708PAINTS

New Hampshire Department of Transportation Standard Specifications – 2016

708.01Description. These specifications are intended to specif y paints that will meet service requirements for highway

construction. Paint shall be homogeneous, free of contaminant, and of a consistency suitable for use in the capacity for which it is specified. Finished paint shall be well ground, and the pigments hall be properly dispersed in the vehicle according to the requirements of the paint. The dispersion shall be of such nature that the pigment does not settle, does not cake or thicken in the container, and does not become granular or curdled. The paints hall be easily broken up with a paddle to form a smooth uniform product of the proper consistency and shall possess satisfactory properties in all respects which affect its application and curing. The color shall match the established standard. The hiding power shall be sufficient to obtain complete hiding of the preceding coat with a single application when applied at normal spreading rates. The finish coat shall dry to a semi -gloss finish, unless specified otherwise. The final color of the paint specified for the work shall conform to FED -STD-595B and the specific color number specified below. The Department may approve a manufacturer’s standard color provided it is very similar to that specified and color ch ips are submitted for approval before the paint is shipped. Federal Standard Colors Color Federal Color Number Light Green 24272 Dark Green 24109 Dark Brown 20062 Aluminum 17178 White 17925 Black 27038 For paint material and application requirements for painting structural steel and steel portions of other structures, refer to 550, 556, a Special Provision for Section 550, Structural Steel, and a Special Provision for Section 556, Painting Existing Structural Steel in the project contract documents.

708.02Packaging. All paint furnished mus t be shipped in original, sealed, strong, new containers having a capacity of not

more than 5 gal each. The containers shall be equipped with a lever -type ring seal or a lug- type cover and wire bails. Each container shall be so filled that the net weigh t of the material in the can is the product of the weight per gallon deter mined at 75º F- 80º F and the specified gallon capacity of the can. All containers of paint shall be clearly labeled with the following information: New Hampshire Paint Number, Name, and Color Name of Product Lot and Batch Number Date of Manufacture Volume and Weight of Contents Volatile Organic Compounds (VOC) Contents Instructions for opening, mixing, thinning and applying the paint Name and Address of Manufacturer

708.03Approval , Sampling and Testing. The Contractor shall submit the complete paint system in writing to the

Department for approval prior to use on the project. The Engineer shall be furnished with a Certificate of Compliance and Material Data Sheet for all paint prior to or upon delivery of painted structural steel to the project. (See 106.04.) The paint may be sampled by lot either at the point of manufacture or application as required for testing by the Department to ensure compliance with material specifications prior to use. Samples of paint furnished for field use shall be submitted at least ten working days before application, in order to allow the Engineer time for testing and accepting the paint. The Engineer may permit application of the paint in a shorter time upon approval of the manufacturer's Certificate of Compliance by the Bureau of Materials & Research. Unless otherwise provided, the materials entering into the composition of the paint shall conform to the requirements of the applicable ASTM and AASHTO standards and FSS covering such materials. Testing shall be in accordance with the latest test methods of the ASTM and AASHTO. However, the Department reserves the right to make use of any information or methods of testing to determine the quality of paint and paint materials.

New Hampshire Department of Transportation Standard Specifications – 2016

708.04[blank]

708.05Traffic Paint Identification. To provide a means of identification, the applicable number and name taken from the

following list, unless otherwise specified, shall be printed on the label. Traffic Paints NH 4.11 White Bead Binder NH 4.12 Yellow Bead Binder General

1.1General. This specification describes ready -mixed traffic markings that shall be used as a base for reflective beads , or for

use as a plain non-reflective marking. The marking shall be suitable for either bituminous or concrete surfaces.

1.2The paint shall be formulated and processed specifically for service as a binder for reflective beads, in such a manner as to

produce maximum adhesion, refraction, and retroreflection. Any capillary action of the paint shall not be such as to cause complete coverage of the beads.

1.3The paint shall be well mixed in the manufacturing process and shall be properly ground when incorporating the pigments in

order to conform to the requirements as specified.

1.4The paint shall not liver, thicken, curdle, gel, or otherwise show any objectionable properties during storage and shall be

readily remixed manually to a smooth uniform consistency throughout.

1.5The paint shall dry on a road surface to a uniform noncracking film that will not darken in sunlight. It shall be formulated

for application with mechanical line -marking equipment and shall meet the opacity (contrast ratio) properties specified herein. The paint is a substrate for binding glass beads so as to produce a highly weather resistant traffic line. Materials

2.1Paint. Paint shall be 100% acrylic, with or without methanol, rated non -combustible with the composition complying with

the following: White Traffic Paint Property Test Method Requirements Binder ASTM D 2621 Infrared Analysis Acrylic

Titanium Dioxide, Rutile Type II ASTM D 1394 1 lb./gal. Min. Total solids ASTM D 3723 76% Min. by weight 62% Min. by volume % Pigment ASTM D 3723 58% Min. to 62% Max.

% Vehicle ASTM D 3723 38% Min. to 42% Max % Non-volatile in vehicle ASTM D 3723 42% Min. by weight Lead ASTM D 3335 0.06% Max. VOC ASTM D 3960 1.25 lb./gal. Max. Weight per gallon ASTM D 1475 14.0 ± 0.3 lb./gal. pH 9.6 Min. Flash Point (Close Cup) D 3278 Setaflash > 140º F Color Without beads a minimum of 24 hours after application Fed-Std-595B No. 37886 - White

New Hampshire Department of Transportation Standard Specifications – 2016 Yellow Traffic Paint Property Test Method Requirements Binder ASTM D 2621 Infrared Analysis Acrylic

Titanium Dioxide, Rutile Type II ASTM D 1394 0.2 lb./gal. Min. Total solids ASTM D 3723 76% Min. by weight 62% Min. by volume % Pigment ASTM D 3723 58% Min. to 62% Max.

% Vehicle ASTM D 3723 38% Min to 42% Max % Non-volatile in vehicle ASTM D 3723 42% Min. by weight Lead ASTM D 3335 0.06% Max. VOC ASTM D 3960 1.25 lb./gal. Max. Weight per gallon ASTM D 1475 13.55 ± 0.3 lb./gal. pH 9.6 Min. Flash Point (Close Cup) D 3278 Setaflash > 140º F Color Without beads a minimum of 24 hours after application Fed-Std-595B No. 33538-yellow

2.2In addition, all traffic paint shall comply with the following requirements:

Property Test Method Requirements Viscosity (Krebs Units) ASTM D 562 80 Min. to 92 Max. @ 77º F Fineness of Grind ASTM D 1210 4 Min. Drying Time -ASTM D 711 with wet film thickness of 5 mils NHDOT Test 2-Test plate-set for an hour 10 minutes Max. @ 77º F Uniformed film and no cracking or flaking Flexibility FSS TT -P-1952D, Section 4.5.5, using 1/2” mandrel bend No Cracking or Flaking Dry Opacity (contrast ratio) ASTM D 2244 with a wet film thickness of 5 mils

0.96Min.

