.10.2 unless otherwise noted. The color of the field coat shall be as shown on the plans. Overcoating of structural steel shall be in accordance with all requirements of Sec 1081.10.3 except surface preparation and unless in conflict with Sec 216, which shall control.

.5.4 Surface Preparation. Surface preparation shall be in accordance with Sec 1081.10.4.4, except that

blast cleaning will not be required.

.5.4.1 Removal of Existing Paint. The existing steel shall be cleaned by approved methods in

accordance with Sec 1081.10.5.4.2.

.5.4.1.1 Environmental Regulations. The paint removal operation shall be in accordance with all local,

state and federal regulations, including those defined in Sec 1081.10.4.4.3.

.5.4.1.2 Water for Power Washing. The water used for power washing shall be clean, potable water,

free from contaminants. During power washing operation, solids shall be contained or removed, but collection of wash water is not required for this activity.

.5.4.1.3 Collection of Residue. Collection of all paint residue shall be in accordance with the following

requirements. The containers shall remain closed at all times, except when necessary to add additional residue. Material other than the residue from the cleaning operations shall not be placed in the containers. Any testing required for the disposal of the residues shall be the responsibility of the contractor. Copies of the inventory, all testing data, required certifications and shipping manifests shall be provided to the engineer and to the Environmental Section in Design Division in accordance with Sec 1081.10.4.4.4.3.2.

.5.4.1.4 Testing of Paint Residue. At the conclusion of the power washing operation, the contractor

shall obtain samples of the paint residue in the presence of the engineer. The samples shall be analyzed by an independent testing laboratory for Toxicity Characteristic Leaching Procedure (TCLP) heavy metals. Samples shall be collected and analyzed in accordance with EPA approved methods. Copies of all test reports shall be supplied to the engineer and the Environmental Section in Design Division. Any additional testing required to comply with any federal, state or local regulations shall be provided by the contractor. If TCLP heavy metals test results exceed the regulatory limits, the contractor shall handle and dispose of the material in accordance with hazardous waste regulations at an EPA-approved RCRA treatment, storage, or disposal (TSD) facility. If test results indicate levels below the regulatory limits, then the material shall be disposed of as a solid waste at a sanitary landfill.

.5.4.2 Cleaning of Structural Steel. All exposed steel surfaces shall be mechanically cleaned in

accordance with Sec 1081.10.5.4.2.1 and in accordance with the paint manufacturer’s recommendations prior to 770 application of the coating. Power washing will not be required. However, the contractor may use power wash cleaning if desired during surface preparation. All surfaces cleaned shall be approved by the engineer prior to application of the coating.

.5.4.2.1 Mechanical Cleaning. Exposed structural steel where mechanical cleaning is required shall be

cleaned in accordance with SSPC-SP2 or SSPC-SP3. Blast cleaning as a substitute cleaning method will be acceptable. Mechanical cleaning will be required for areas of rusted steel, loose, cracked or brittle paint or areas indicated by the engineer. The cleaning shall be performed 2 inches beyond the areas of rust or defective paint in all direction or until tightly adhered paint is obtained with no rust or blisters. Edges between the bare steel and the paint shall be feathered. Collection of the residue removed shall be in accordance with Sec 1081.10.5.4.1.3.

.5.4.2.2 Power Wash Cleaning. The contractor may clean the steel by a low-pressure power wash to

remove loose paint, dirt and other loose deleterious material. The maximum pressure for the power washing shall be 1,500 psi. Construction of a containment system around the work area is required and shall consist of wooden framed construction, installation of a drip tarps consisting of #100 sieve filter fabric, or other alternative method that effectively filters the water and captures solids, as approved by the Engineer. If necessary, solvent cleaning in accordance with SSPC-SP1 shall be employed to augment the power washing. Collection of the residues from the power washing operation shall be in accordance with Sec 1081.10.5.4.1.2. After the power washing operation, areas that have remaining rust or loose paint shall be recleaned in accordance with Sec

.5.4.2.1, except that vacuum power tools will be required for power tool cleaning. All surfaces washed

shall be completely free of all foreign matter, surface dry and approved by the engineer prior to application of the coating.

.5.5 Application. Coating shall be applied in accordance with Sec 1081.10.3 and the manufacturer’s

recommendations. The steel shall be free of all cleaning residues prior to coating. Areas that have been cleaned to bare steel shall be prime coated on the same day as the cleaning. Any areas that rust prior to application of the prime coat shall be recleaned. The prime coat and field coat shall be applied to all steel surfaces with the exception of steel encased in concrete. Any existing paint that curls or lifts after application of the specified system shall be removed, the area recleaned and the coating reapplied.