Daylight Reflectance Federal Test Method No. 141c 85% Min. for White Paint 50% Min. for Yellow Paint Bleeding (ratio) FSS TT-P-1952D 0.97 Min. Scrub Resistance ASTM D 2486 Pass 300 cycles Freeze-Thaw Stability FSS TT-P-1952D < 10% change Heat Stability (Krebs Units) FSS TT-P-1952D < 10% change

2.2.1 Condition in Container: The paint shall show no livering, skinning, mold growth, putrification, corrosion of the container, or hard settling of the pigment in the container. Any settling shall be readily dispersed when stirred by hand with no persistent foaming. 2.2.2 No Track Time: Paint shall dry to a no tracking condition in no longer than 75 seconds. The “ no tracking” condition shall be determined by actual application on the pavement at a wet film thickness of 20 mils with white or yellow paint covered with glass beads at a rate of 8 pounds per gallon. The paint lines for this test shall be applied with the striping equipment with the paint at temperatures between 85º - 105º F at the spray orifice. This maximum tracking time shall not be exceeded when the pavement temperature varies from 50º F to 120º F , and under humidity conditions of 80% or less providing that the pavement is dry. The “ no tracking” time shall be determined by passing over the paint line three (3) minutes after paint application, in a simulated passing maneuver at a constant speed of 30 to 40 miles per hour with a passenger car. A line showing no visual deposition of the paint to the pavement surface when viewed from a distance of ap proximately 50 feet from the point where the test vehicle

New Hampshire Department of Transportation Standard Specifications – 2016 has crossed the line shall be considered as showing “ no tracking” and conforming to the requirement for field drying conditions. This field dry time test shall be used for production samples only. 2.2.3 Dry Through (Early Washout): A 15 mil wet film thickness paint sample placed immediately in a humidity chamber maintained at 72.5º F ± 2. 5º F and 90% ± 3% relative humidity shall have a “ dry-through” time less than or equal to paint film tested in accordance with ASTM D 1640, except that the pressure exerted will be the minimum needed to maintain contact between the thumb and film.

2.3Material Safety Data Sheets (OSHA Form 20 or equivalent) pertinent to all materials in this product shall be within the

striping vehicle.

New Hampshire Department of Transportation Standard Specifications – 2016 APPENDIX A DUPLEX COATINGS - PAINT OVER GALVANIZING

Highlight these requirements: • Apply galvanizing and paint within the same facility (see 1.2); • Apply first coat of paint over galvanizing within a maximum 12-hour window (see 3.4.1).

DESCRIPTION

General. This appendix specifies a duplex coating, consisting of hot dip galvanizing and a high- performance, shop-applied,

paint system for fabricated steel products for exterior use, as shown on the plans or as directed.

Duplex Coating Facility . The galvanizer shall be qualified and have demonstrated a minimum of ten years’ experience in

the successful application of hot dip galvanizing using the dry kettle process, and a minimum of five years’ experience in the successful application of paint over galvanizing within the same facility.

Scope Of Work . All fabricated products and components, as shown on the plans or as directed, shall be furnished with a

duplex coating color finish as described. See Summary Table 1.3. MATERIALS

Galvanizing. Hot dip galvanizing shall conform to AASHTO M111 (ASTM A123) and utilize the dry kettle process in a bath

of molten zinc. The galvanizing kettle shall contain special high grade zinc, nickel, and other earthly materials. The galvanizing process shall not include quenching with water or treatment with a chromate conversion coating. Provide thickness of galvanizing specified in the reference standards. Hardware shall be hot dip galvanized in conformance with AASHTO M232 (ASTM A153).

Abrasives. Provide abrasives that are dry and free of oil, grease, and corrosion -producing, or other deleterious contaminants.

Provide an abrasive that is sized to produce a dense, consistent, sharp, angular, uniform anchor pattern with a profile height of 1.0- 1.5 mils, unless the requirements of the coating manufacturer are more restrictive. The use of iron shot, steel shot, aluminum oxide grit, sand, or coal slag products as blast abrasives, and power wire brushes are NOT permitted. Use approved abrasives [e.g. garnet, stainless steel grit, Dupont StarBlast® XL (fractured), etc.] that will not leave a residue on the galvanized surface after blowing down with compressed air.

Paint System. The duplex coating shall be a two-coat shop-applied, high performance, paint system consisting of an epoxy

polyamide intermediate coating and an aliphatic polyurethane topcoat applied over hot dipped galvanized (HDG) steel substrates. An alternative paint system applied over the hot dipped galvanizing consists of a single -component moisture -cure (SC MC) aromatic polyurethane intermediate coat with micaceous iron oxide, and an SC MC aliphatic polyur ethane topcoat. For extra protection an additional clearcoat may be specified. 2.3.1 Furnish intermediate and finish coat paint materials from Paint System A, B, C, or D in a NHDOT 550/556 Special Provision, or from Paint System A or B in the NEPCOAT Qualified Products List. 2.3.2 The galvanizing-paint duplex system shall consist of the following generic type and coating thicknesses: Coating Description Thickness Galvanized: Hot-dip galvanizing per AASHTO Surface prep: SP1 Solvent Cleaning (as required); and per section 3.2.2 SP7 Brush-Off Blast Cleaning, or approved mechanical means

Intermediate High build epoxy polyamide, or Single-component moisture-cure aromatic polyurethane with micaceous iron oxide 4-6 mils DFT Finish Aliphatic polyurethane, or Single-component moisture-cure aliphatic polyurethane 2-4 mils DFT

New Hampshire Department of Transportation Standard Specifications – 2016 2.3.3 Film thicknesses shall be as shown in 2.3.2 unless the paint manufacturer’s recommended thickness range differs, in which case the manufacturer shall provide documentation that the range cited satisfies the Department’s performance requirements. 2.3.4 The maximum VOC limit is 2.8 lb/gal. at the time of application, including thinners. 2.3.5 Use the same manufacturer for all coats on a given structure, including thinners and additives. 2.3.6 Provide each coat of paint in sufficiently contrasting color to facilitate proper coverage and to distinguish it from previously applied coatings. The previous coat shall be hidden by application of each coat at the specified min imum thickness. 2.3.7 Provide all paint materials in sealed, original, containers that are properly marked and labeled to allow verification, with applicable material safety data sheets, application precautions, instructions, and including the manufacturer’s name, type of material, brand name, color, shelf life, purchase order number, lot and batch numbers, and quantity. 2.3.8 Color. The final color of the product shall be as specified (semi-gloss), closely matching the Federal Standard 595B, as follows:

Description Federal Color # DARK GREEN 24109 DARK BROWN 20062 BLACK 27038 2.3.9 Touchup materials. Repair and touch -up materials shall be supplied by the paint applicator and applied in accordance with the paint manufacturer's recommendations. 2.3.10 The paint manufacturer shall certify in writing that the duplex coating facility applying the paint is certified to apply the paint by the coating manufacturer.

2.4Equipment.

2.4.1 Inspection Equipment. Provide inspection equipment needed to verify the quality of the galvanizing, surface preparation, and paint application processes, including a Type II dry film thickness gage that can be calibrated, calibration standards, s ling psychrometer and psychometric tables, and a mirror for use by the Department. DUPLEX COATINGS - PAINT OVER GALVANIZING

3.1General.

3.1.1 Provide all materials, equipment, and labor necessary to perform the scope of work whether or not the material or equipment is specifically identified in this Item. Conduct all galvanizing, surface preparation, paint application operations, handling, shipment, and installation in a workmanlike manner in conformance with SSPC -PA1, these requirements, and to the reasonable satisfaction of the Department. 3.1.2 Basis of Design. [blank] 3.1.3 Specifications. Perform the work in conformance to the Contract requirements, the reference standards, and the coating manufacturer's instructions, respectively. 3.1.3.1 Reference Standards. The latest edition of the following standards and regulations in effect at the time of the Bid form a part of this Specification. A copy of the reference standards applicable to the work shall be available at the shop f acility for use by the Department’s representative.

and Hardware Surfaces for Painting.

and Hardware Surfaces for Powder Coating

New Hampshire Department of Transportation Standard Specifications – 2016

Executive Director

3.1.4 Submittals. 3.1.4.1 Surface Preparation and Painting Plan.

the paint system to be applied, film thickness, cure time between coats, repair materials and procedures of typical damage and defects in the duplex coating, and other information needed to successfully apply all coats of the duplex system.

use for approval to the Department (Bureau of Bridge Design, Tel. 603 -271-2731) a minimum two weeks prior to coating application. Samples shall be made of the same or comparable material and thickness as production pieces.

conformance to 106.04.

3.1.4.2 Substitutions or Approved Equals.

referenced in this specification, and shall be accompanied by proof that the Substitution or 'Approved Equal' m eets or exceeds these criteria. Approval is the discretion of the Department. Coatings or processes not matching or exceeding the approved specified process and aesthetic, durability , and performance criteria shall be removed and replaced at the expense of the Contractor and all Subcontractors that were involved with the supply of and application of the non-conforming product. 3.1.5 Supplier Coordination.

Department, fabricators shall submit shop drawings to the galvanizer for all metal fabrications to receive shop - applied duplex coatings, to review fabricator's shop drawings for suitability of materials for galvanizing and coatings, and to coordinate any required modifications to fabrications required to be performed by the fabricator.

exceeds the following limits in order to determine its suitability for processing: 0.25% carbon, 0.22% silicon, 0.04% phosphorous, and 1.3% manganese.

3.2Hot Dip Galvanizing (HDG)

3.2.1 Fabricated products shall meet the requirements of ASTM A385 (for material composition, cleanliness, drainage vents, etc.) prior to galvanizing, and galvanized surfaces shall meet the requirements of ASTM D6386 (preparing zinc surfaces for painting), as applicable and as stated herein.

provide an acceptable substrate for applied coatings. The dry kettle process shall be used to eliminate any flux inclusions on the surface of the galvanized material.

shall be 12-14 Baumé and contain less than 0.4 percent iron. The wet kettle process is prohibited.

New Hampshire Department of Transportation Standard Specifications – 2016

temperature.

than 3 percent. Titrations shall be taken weekly at a minimum.

standards. All testing will be done using atomic absorption spectrometry or x -ray fluorescence (XRF) equipment at a lab in the galvanizing plant. 3.2.2 Surface Preparation of Hot Dip Galvanizing (HDG)

Preparation and Painting Plan provided under 3.1.4, Submittals.

Powder Coating over Galvanized Steel, Feb 2010 Tom Langill for cautions regarding cleaning.) If applicable apply cleaning materials with clean lint-free rags or soft bristle brushes frequently changed to prevent reapplying contaminants. After cleaning, rinse thoroughly with hot water and allow the part to dry completely.

nozzle pressure as recommended by the equipment manufacturer, or abraded by approved mechanical means using sanding disks with appropriate abrasive, to thoroughly roughen the entire surface and produce a dense, consis tent, sharp, angular, uniform anchor pattern with a profile height of 1.0-1.5 mils, exhibiting a uniform gray color free of any bright, shiny spangles and to an appearance and feel similar to sandpaper.

shall be acceptable to the paint manufacturer's requirements. Additional surface preparation or a tie coat may be considered if required by the paint manufacturer and approved by the Department.

3.2.3Discontinuities. All visually evident detrimental surface imperfections (e.g. flux inclusions, dross inclusions, oil) that are

present on galvanized surfaces shall be cleaned, and any high spots, rough areas and edges, spikes, and sharp protrusions shall be removed by grinding to produce a smooth surface. Disbondment (peeling) of galvanizing is not acceptable and the piece shall be regalvanized, or investigated for extent and severity and a repair solution proposed to the Department for approval before corrective action is taken. 3.2.4 Surface profiling shall be performed prior to the formation of “ white rust” on the galvanized surface. If any “ white rust” is detected by visual means, the galvanizing shall be stripped off and the steel re- galvanized in conformance with these specifications. “ White rust” shall be as defined in the Inspection of Products Hot Dip Galvanized After Fabrication, Table IV, by the American Galvanizers Association. 3.2.5 Prior to painting galvanized products shall not be nested, stacked or stored with adjacent surfaces touching but shall be kept separated to be remain dry and permit the circulation of air between products. 3.3 [Blank]

3.4Paint Application.

3.4.1 Time limits. The first coat of paint shall be applied within twelve (12) hours of galvanizing and within one hour of surface preparation of the galvanized surface and outgassing, at the galvanizer’s facility, and in a controlled environment meeting applicable atmospheric requirements, as recommended by the coating manufacturer. 3.4.2 Paint application. Pretreatment and paint application and curing shall be performed after galvanizing in conformance with the paint manufacturer's recommendations and shall consist of the following, unless approved otherwise:

all parts. The paint shall only be applied when both the ambient temper ature is 50º F. or above, and the part surface temperature is between 50º and 95º F., is 5º F. (min.) higher than the dew point, and the relative humidity is less than 85 percent (max.). For the SC moisture-cure urethane use 2º F dew point differential and 98% maximum R.H.

60-95°F for the duration of the cure -to-recoat cycle listed on the paint product data sheet, unless the paint manufacturer’s requirements are more restrictive.

New Hampshire Department of Transportation Standard Specifications – 2016

verify that the compressed air supply is clean and dry as determined by the blotter test in accordance with ASTM D 4285.

instructions, but as soon as possible to minimize the length o f time that the coating is exposed to dust and contamination. Do not allow any coat to remain exposed for longer than 14 days prior to overcoating.

achieve a smooth, streamline surface free of dryspray, overspray, and orange peel. Shadow -through, pinholes, bubbles, skips, misses, lap marks between applications, or other visible discontinuities in any coat are unacceptable. Runs or sags may be brushed out while the material remains wet.

finish, remove as directed by the Department and apply another coat of finish to the area. Remove all other defective coating to sound material and reapply.

configurations such as bolts, apply the material from multiple directions to assure co mplete coverage.

application of any coat causes lifting of an underlying coat, or there is poor adhesion between coats or to the substrate, remove the coating in the affected area to adjacent sound, adherent coating, and reapply the material.

application.

without holidays, runs, or detrimental build at edges.

does meet the specified coating thickness may be recoated immediately after lightly abrading (sanding) the surface. All parts shall be allowed to cure sufficiently before further handling. 3.4.3 Surface smoothness - Duplex coatings shall exhibit a smo othness (i.e. rugosity) not greater than 4 rug (16-20 microns of variation) when measured by a profilometer over a 1-inch straight line on the surface of metal products less than 24 lbs/ linear foot. The profilometer shall be capable of operating in 1 micron increments. 3.4.4 Hardware shall be galvanized and fasteners exposed to view after installation shall receive the painted or powder coated duplex coating. Furnish an application procedure to the Department. Coating procedures for fasteners are not restricted to the same-facility (1.2) and 12-hour maximum window (3.4.1) restrictions, due to the different nature of fastener supply.

3.5Inspection.

3.5.1 Quality Control (QC). The applicator is required to conduct and document quality control inspection of the cleaning and painting operations including at a minimum, measurements of surface profile, surface cleanliness, dry film coating thickness, and visual inspection for coating defects. The data shall be recorded in a log maintained at the site and available for the Depa rtment’s review during working hours. 3.5.2 Quality Assurance (QA). The work is subject to QA inspection by the Department.

providing access to the work. Furnish, until final acceptance of the coating system, all equipment, reference documents, and instrumentation needed to inspect all phases of the work.

PA2 for the calibration and use of gages and the minimum frequency of thickness measurements. QA Inspectors will not be limited by the frequ ency of thickness measurements of PA2 but will take measurements sufficient to assure that proper thickness is achieved on all surfaces as specified.

comply with all requirements of this Item, and to provide adequate inspections of its own to assure compliance with the requirements of this Item.

shall be shipped without the prior approval of the Department.