.5.6 Identification. At the completion of the final coating application, the contractor shall, stencil in

black paint on the structure the number of the bridge, the words “OVERCOATED – System _” and the month and year the coating was completed. The letters shall be capitals approximately 3 inches high. The legend shall be stenciled on the outside face of an outside girder near each end of the bridge as directed by the engineer.

.5.7 Property and Traffic Protection. The contractor shall provide protection in accordance with Sec

.6 Aluminum & Gray Epoxy-Mastic Primer

.6.1 Scope. This specification covers the application of other approved primer coatings for touch-up and

other repair applications.

.6.2 Surface Preparation. The epoxy-mastic shall be applied over an SSPC-SP2, SSPC-SP3 or SSPC-

SP6 surface preparation, including removal of all rust scale, loose rust, loose mill scale and loose or non- adherent paint. Oil and grease shall be removed in accordance with SSPC-SP1 Solvent Cleaning. Areas adjacent to required areas will not be required to be masked to prevent overspray.

.6.2.1 Environmental Regulations. The surface preparation operation shall be in accordance with all

local, state and federal regulations, including those defined in Sec 1081.10.4.4.3.

.6.2.2 Collection of Residue. The collection of residue shall be in accordance with Sec 1081.10.4.4.4

and 1081.10.5.4.1.3.

.6.3 Application. Material application methods, air and surface temperatures and relative humidity shall

be in accordance with the manufacturer’s written instructions and Sec 1081.10.3. The most restrictive application and environmental requirements for the epoxy-mastic shall be used when applying the primer to the steel. 771

.7 Organic Zinc-Rich Primer

.7.1 Scope. This specification covers the application of an approved organic zinc-rich primer for

recoating, repair, touch-up and other field applications.

.7.2 Surface Preparation

.7.2.1 Recoating Steel. Surface preparation shall be in accordance with Sec 1081.10.4.4

.7.2.2 Touch-up on Inorganic Zinc-Rich Primer. Oil and grease shall be removed in accordance with

SSPC-SP1 Solvent Cleaning. Surface preparation shall be in accordance with SSPC-SP2 or SSPC-SP3, including removal of all loose rust, loose mill scale and loose or nonadherent paint.

.7.2.3 Touch-up on Existing Galvanized Steel. Oil and grease shall be removed in accordance with

SSPC-SP1 Solvent Cleaning. Surface preparation shall be in accordance with SSPC-SP7, including removal of all rust scale, loose rust and loose mill scale.

.7.2.4 Environmental Regulations. The surface preparation operation shall be in accordance with all

local, state and federal regulations, including those defined in Sec 1081.10.4.4.3.

.7.2.5 Containment and Collection of Blast Residue. The collection of residue shall be in accordance

with Sec 1081.10.4.4.4.

.7.3 Application. Material application methods, air and surface temperatures and relative humidity shall

be in accordance with the manufacturer’s written instructions and Sec 1081.10.3. The most restrictive application and environmental requirements for the organic zinc shall be used when applying the primer to the steel.

1081.20GALVANIZING OF STRUCTURAL STEEL

.1 Scope. This specification covers galvanizing new and existing bridges and structures made of

structural steel and miscellaneous metals.

.2 Material. All material shall be in accordance with Division 1000, Material Details, and in

conjunction with: Item Specification Galvanizing ASTM A123 Galvanizing RepairASTM A780

.3 Galvanized Metal. Structural steel beams or girders, bracing and diaphragms shall be galvanized as

shown on the plans and in accordance with this specification. After fabrication and prior to galvanizing, the steel surfaces shall be solvent cleaned in accordance with SSPC-SP1 Solvent Cleaning and then blast cleaned in accordance with SSPC-SP6 Commercial Blast Cleaning requirements. Structural steel beams and girders webs shall remain vertical while being galvanized. Galvanized material on which the galvanizing has been damaged will be rejected or may, with approval from the engineer, be repaired in the field, fabrication shop, or at the galvanizing facility by the zinc alloy stick method in accordance with this specification. Required field welds and adjacent areas on which galvanizing has been damaged shall be galvanized by this same repair method. The area to be regalvanized shall be thoroughly cleaned, including the removal of slag on welds. Touch-up of galvanizing of sheet material less than 3/16 inch may be completed by the use of an approved aluminum epoxy mastic coating if the material will not be in direct contact with concrete or with an approved non-aluminum epoxy mastic coating if the material will be in direct contact with concrete. Other protective coatings specified in ASTM A780 will not be permitted for galvanized beams, girders, bracing and diaphragms.

.4 Acceptance Criteria. All galvanized steel products shall be free from any bare steel, blisters, flux

deposits, and dross inclusions. The minimum average coating thickness shall be 3.9 mils and the maximum average coating thickness shall be 25 mils. The finished galvanized product shall be uniform in appearance with no lumps, projections, indentations, globules, runs, sags, or heavy build-up at welded joints.