New Hampshire Department of Transportation Standard Specifications – 2016

3.6Handling / Shipping / Installation.

3.6.1Duplex-coated materials shall not be lifted, placed on supports, or loaded for shipment until the shop coating has been

adequately cured and inspected.

3.6.2Protective measures. Exercise care in handling shop -coated materials in the shop, and du ring storage, shipping, field

installation, and subsequent construction to protect the coating from any scraping, marring, or other damage to the surface f inish. Coated material shall be insulated from lifting devices and from the scraping and rubbing of parts that would damage the coating, by the use of lifting softeners, nylon slings, padded cables, storage pallets, separators, cushioners, tie -downs, and other approved supports. Individual parts shall be wrapped or padded with effective protective material (e.g. foam, not paper or cardboard).

3.6.3Installation. Comply with fabricator's and galvanizer's requirements for installation of materials and fabrications,

including use of nylon slings or padded cables for handling shop-coated materials.

3.7Touch-Up and Repairs.

3.7.1 The total repair area shall be less than one quarter of one percent ( 0.25% ) of the area of an individual member, or the member shall be rejected and regalvanized and recoated with the duplex coating. [The repair area definition is comparable to Rust Grade 7 in ASTM D610, Standard Test Method for Evaluating Degree of Rusting on Painted Steel Surfaces. ] 3.7.2 HDG- Repair damaged galvanizing and bare steel surfaces in accordance with ASTM A780, Standard Practice for Repair of Damaged Hot Dipped Galvanized Coatings, Annex A2. Thoroughly clean damaged areas to produce a clean, bare and dry bright metal surface with a roughened profile and feather into the edges of adjacent undamaged galvanizing. Use a power sanding disk per SSPC-SP3. For bolts use a thorough hand wire brushing and SP1 cleaning as a minimum. 3.7.3 Apply an approved organic zinc-rich repair paint containing 92 percent (min.) zinc by weight in the dry film, according to the manufacturer’s recommendations, in two to four coats to a thickness equivalent to the surrounding galvanizing. Silver paint, brite paint, or aluminum paint is not acceptable. 3.7.4 Paint - The repair to the paint may be a liquid and brushed on or an aerosol and sprayed, whichever is appropriate to achieve an aesthetic finish and as long as the coats, cure, and minimum thickness of the original system are achieved. The Contractor shall provide a dry film thickness gage and check the thickness of the repair areas. Touch -ups shall be such that the repair is not noticeably visible from a distance of six feet.

coating facility for the warranty to apply.

tensioning fasteners.

shop-applied finish. Additional touchup repair kits and instructions shall be furnished to the Department for use after project acceptance for maintenance repairs.

3.8Final Acceptance.

Although the Department’s QA Inspector may accept the finished duplex coated fabricated products before sh ipment to the jobsite, final acceptance of the duplex coat system by the Department will occur at the jobsite after installation of the product, and after all coats and repairs have been completed.

3.9Three-Year Warranty.

Should the duplex system fail within three years after the project has been accepted, the coating shall be repaired or replaced by the Contractor at no cost to the State. The extent and method of repair must be acceptable to the Department. System failure does not include damage from ex ternal agents, such as scraping from snow removal equipment, vandalism, debris impacts, collisions, etc., or normal loss of gloss and color. Once the duplex system has been accepted, a failure shall mean any visi ble corrosion, blistering, checking, cracking, or delamination (peeling) of the galvanizing or paint resulting from the installation of the product or from the performance of the duplex coating.

New Hampshire Department of Transportation Standard Specifications – 2016 APPENDIX B DUPLEX COATINGS - POWDER COATING OVER GALVANIZING

Highlight these requirements: • Apply galvanizing and powder coating within the same facility (see 1.2); • Apply first powder coating over galvanizing within a maximum 12-hour window (see 3.4.1).

DESCRIPTION

General. This appendix specifies a duplex coating, consisting of hot dip galvani zing and high -performance, shop-applied,

thermosetting-based, super-durable powder coatings, for fabricated steel products for exterior use, as shown on the plans or as directed.

Duplex Coating Facility . The galvanizer shall be qualified and have dem onstrated a minimum of ten years’ experience in

the successful application of hot dip galvanizing using the dry kettle process, and a minimum of five years’ experience in the successful application of powder coatings over galvanizing within the same facility.

Scope Of Work . All fabricated products and components, as shown on the plans or as directed, shall be furnished with a

duplex coating color finish as described. See Summary Table 1.3. MATERIALS

Galvanizing. Hot dip galvanizing shall conform to AASHTO M111 (ASTM A123) and utilize the dry kettle process in a bath

of molten zinc. The galvanizing kettle shall contain special high grade zinc, nickel, and other earthly materials. The galv anizing process shall not include quenching with water or treatment with a chromate conversion coating. Provide thickness of galvanizing specified in the reference standards. Hardware shall be hot dip galvanized in conformance with AASHTO M232 (ASTM A153).

Abrasives. Provide abrasives that are dry and free of oil, grease, and corrosion-producing, or other deleterious contaminants.

Provide an abrasive that is sized to produce a dense, consistent, sharp, angular, uniform anchor pattern with a profile height of 1.0- 1.5 mils, unless the requirements of the coating manufacturer are more restrictive. The use of iron shot, steel shot, aluminum oxide grit, sand, or coal slag products as blast abrasives, and power wire brushes are NOT permitted. Use approved abrasives [e.g. garnet, stainless steel grit, Dupont Sta rBlast® XL (fractured), etc.] that will not leave a residue on the galvanized surface after blowing down with compressed air.

Powder Coating. The duplex coating shall be a two-coat shop-applied, oven-cured, high performance, exterior thermosetting

powder coating consisting of a durable zinc-rich powder coating primer, and a super-durable powder coating topcoat applied over hot dipped galvanized (HDG) steel substrates. For extra protection a third coat consisting of a powder clearcoat may be specified. SCOPE OF WORK - SUMMARY TABLE 1.3 Treatment Surfaces to be powder coated, as shown on the plans * Duplex System (2.3) Final Color (satin) Standard (use u.n.o.) example: Item 606.000, Steel Beam for Beam Guardrail Hot Dip Galvanizing, plus durable powder primer, and super durable powder topcoat Dark Brown u.n.o. Fed # 20062 Extra Protection example: Item 563.5208, Bridge Pedestrian Rail (Galv-Powder Coated) Hot Dip Galvanizing, plus durable powder primer, super durable powder topcoat, and powder clearcoat Dark Brown u.n.o. Fed # 20062 * Fasteners exposed to view after installation shall receive duplex coating per section 3.4.4 and 3.7.4.(2). 2.3.1 Furnish powder coating materials from one of the following approved suppliers:

2.3.2 The powder coating manufacturer shall certify in writing that:

New Hampshire Department of Transportation Standard Specifications – 2016

galvanized surfaces: Powder Coating (min.) Performance Requirements Test Powder Primer Powder Topcoat

delamination Pass, no cracking or delamination

4000 hours) blister rating: 10 rust rating: 7 ---

resins)

2.3.3 Provide each coat of powder coating in sufficiently contrasting color to facilitate proper coverage and to distinguish it from previously applied coatings. The previous coat shall be hidden by application of each coat at the specified minimum thickness. 2.3.4 Provide all powder coating materials in sealed, original, containers that are properly marked to allow verification, with applicable material safety data sheets, application instructions and precautions, including the manufacturer’s name, type of material, brand name, color, shelf life, purchase order number, lot and batch numbers, and quantity. 2.3.5 Color. The final color of the painted product shall be (see Table 1.3) (satin) unless specified otherwise, closely matching the Federal Standard 595B or RAL Color Standard number, as follows: Description Fed Color # Dark Green 24109 Dark Brown 20062 Black 27038 2.3.6 Touchup materials. Repair and touch -up materials shall be supplied by the powder coating applicator and applied in accordance with the powder coating manufacturer's recommendations.

Equipment.

2.4.1 Inspection Equipment. Provide inspection equipment needed to verify the quality of the entire galvanizing, surface preparation, and powder coating processes, including a Type II dry film thickness gage that can be calibrated, calibration standards, and a mirror for use by the Department. Duplex Coatings - Powder Coating Over Galvanizing

General.

3.1.1 Provide all materials, equipment, and labor necessary to perform the scope of work whether or not the material or equipment is specifically identified in this Item. Conduct all galvanizing, surface preparation, powder coating operations, handling, shipment, and installation in a workmanlike manner in conformance with SSPC -PA1, these re quirements, and to the reasonable satisfaction of the Department.

New Hampshire Department of Transportation Standard Specifications – 2016 3.1.2 Basis of Design. [blank] 3.1.3 Specifications. Perform the work in conformance to the Contract requirements, the reference standards, and the coating manufacturer's instructions, respectively. 3.1.3.1 Reference Standards. The latest edition of the following standards and regulations in effect at the time of the Bid form a part of this Specification. A copy of the reference standards applicable to the work shall be available at th e shop facility for use by the Department’s representative.

and Hardware Surfaces for Painting.

Executive Director

3.1.4 Submittals. 3.1.4.1 Surface Preparation and Powder Coating Plan.

the powder coat system to be applied, film thickness, cure time between coats, repair materials and procedures of typical damage and defects in the duplex coating, and other information needed to successfully apply all coats of the duplex system.

conformance to the performance criteria required.

use for approval to the Department (Bureau of Bridge Design, Tel. 603 -271-2731) a minimum four weeks prior to coating application. Samples shall be made of the same or comparable material and thickness as production pieces.

conformance to 106.04.

3.1.4.2 Substitutions or Approved Equals.

described in this specification, and shall be accompanied by proof that the Substitution or 'Approved Equal' meets or exceeds these criteria. Approval is the discretion of the Department. Coatings or processes not matching or exceeding the approved specified process and aesthetic, durability , and performance cr iteria shall be removed and replaced at the expense of the Contractor and all Subcontractors that were involved with the supply of and application of the non-conforming product.

New Hampshire Department of Transportation Standard Specifications – 2016 3.1.5 Supplier Coordination.

Department, fabricators shall submit shop drawings to the galvanizer for all metal fabrications to receive shop - applied duplex coatings, to review fabricator's shop drawings for suitability of mate rials for galvanizing and coatings, and to coordinate any required modifications to fabrications required to be performed by the fabricator.

exceeds the following limits in order to determine its suitability for processing: 0.25% carbon, 0.22% silicon, 0.04% phosphorous, and 1.3% manganese.

Hot Dip Galvanizing (HDG)

3.2.1 Fabricated products shall meet the requirements of ASTM A385 (for material composition, cleanliness, drainage vents, etc.) prior to galvanizing, and galvanized surfaces shall meet the requirements of ASTM D6386 (preparing zinc surfaces for painting), as applicable and as stated herein.

provide an acceptable substrate for applied coatings. The dry kettle process shall be used to eliminate any flux inclusions on the surface of the galvanized material.

shall be 12-14 Baumé and contain less than 0.4 percent iron. The wet kettle process is prohibited.

temperature.

than 3 percent. Titrations shall be taken weekly at a minimum.

standards. All testing will be done using atomic absorption spectrometry or x- ray fluorescence (XRF) equipment at a lab in the galvanizing plant. 3.2.2 Surface Preparation of Hot Dip Galvanizing (HDG)

coating Plan provided under 3.1.4, Submittals.

(See Powder Coating over Galvanized Steel, Feb 2010 Tom Langill for cautions regarding cleaning.) If applicable apply cleaning materials with clean lint-free rags or soft bristle brushes frequently changed to prevent reapplying contaminants. After cleaning, rinse thoroughly with hot water and allow the part to dry completely.

nozzle pressure as recommended by the equipment manufacturer, or abraded by approved mechanical means using sanding disks with appropriate abrasive, to thoroughly roughen the entire surface and produce a dense, consistent, sharp, angular, uniform anchor pattern with a profile height of 1.0-1.5 mils, exhibiting a uniform gray color free of any bright, shiny spangles and to an appearance and feel similar to sandpaper.

preparation shall be acceptable to the powder coating manufacturer's requirements. Additional surface preparation or a tie coat may be considered if required by the powder coating manufacturer and approved by the Department.

3.2.3 Discontinuities. All visually evident detrimental surface imperfections (e.g. flux inclusions, dross inclusions, oil) that are present on galvanized surfaces shall be cleaned, and any high spots, rough areas and edges, spikes, and sharp protrusions shall be removed by grinding to produce a smooth surface. Disbondment (peeling) of galvanizing is not acceptable and the piece shall be regalvanized, or investigated for extent and severity and a repair solution proposed to the Department for approval before corrective action is taken. 3.2.4 Surface profiling shall be performed prior to the formation of “ white rust” on the galvanized surface. If any “ white rust” is detected by visual means, the galvanizing shall be stripped off and the steel re- galvanized in conformance with these specifications. “ White rust” shall be as defined in the Inspection of Products Hot Dip Galvanized After Fabrication, Table IV, by the American Galvanizers Association. 3.2.5 Prior to powder coating galvanized products shall not be nested, stacked or stored with adjacent surfaces touching but shall be kept separated to be remain dry and permit the circulation of air between products.

New Hampshire Department of Transportation Standard Specifications – 2016

3.3Galvanized Steel Outgassing.

3.3.1 The galvanized parts shall be subjected to a thermal cy cle (i.e. outgassing) after surface profiling and before powder coating application. The thermal cy cle should be set at the appropriate temperature and duration for the thickness of the product recommended by the powder coating manufacturer.

Powder Coat Application.

3.4.1 Time limits. The first coat of powder coating shall be applied within twelve (12) hours of galvanizing and within one hour of surface preparation of the galvanized surface and outgassing, at the galvanizer’s facility, and in a controlled envir onment meeting applicable atmospheric requirements, as recommended by the coating manufacturer. 3.4.2 Powder coating application. Pretreatment and powder coating application and curing shall be performed after galvanizing in conformance with the powder coating manufacturer's recommendations and shall consist of the fo llowing, unless approved otherwise:

maintaining even coverage on all parts. The powder shall only be applied when both the ambient temperature is 65º

Relative humidity shall be less than 85 percent (max.).

levels (e.g. approximately 392º F. for 25 minutes). The Contractor shall ensure that a stable transfer exists between the powder application system and the curing oven to prevent the loss of powder from the parts.

manner that will ensure a uniform coating without holidays, runs, or detrimental build at edges. A clear coat shall be applied at the manufacturer's recommended thickness.

does meet the specified coating thickness may be recoated immediately after lightly abrading (sanding) the surface. Once cured, all parts shall be allowed to cool sufficiently before further handling. 3.4.3 Surface smoothness - Duplex coatings shall exhibit a smoothness (i.e. rugosity) not greater than 4 rug (16-20 microns of variation) when measured by a profilometer over a 1-inch straight line on the surface of metal products less than 24 lbs/ linear foot. The profilometer shall be capable of operating in 1 micron increments. 3.4.4 Hardware shall be galvanized and powder coated as follows. Furnish an application procedure to the Department. Coating procedures for fasteners are not restricted to the same- facility (1.2) and 12-hour maximum window (3.3.1) restrictions, due to the different nature of fastener supply.

Inspection.

3.5.1 Quality Control (QC). The applicator is required to conduct and document quality control inspection of the cleaning and powder coating operations including at a minimum, measurements of surface profile, surface cleanliness, dry film coating thickness, and visual inspection for coating defects. The data shall be recorded in a log maintained at the site and available for the Department’s review during working hours. 3.5.2 Quality Assurance (QA). The work is subject to QA inspection by the Department.

providing access to the work. Furnish, until final acceptance of the coating system, all equipment, reference documents, and instrumentation needed to inspect all phases of the work.

PA2 for the calibration and use of gages and the minimum frequency of thickness measurements. QA Inspectors will not be limited by the frequ ency of thickness measurements of PA2 but will take measurements sufficient to assure that proper thickness is achieved on all surfaces as specified.

New Hampshire Department of Transportation Standard Specifications – 2016

comply with all requirements of this Item, and to provide adequate inspections of its own to assure compliance with the requirements of this Item.

shall be shipped without the prior approval of the Department.

Handling / Shipping / Installation.

Duplex-coated materials shall not be lifted, placed on supports, or loaded for shipment until the shop coating has been

adequately cured and inspected.

Protective measures. Exercise care in handling shop -coated materials in the shop, and during storage, shipping, field

installation, and subsequent construction to protect the coating from any scraping, marring, or other damage to the surface f inish. Coated material shall be insulated from lifting devices and from the scraping and rubbing of parts that would damage the coating, by the use of lifting softeners, nylon slings, padded cables, storage pallets, separators, cushioners, tie -downs, and other approved supports. Individual parts shall be wrapped or padded with effective protective material (e.g. foam, not paper or cardboard).

Installation. Comply with fabricator's and galvanizer's requirements for installation of materials and fabrications,

including use of nylon slings or padded cables for handling shop-coated materials.

Touch-Up And Repairs.

3.7.1 The total repair area shall be less than one quarter of one percent ( 0.25% ) of the area of an individual member, or the member shall be rejected and regalvanized and recoated with the duplex coating. [The repair area definition is comparable to Rust Grade 7 in ASTM D610, Standard Test Method for Evaluating Degree of Rusting on Painted Steel Surfaces. ] 3.7.2 HDG- Repair damaged galvanizing and bare steel surfaces in accordance with ASTM A780, Standard Practice for Repair of Damaged Hot Dipped Galvanized Coatings, Annex A2. Thoroughly clean damaged areas to produce a clean, bare and dry bright metal surface with a roughened profile and feather into the edges of adjacent undamaged galvanizing. Use a power sanding disk per SSPC-SP3. For bolts use a thorough hand wire brushing and SP1 cleaning as a minimum. 3.7.3 Apply an approved organic zinc-rich repair paint containing 92 percent (min.) zinc by weight in the dry film, according to the manufacturer’s recommendations, in two to four coats to a thickness equivalent to the surrounding galvanizing. Silver pa int, brite paint, or aluminum paint is not acceptable. 3.7.4 Powder coating - The repair to the powder coat may be a liquid and brushed on or an aerosol and sprayed, whichever is appropriate to achieve an aesthetic finish and as long as the coats, cure, and minimum thickness of the original system are achieved. The Contractor shall provide a dry film thickness gage and check t he thickness of the repair areas. Touch -ups shall be such that the repair is not noticeably visible from a distance of six feet.

coating facility for the warranty to apply.

tensioning fasteners.

shop-applied finish. Additional touchup repair kits and instructions shall be furnished to the Department for use after project acceptance for maintenance repairs.

Final Acceptance.

Although the Department’s QA Inspector may accept the finished duplex coated fabricated products before shipment to the jobsite, final acceptance of the duplex coat system by the Department will occur at the jobsite after installation of the product, and after all coats and repairs have been completed.

Five-Year Warranty.

Should the duplex system fail within five years after the project has been accepted, the coating shall be repaired or replaced by the Contractor at no cost to the State. The extent and method of repair must be acceptable to the Department. System failure does not include damage from external agents, such as scraping from snow removal equipment, vandalism, debris impacts, collisions, etc., or normal loss of gloss and color. Once the duplex system has been accepted, a failure shall mean any visible corrosion, blistering, checking, cracking, or delamination (peeling) of the galvanizing or powder coating resulting from the installation of the product or from the performance of the duplex coating.

New Hampshire Department of Transportation Standard Specifications – 2016

APPENDIX C DUPLEX COATINGS - METALLIZING AND SEALER DUPLEX COATINGS - METALLIZING AND PAINT

This Appendix amends the Special Provision for Section 550, Structural Steel, (Spec Prov 550) and specifies a duplex coating, consisting of metallizing and sealer, or metallizing, sealer, and paint for a color finish, for fabricated structural steel components, as shown on the plans or as directed. The requirements of Spec Prov 550 apply, except as modified herein. Use o f the term Thermal Spray Coating (TSC) is intended to mean the same as, and to be used interchangeably with, the term metallizing.

Point of Emphasis: • Blast steel, and apply metallizing and sealer/paint, within the same facility (see 1.2) • Apply metallizing to steel surface within six hours (max.) after blasting (see 3.3.4.2) • Apply sealer coat to metallizing within eight hours (max.) after metallizing (see 3.4.2)

DESCRIPTION

GENERAL. The work to apply a metallizing duplex coating shall meet the requirements of the Joint Standard, SSPC CS

23.00/ AWS C2.23/ NACE No. 12, Specification for the Application of Thermal Spray Coatings (Metallizing), and the applicable

requirements of Spec Prov 550 as modified herein. (Joint Standard references herein are abbreviated, e.g. JS 6.1).

DUPLEX COATING FACILITY. The facilit y performing the work shall be qualified (3.1.2) and have demonstrated a

minimum of five years’ experience within the same facility in successful surface preparation and the application of thermal spray coatings (TSC) over blasted steel surfaces, and application of a sealer/paint over TSC.

SCOPE OF WORK. See Spec Prov 550 Scope of Work Summary Table 1.3 for the specific structural steel components

and duplex coating(s) required. Furnish structural steel components complete in place and accepted, using approved TSC materials, equipment, and procedures by qualified applicators. MATERIALS

ABRASIVES. Provide a 100% steel grit abrasive sized to prepare steel surfaces to an SSPC-SP5 White Metal Blast

condition, and produce a dense, uniform, sharp, angular anchor pattern with a profile height of 3-5 mils, unless the requirements of the TSC manufacturer are more restrictive, and having hardness of 50 Rockwell C or higher. Shot is not permitted even if mixed with angular grit abrasive.

METALLIZING. The TSC material shall conform to Joint Standard Sect 6 and the following:

2.2.1 Slip B Coefficient Testing - The TSC shall meet Slip Coefficient requirements for Class B, per the RCSC specification for Structural Joints Using High Strength Bolts, Appendix A, required to apply to slip -critical bolted connections. See 3.6, Bolted Connections.

2.2.2 Porosity - The TSC Applicator shall demonstrate by means of metallographic examination per ASTM E2109, that the mean average area of porosity in the TSC is less than 10%. (JS Table 1, Footnote F).

CLEAR SEALER. All TSC zinc coated surfaces (except bolted faying surfaces) shall receive one coat of clear sealer at

1.5-2 mils DFT, thinned per manufacturer's instructions, with the intent of sealing porosity in the TSC, reducing zinc oxide staining, and improving adhesion of the TSC to the steel substrate. This sealer coat is not interpreted as providing barrier protection.

2.3.1 The duplex system (TSC/Sealer) shall consist of the following type and coating thicknesses:

New Hampshire Department of Transportation Standard Specifications – 2016

Coating Description Thickness (mils DFT) Primer: Thermal Spray Coating (metallizing) 10 mils target ± 2 Clear Sealer Carboline Carbothane 134 Clear Coat, or as recommended by coating manufacturer 1.5-2 mils DFT

PAINT SYSTEM. When a color finish is desired and specified, the duplex coating shall include a two-coat shop-applied,

high-performance, paint system consisting of an intermediate and top coat applied over the TSC and sealer coat.

2.4.1 Furnish the intermediate and finish coat paint materials from Paint System A, B, or C in Spec Prov 550, or from Paint System List A or B in the current NEPCOAT Qualified Products List, and as recommended by the Coating Manufacturer.

2.4.2 The duplex system (TSC/Sealer/Paint) shall consist of the following type and coating thicknesses:

Coating Description Thickness Primer: Thermal Spray Coating (metallizing) 10 mils target ± 2 Sealer As recommended by coating manufacturer 1.5-2 mils DFT Intermediate High build epoxy polyamide, or Single-component moisture-cure polyurethane w/ MIO 4-6 mils DFT Finish Aliphatic polyurethane, or Single-component moisture-cure aliphatic polyurethane 2-4 mils DFT

2.4.3 Color. The final color of paint, if required, shall be as specified in Spec Prov 550 Table 1.3, closely matching the Federal Standard 595B, as follows:

Description Federal Color # DARK BROWN 20062 LIGHT GRAY (to match TSC) 26373

2.4.4 Touchup materials. Repair and touch-up materials for TSC, sealer coat, and paint shall be supplied by the paint applicator and applied in accordance with the paint manufacturer's recommendations.

2.5GALVANIZING. Structural fasteners (i.e. bolts) will not be coated with TSC but shall be coated in accordance with

ASTM B695 Class 50 for mechanically-deposited galvanizing.

2.6EQUIPMENT. In addition to inspection equipment listed in Spec Prov 550 Sect. 2.6, provide a Surface Profile

Comparator.

DUPLEX COATINGS - METALLIZING AND SEALER DUPLEX COATINGS - METALLIZING AND PAINT

GENERAL

3.1.1 Provide all materials, equipment, and labor necessary to perform the scope of work whet her or not the material or equipment is specifically identified in this Item. Conduct all surface preparation, metallizing, sealer and paint applicatio n operations, handling, shipment, and installation in a workmanlike manner in conformance with the Joint Standard (SSPC CS

, AWS C2.23, NACE No. 12), the requirements of Spec Prov 550, this Appendix, the coating manufacturer's instructions,

and to the reasonable satisfaction of the Department.

New Hampshire Department of Transportation Standard Specifications – 2016 3.1.2 Facility and Personnel Qualification.

demonstrate a comparable level of approved qualification, having five years (min.) experience, having completed at least three projects on structures with TSC, sealer, and paint, and including at least one bridge. Supplement lack of experience as required with subcontracted on-site TSC expertise.

3.1.2.1 Sub-Contractors.

Contractor shall meet qualification requirements, comply with the same requirements, standards, specifications, use the same materials, and use the same or comparable equipment as the approved Facility.

3.1.3 Reference Standards. The latest edition of the applicable standards of Special Provision 550, and the following standards and regulations in effect at the time of the Bid form a part of this Specification. A copy of the reference standards applicable to the work shall be available at the shop facility for use by the Department’s representative. (JS Section 2)

2003 edition),

3.1.4 Submittals.

3.1.4.1 Surface Preparation/Coating Plan.

preparation, TSC application, sealer/paint application, and in-process quality control, job control record, equipment, materials, and repair procedures, etc. for work in the shop and field.

New Hampshire Department of Transportation Standard Specifications – 2016

proposed for use, for approval to the Department (Bureau of Bridge Design, Tel. 603-271-2731) a minimum two weeks prior to coating application. Samples shall be made of the same or comparable material and of a thickness sufficient to represent the process.

conformance to 106.04.

referenced in this specification, and shall demonstrate by documentation that the Substitution or 'Approved Equal' meets or exceeds these criteria. Approval is at the discretion of the Department. Coatings or processes not matching or exceeding the approved specified process and aesthetic, durability, and performance criteria shall be removed and replaced at the expense of the Contractor and all Subcontractors that were involved with the supply of and application of the non-conforming material.

STEEL SURFACE PREPARATION REQUIREMENTS.

3.2.1 Surface Preparation.

hardened flame-cut surface in order to achieve the desired blast profile. Corners shall be blunted by grinding to a beveled edge.

grit. Shot is not permitted even if mixed with angular grit abrasive. The Joint Standard indicates blasting media and mesh size found suitable for TSC on steel substrates. (JS Table 2).

for manual blasting: take one profile depth measurement for every 10-20 ft² of blasted surface. Check the profile density with a Surface Profile Comparator. (JS 6.3)

frequency (e.g. twice per project), using the Chlor*Test as manufactured by Chlor*Rid International Inc. (Tel. 800-422-3217).

METALLIZING APPLICATION

3.3.1 Job Reference Standard (JRS) pre-production test plate

JRS shall be used as a “ comparator” to evaluate the suitability of the application process. (JS 3.9, 13.2)

Coating (TSC) equipment, process parameters, and procedures, and under the same environmental conditions, to be used in production. (JS 13.2)

TSC adhesion test results (per ASTM D4541), and sealer/paint application parameters.

New Hampshire Department of Transportation Standard Specifications – 2016

average of the area of porosity in the TSC (JS Table 1 Footnote F). The Applicator Facility may use results from previous testing using the same TSC materials and equipment operating parameters.

profile with 100% grit for automatic blasting shall be confirmed with a metallographic examination per ASTM E 3 and ASTM E 2109 (JS Table 1 Footnote F).

to the parameters used and documented while preparing the JRS plate. QC and QA shall verify that the proper parameters are used. (JS 13.2)

3.3.2 Production Bend Test Coupons. Five bend test coupons shall be prepared per each TSC operator, once at the start of each shift, prior to applying the TSC to the production pieces. Bend tests are performed on coupons without a sealer coat. (JS 6.5)

cannot be lifted from the substrate with a knife blade. (JS 3.2, 6.5)

and re-make five additional bend coupons for testing. All five coupons must pass the bend test before production work may begin. 3.3.3 Production Companion Plates. A “ companion plate” shall be blast cleaned to the proper finish at the same time as the production piece being metallized. One companion plate shall be prepared, metallized, and tested for every 500 ft² surface area of production pieces being metallized. (JS 3.4)

required pull-off adhesion strength is observed. This value shall be based on the average of three adhesion tests for each companion plate.

sharp chisel and hammer shall be used to strike and “ cut” the TSC coating at a shallow angle. No peeling or delamination of the TSC is permitted. (JS 3.6)

the 500 ft² of TSC applied on the production piece shall be removed and re-applied. (JS 6.4.1.2 and 6.5) 3.3.4 Production TSC Application

50 and 100 deg F. (JS 7.3.1)

shall be no longer than six hours. (JS 7.3.2.1)

New Hampshire Department of Transportation Standard Specifications – 2016

contamination to the steel.

of the completion of the blasting operation:

preparation to extend the hold time four hours, giving the piece a total time of 10 hours within which final TSC application must be finished, provided the surface can be maintained free of contaminants. Validate the use of the flash coat with additional adhesion and bend tests as described. (JS 7.4.1.1)

Sponge Jet abrasive media. [This option is outside the Joint Standard but may be approved with validation of the procedure per 7.4.2 furnishing an additional companion plate and bend coupons and testing.]

QC shall perform a complete visual examination of the “ brush blast” for evidence of rust bloom or TSC degradation.

thickness, to ensure the proper coating thickness, thorough coverage, and adhesion strength to the steel substrate. (JS 8.2.1)

6.1.3 and 6.2)

owner. If any damage of this area occurs during shipment or erection, the TSC Facility shall be liable for the repair costs. Repair to this area may be made prior to shipment. (JS 6.2.2)

without blisters, cracks, loose particles, or exposed steel examined under 10x magnification. (JS 6.6)

SEALER APPLICATION.

D8.

9.2.2)

and, therefore, the dry film thickness cannot be measured directly. Demonstrate by some means or procedure that the minimum sealer thickness is achieved. It is recommended that the wet film thickness (WFT) of the sealer be measured on a piece of plastic or cardboard at 4 mils WFT, and then use the same parameters and spray techniques to apply the sealer to the TSC on the production work piece to ensure proper coverage of the sealer.

New Hampshire Department of Transportation Standard Specifications – 2016

thinned at the maximum allowable thinning rate as listed on the product data sheet. The intent of the mist coat is to saturate the porous TSC surface and displace entrapped air within the porosity of the TSC. After allowing the mist coat to flash off for 20 minutes, apply a second full coat of clear sealer to achieve the intended total thickness.

PAINT APPLICATION

3.5.1 Paint application. The duplex coating consists of TSC and sealer coat plus a two-coat paint system. Surface preparation, i.e. retreatment if required, and paint application and curing shall be performed after the TSC and sealer are applied, in conformance with the Spec Prov 550 Sections 3.3 and 3.4, the paint manufacturer's recommendations and shall consist of the following, unless approved otherwise (JS 9.1.2):

and curing facility shall be maintained free of airborne dust and dirt until coatings are completely cured.

all parts. The paint shall only be applied when both the ambient temperature is 50º F. or above, and the part surface temperature is between 50º and 95º F., is 5º F. (min.) higher than the dew point, and the relative humidity (RH) is less than 85 percent (max.). For the SC moisture-cure urethane use 2º F (min.) dew point differential and 98% maximum RH.

3.5.2 Faster hardware (i.e. bolts) shall be galvanized and fasteners exposed to view after installation shall be painted for a color match with the intermediate and finish coats of the approved paint system. Furnish an application procedure to the Department. Coating procedures for fasteners are not restricted to the same-facility (1.2) due to the different nature of fastener supply.

BOLTED CONNECTIONS

3.6.1 Bolted Connections

for 99.9% Zinc.

consistency of appearance with adjacent steel surfaces.

surfaces only.

HANDLING / SHIPPING / INSTALLATION

been adequately cured and inspected.

field erection, or subsequent construction of the bridge. Coated steel shall be insulated from lifting devices and from the scraping and rubbing of parts that would damage the coating by the use of lifting softeners, nylon slings, storage pallets, separators, cushions, tie-downs, and other approved supports.

and during shipping to protect the coating, as described above.

New Hampshire Department of Transportation Standard Specifications – 2016

TOUCH-UP AND REPAIRS

3.8.1 General

in the shop for equipment, procedures, personnel, supervision, and inspection until final acceptance of the work.

approved surface preparation.

surface preparation. 3.8.2 Apply an approved organic zinc-rich repair paint containing 92 percent (min.) zinc by weight in the dry film, according to the manufacturer’s recommendations, in multiple coats as required to achieve a thickness equivalent to the surrounding TSC. Silver paint, bright paint, or aluminum paint is not permitted.

3.8.3 Paint - The repair to damaged paint shall be a liquid and brushed on to achieve an aesthetic finish and minimum thickness of the original system. The Contractor shall provide a dry film thickness gage and check the thickness of the repair areas. Touch-ups shall be such that the repair is not noticeably visible from a distance of six feet.

coating facility, or approved SSPC QP2 applicator, for the warranty to be accepted.

tensioning fasteners.

FINAL ACCEPTANCE. Although the Department’s QA Inspector may accept the finished duplex coated fabricated

products before shipment to the jobsite, final acceptance of the duplex coat system will occur at the jobsite by the Departme nt after installation of the product, and after all coats and repairs have been completed.

3.10THREE-YEAR WARRANTY. Should the duplex system fail within three years after the project has been accepted, the

coating shall be repaired or replaced by the Contractor at no cost to the State. The extent and method of repair must be acceptable to the Department. System failure does not include damage from external agents, such as scraping from snow removal equipment, vandalism, debris impacts, collisions, etc., or normal loss of gloss and color. Once the duplex system ha s been accepted, a failure shall mean any visible corrosion, blistering, checking, cracking, or delamination (peeling) of the TSC or paint resulting from the installation of the product or from the performance of the duplex coating.

New Hampshire Department of Transportation Standard Specifications – 2016

ALUMINUM ALLOYS FOR HIGHWAY STRUCTURES General

Description. These specifications apply to the welding of aluminum alloys used in bridge railing, structural supports for

highway signs, luminaires, traffic signals, and the like.

Specifications.

1.2.1 The welding terms used in these specifications shall be interpreted in accordance with the definitions given in the latest edition of Welding Terms and Definitions, ANSI/AWS A3.0. 1.2.2 The welding symbols used on the plans will be thoses hown in the latest edition of Symbols for Welding, Brazing and Nondestructive Examination, ANSI/AWS A2.4. Special conditions will be fully explained by added notes or details. 1.2.3 The welding of aluminum bridge railing shall conform to Section 10 of the ANSI/AWS D1.2 “ Structural Welding Code – Aluminum” including Part E “ Workmanship Class II Structures ”. The fabrication and erection of bridge railing shall conform to Section 6 of the Specifications for Aluminum Structures, published by the Aluminum A ssociation. 1.2.4 The welding of aluminum sign supports, luminaires, and traffic signals shall conform to Section 10 of the ANSI/AWS D1.2 “ Structural Welding Code – Aluminum” including Part D “ Workmanship Class I Structures”. The fabrication and erection of aluminum sign supports, luminaires, and traffic signals shall conform to the requirements of the AASHTO Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals. Special consideration may be given to certain support structures, which may be fabricated according to the provisions of 1.2.3. Base Metals

The aluminum alloys to be welded under these specifications may be any of the following alloy designations:

Wrought non-heat-treatable alloys Alloy 3003 Alloy 3004 Alloy 5052 Alloy 5083 Alloy 5086 Alloy 5456 Wrought heat-treatable alloys Alloy 6061 Alloy 6063 Cast heat-treatable alloy Alloy 356.0

Material used for permanent backing shall be at least equivalent in weldability to the base metal being welded .

Welding Processes.

These specifications include provisions for welding by the gas metal -arc process and the gas tungsten -arc process. Other

processes may not be used except as permitted. Filler Metal.

4.1Bare wire electrodes for use with the gas metal -arc process and welding rods for use with the gas tungsten -arc process shall

conform to the requirements of the latest edition of Specification for Bare Aluminum and Aluminum Alloy, Welding Electrodes and Rods, ANSI/AWS A5.10.

4.2Tungsten electrodes for the gas tungsten-arc process shall conform to the requirements of the latest edition of Specification

for Tungsten and Tungsten Alloy Electrodes for Arc Welding, ANSI/AWS A5.12.

4.3Filler metals to be used with particular base metals shall be as shown in Table 1. Other filler metals may be used as approved.